Question

.. 9.4 Roy Creasey Enterprises, a machine shop, is planning to move to a new larger location. The new building will be 60 feet Tong by 40 feet wide. Creasey envisions the building as having six distinct production areas, roughly equal in size. He feels strongly about safety and intends to have marked pathways throughout the building to facilitate the movement of people and materials. See the following building schematic Building Schematic (with work areas 1-6) His foreman has completed a month-long study of the number of loads of material that have moved from one process to another in the current building. This information is contained in the following flow matrix. Flow Matrix between Production Processes Το From Materials Welding Drills Lathes Grinders Benders Materials 0 100 500 0 50 Welding 25 00 500 Drills 0 0 0 50 Lathes 0 25 0 0 200 Grinders 0 1000 Benders 10 0 20 0 0 0 Finally, Creasey has developed the following matrix to indicate distances between the work areas shown in the building schematic

Answer 1

Answer:

Given that,

$\rightarrow$ Roy Creasey Enterprises, a machine shop, is planning to move to a new, larger location. The new building will be 60 feet long by 40 feet wide.

$\rightarrow$ Creasey envisions the building as having six distinct production areas , roughly equal in size. He feels strongly about safety and intends to have marked pathways throughout the building to facilitate the movement of people and materials.

Process layout:

$\rightarrow$ Process layout is the design of the plant in the manufacturing engineering. The major goal or process layout is to improve the efficiency of the function of the plant by arranging the equipment or department in certain order.

Given Layout:

1	2	3
4	5	6

Distance between work areas:

	1	2	3	4	5	6
1		20	40	20	40	60
2			20	40	20	40
3				60	40	20
4					20	40
5						20
6

Flow Matrix:

	M	W	D	L	G	B
M	0	100	50	0	0	50
W	25	0	0	50	0	0
D	25	0	0	0	50	0
L	0	25	0	0	20	0
G	50	0	100	0	0	0
B	10	0	20	0	0	0

Where,

M= Materials

W=Welding

D=Drilling

L=Lathe

G=Grinding

B=Bending

The volume of movements in the descending order is as follows:

• Drilling and Grinding 150
• Materials and Welding 125
• Materials and Drilling 75
• Welding and Lathe 75
• Materials and Bending 60
• Materials and Grinding 50
• Lathe and Grinding 20
• Bending and Drilling 20

The volumes of movements in each department in descending order as follows:

• Materials 125+75+60+50=310
• Drilling 150+75+20=245
• Grinding 150+50+20=220
• welding 125+75=200
• Lathe 75+20=95
• Bending 60+20=80

Materials, Drilling and Grinding departments have the largest movements and to the extent possible, they should be centrally located. They preferably need to be close to each other because 150+75+50=275 movements are among these departments.

Lathe and Bending have the least volumes of movements and therefore these departments could be in remote corner. wedding can preferably be close to Lathe. Bending would preferably close to Materials.

Trail and error method:

By trail and error, the layout solution shown below to some extent satisfies the above conditions and at the same time keeping the total material handling distance minimum.

Bending	Material	Welding
Drilling	Grinding	Lathe

Calculate the total trips multiplied by distances as shown below:

M to W =100 $\times$ 20=2,000

M to D =50 $\times$ 40=2,000

M to B =50 $\times$ 20=1,000

W to M =25 $\times$ 20=500

W to L =50 $\times$ 20=1,000

D to M =25 $\times$ 40=1,000

D to G =50 $\times$ 20=1,000

L to W =25 $\times$ 20=500

L to G =20 $\times$ 20=400

G to M =50 $\times$ 20=1,000

G to D =100 $\times$ 20=2,000

B to M =10 $\times$ 20=200

B to D =20 $\times$ 20=400

Adding all the distances, the total material handling distance for the proposed layout

=13,000 feet.