Background: ACME Manufacturing has a history of producing high quality components and on-time customer delivery for the past 50 years. Recently, upper management has observed that a complete facility re-design is critical to maintaining a competitive advantage for the next 50 years. Currently, ACME Manufacturing is operating as a job shop process layout to produce 5 different products using 8 different machines. ACME has two storage/warehousing areas: one for raw material (RM) to manufacture products and one for finished goods (FG), and has separate office space for sales/marketing and engineering/operations/maintenance (total of 7 departments). Their facility contains one receiving department and one shipping department with docks on opposite sides of the facility. The manufacturing department (MFG) will contain all groups/cells in the new layout and can be considered one entire department for steps 4 and 5. Objective: ACME desires to: 1) move from a process job shop layout to a group technology layout, 2) re- design raw material and finished goods storage areas for double deep and single deep racks, respectively, and 3) propose a new facility layout based on historical observations of the flow between current departments and using the current facility. Summary: You have been provided with the product design/manufacturing data, historical data on the amount of raw materials and finished goods in inventory, availability/capacity data for machines that manufacture the products, and the floorplan of the current factory space. As the lead facility designer you are tasked to: 1. Group machines to determine the product/machine cells that ACME will implement in their group technology layout 2. Determine the number of machines required for ACME to achieve their desired production amount and the square footage for each group/cell (assume 8 hour shift) Determine the square footage of the raw material and finished goods storage. Raw material storage uses double deep racks that store 18 pallets (3 wide and 3 tall and two deep) with 12 ft. aisles between racks. Finished Goods storage uses single deep racks that store 9 pallets (3 wide and 3 tall) with 10 ft aisles between racks. Consider that the dimensions of the rack are the height, width, depth of the pallets stored on the rack plus 10% more in each dimension a. Pallet with load dimensions are 48" x 48" and 54" total in height b. Each rack requires half the aisle width specified 4. Use the flow-between data provided to construct a layout using the graph based approach. 5. Create a layout based on parts 1-4 using the grid provided and calculate the distance based objective function for the new layout and identify and improvement opportunities that may exist. Use the center point or estimate of the center point of each department. Submission: Complete all work individual and submit a 2-5 page report, not counting title page, appendices, or references (use the title page and formatting provided in this document). Attach all calculations in an appendix. If you do your calculations by hand, scan all clearly written and organized equations in your appendix. If you use excel, submit your excel file with your 3-5 page report. Data: All data for this take home exam is provided in this document and the excel file. If you feel that you need other data, clearly state your assumptions or contact me by email. The excel file contains one year of data for weekly raw material (RM) and finished goods (FG) pallets moved (50 weeks of data). The storage areas you design must store 4 weeks of inventory for raw material and 5 weeks of inventory for finished goods. H 1 2 3 15 Pallets moved per week for 8 raw materials (required to store 4 weeks of inventory) RM1 RM2 RM3 RM4 RM5 RM6 RM7 RM8 10 17 18 12 18 14 15 16 15 12 20 15 11 12 19 15 15 14 4 13 16 16 8 9 18 10 12 11 17 12 13 14 15 16 17 18 15 20 14 16 14 19 20 11 11 14 20 15 21 14 22 23 20 24 11 16 10 25 26 10 18 14 27 28 11 29 17 30 31 32 10 33 12 15 34 35 36 37 38 39 15 40 17 12 41 42 43 44 41 42 45 43 46 47 48 10 49 47 19 50 51 10 11 16 52 11 16 16 17 17 Product Data Demand Product per shift (parts 100 Machines Required 140 60 150 80 M2, M4, M7 M1, M4, M5, M7 M2, M3, M6, M8 M3, M6, M8 M1, M5, M7 Machine Data Performance Reliability Grids per machine 0.98 0.9 0.9 0.9 Available Time/shift (min) 400 400 420 400 Processing Time (min) 10 7 5 3 0.95 0.9 4 Mi M2 M3 M4 M5 M6 MZ M8 0.99 0.9 3 0.95 380 12 0.95 0.97 0.94 0.9 0.9 0.9 0.9 400 420 400 24 4 2 102 Receiving Department Flow Between Matrix Flow Eng Sales Mfg Bet. Eng 10 25 Sales 5 Mfg FG 15 12 30 10 RM 17 2 30 Ship 3 10 25 FG RM Ship Rec. Department Area (in grids) # of Dept. Grids 70 Eng 30 Sales Mfg FG RM Shipping Receiving 20 20 Grid layout of the facility, shipping must be located on the left side of the facility and receiving must be located on the right side of the facility. Each grid is 8 ft x 8 ft. Assume you have the necessary height for the facility. Grid is 20 x 20 for a total of 400 