HW#2 (Due March 1.2020) Q(1) (10 points): What are the layout types of production departments? Provide real examples of each type (mention the company name and its products, and then explain how this industry fits to this type of layout). What are the limitations of each type? Q(2)(30 points): Consider the following data (Table 1) from a small workshop located at Al-Khobar. Based on the fragility of the product, a movement factor is estimated (as shown in the table). Use movement factor for within the department analysis. Product Route Demand Per Period Movement Factor 4-1-6-2 4-5-8-6-1 7-3-6-1-2 6-1-2-4 Table 1: Data of Q(2) 40 Data Preprocessing (this will be a typical step before a layout analysis): a. Construct the flow matrix for the above data. Clearly indicate the units. b. Calculate the flow dominance measure. What can you infer from the measure? c. You as a decision maker, come up with your valid and reasonable rules to Construct a relationship chart using these rules. Q(3)/30 points): Evaluation (let us see how good the above layout is w.rt to the flow criterion): a. Calculate the flow path of all the products, if the machines are arranged as in Figure 1. Figure 1: The distances between every intersection on spline is 1 meter. b. Using the calculated flow paths from part (a) and the data given in table (1), calculate the total flow distance, TFD(1), defined as TFD(1) = FP, X V PEP c. Considering the data given in tablel and figure 1, calculate the total flow distance, TFD(2), defined as TFD(2) = 5 dij Wij led je Loop layout (what if we make a loop layout?): Q(4)(15 points): Assume that a single LUL is added to the given system, i.e., the rout of each product becomes a loop by adding one LUL station either before or after every route. a. Construct the distance matrix for the following machine position assignments: if i is odd if i is even Machines with the same positions, order of lower machines should be sequenced first. b. Calculate the total flow distance, using the data given in table 1, and part (a). a(i) = {i+1 Q(5) (15 points): Cellular layout 2 (what if we make a cellular layout?): Create a cellular layout for the data given in Table 1 using the DCA algorithm. If there are any bottlenecks, then generate alternative solutions or duplicate minimum number of machines to resolve the bottlenecks. HW#2 (Due March 1.2020) Q(1) (10 points): What are the layout types of production departments? Provide real examples of each type (mention the company name and its products, and then explain how this industry fits to this type of layout). What are the limitations of each type? Q(2)(30 points): Consider the following data (Table 1) from a small workshop located at Al-Khobar. Based on the fragility of the product, a movement factor is estimated (as shown in the table). Use movement factor for within the department analysis. Product Route Demand Per Period Movement Factor 4-1-6-2 4-5-8-6-1 7-3-6-1-2 6-1-2-4 Table 1: Data of Q(2) 40 Data Preprocessing (this will be a typical step before a layout analysis): a. Construct the flow matrix for the above data. Clearly indicate the units. b. Calculate the flow dominance measure. What can you infer from the measure? c. You as a decision maker, come up with your valid and reasonable rules to Construct a relationship chart using these rules. Q(3)/30 points): Evaluation (let us see how good the above layout is w.rt to the flow criterion): a. Calculate the flow path of all the products, if the machines are arranged as in Figure 1. Figure 1: The distances between every intersection on spline is 1 meter. b. Using the calculated flow paths from part (a) and the data given in table (1), calculate the total flow distance, TFD(1), defined as TFD(1) = FP, X V PEP c. Considering the data given in tablel and figure 1, calculate the total flow distance, TFD(2), defined as TFD(2) = 5 dij Wij led je Loop layout (what if we make a loop layout?): Q(4)(15 points): Assume that a single LUL is added to the given system, i.e., the rout of each product becomes a loop by adding one LUL station either before or after every route. a. Construct the distance matrix for the following machine position assignments: if i is odd if i is even Machines with the same positions, order of lower machines should be sequenced first. b. Calculate the total flow distance, using the data given in table 1, and part (a). a(i) = {i+1 Q(5) (15 points): Cellular layout 2 (what if we make a cellular layout?): Create a cellular layout for the data given in Table 1 using the DCA algorithm. If there are any bottlenecks, then generate alternative solutions or duplicate minimum number of machines to resolve the bottlenecks