grids. Background: ACME Manufacturing has a history of producing high quality components and on-time customer delivery for the past 50 years. Recently, upper management has observed that a complete facility re-design is critical to maintaining a competitive advantage for the next 50 years. Currently, ACME Manufacturing is operating as a job shop process layout to produce 5 different products using 8 different machines. ACME has two storage/warehousing areas: one for raw material (RM) to manufacture products and one for finished goods (FG), and has separate office space for sales/marketing and engineering/operations/maintenance (total of 7 departments). Their facility contains one receiving department and one shipping department with docks on opposite sides of the facility. The manufacturing department (MFG) will contain all groups/cells in the new layout and can be considered one entire department for steps 4 and 5. Objective: ACME desires to: 1) move from a process job shop layout to a group technology layout, 2) re- design raw material and finished goods storage areas for double deep and single deep racks, respectively, and 3) propose a new facility layout based on historical observations of the flow between current departments and using the current facility. Summary: You have been provided with the product design/manufacturing data, historical data on the amount of raw materials and finished goods in inventory, availability/capacity data for machines that manufacture the products, and the floorplan of the current factory space. As the lead facility designer you are tasked to: 1. Group machines to determine the product/machine cells that ACME will implement in their group technology layout 2. Determine the number of machines required for ACME to achieve their desired production amount and the square footage for each group/cell (assume 8 hour shift) Determine the square footage of the raw material and finished goods storage. Raw material storage uses double deep racks that store 18 pallets (3 wide and 3 tall and two deep) with 12 ft. aisles between racks. Finished Goods storage uses single deep racks that store 9 pallets (3 wide and 3 tall) with 10 ft aisles between racks. Consider that the dimensions of the rack are the height, width, depth of the pallets stored on the rack plus 10% more in each dimension a. Pallet with load dimensions are 48" x 48" and 54" total in height b. Each rack requires half the aisle width specified 4. Use the flow-between data provided to construct a layout using the graph based approach. 5. Create a layout based on parts 1-4 using the grid provided and calculate the distance based objective function for the new layout and identify and improvement opportunities that may exist. Use the center point or estimate of the center point of each department. Submission: Complete all work individual and submit a 2-5 page report, not counting title page, appendices, or references (use the title page and formatting provided in this document). Attach all calculations in an appendix. If you do your calculations by hand, scan all clearly written and organized equations in your appendix. If you use excel, submit your excel file with your 3-5 page report. Data: All data for this take home exam is provided in this document and the excel file. If you feel that you need other data, clearly state your assumptions or contact me by email. The excel file contains one year of data for weekly raw material (RM) and finished goods (FG) pallets moved (50 weeks of data). The storage areas you design must store 4 weeks of inventory for raw material and 5 weeks of inventory for finished goods. H 1 2 3 15 Pallets moved per week for 8 raw materials (required to store 4 weeks of inventory) RM1 RM2 RM3 RM4 RM5 RM6 RM7 RM8 10 17 18 12 18 14 15 16 15 12 20 15 11 12 19 15 15 14 4 13 16 16 8 9 18 10 12 11 17 12 13 14 15 16 17 18 15 20 14 16 14 19 20 11 11 14 20 15 21 14 22 23 20 24 11 16 10 25 26 10 18 14 27 28 11 29 17 30 31 32 10 33 12 15 34 35 36 37 38 39 15 40 17 12 41 42 43 44 41 42 45 43 46 47 48 10 49 47 19 50 51 10 11 16 52 11 16 16 17 17 Product Data Demand Product per shift (parts 100 Machines Required 140 60 150 80 M2, M4, M7 M1, M4, M5, M7 M2, M3, M6, M8 M3, M6, M8 M1, M5, M7 Machine Data Performance Reliability Grids per machine 0.98 0.9 0.9 0.9 Available Time/shift (min) 400 400 420 400 Processing Time (min) 10 7 5 3 0.95 0.9 4 Mi M2 M3 M4 M5 M6 MZ M8 0.99 0.9 3 0.95 380 12 0.95 0.97 0.94 0.9 0.9 0.9 0.9 400 420 400 24 4 2 102 Receiving Department Flow Between Matrix Flow Eng Sales Mfg Bet. Eng 10 25 Sales 5 Mfg FG 15 12 30 10 RM 17 2 30 Ship 3 10 25 FG RM Ship Rec. Department Area (in grids) # of Dept. Grids 70 Eng 30 Sales Mfg FG RM Shipping Receiving 20 20 Grid layout of the facility, shipping must be located on the left side of the facility and receiving must be located on the right side of the facility. Each grid is 8 ft x 8 ft. Assume you have the necessary height for the facility. Grid is 20 x 20 for a total of 400 grids