INDUSTRIAL MANAGEMENT ENGINEERING SOCIETY

FACPLAD REVIEWER for Quiz 1

I. Fill in the blanks

Answers Questions
1. Effective facilities planning can reduce costs by at least ___%.
2. If the flow of products from manufacturing facility is to be the
subject of the flow, the flow process is referred to as the
________.
3. _______ are defined by material or personnel flow,
environmental considerations, and organizational structure.
4. A systems designer decided to buy a hand pallet truck to help
the workman in transporting sacks of rice from the container
van to the warehouse. The material handling principle used is
___.
5. _____ means that a full container can be stacked on top of
another full container in the same spatial orientation.
6. The _____ is a unitizing process that is used in packaging
tablets in the pharmaceutical industry.
7. Graph based construction method follows the property of ____
which implies that arcs should not intersect.
8. Space is provided for the _____ to facilitate movement of
materials, handling equipment and people inside a
manufacturing plant.
9. ____ refers to the single item, a number of items which is
arranged and restrained so that the load can be stored, picked
up and moved between two locations as a single mass.
10. The manufacture of space shuttle should follow a ____ layout
11. _____ (full name) is the proponent of Systematic Layout
Planning.
12. If the material flow between two departments is voluminous, it
is better to make two departments adjacent to one another. The
material handling principle for this decision used is ___.
13. ____ plant layout procedure provides flexibility since it allows
jumping around among steps.
14. If the company has separate warehouses for raw materials and
finished goods located at opposite sides, it must follow a ___
shaped layout.
15. ____ is a term that is used to describe layout problems
involving the height of the facility.

II. Enumeration
A. Four search steps of the Systematic Layout Planning (SLP)
B. Five types of flow within Product Departments
C. Three Important Considerations in Determining the Requirements of a Facility
D. Four steps if Ideal Systems Approach
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FACPLAD REVIEWER for Quiz 1
III. Three machines (A, B and C) are needed to process a unit of a product. The product must be processed
by machine A before going to machine B and machine C. There are two machine C’s in the process. The
figure below shows the sequence.

C
A B
C
Machine A has a processing time of 2 minutes per piece. Machine B has a processing time of 1 minute
per unit and machine C has a processing time of 3 minutes per unit. Handling time per move is
equivalent to 1 minute. Find the appropriate unit load size common to all processes that minimizes total
processing time of 12 units. Since there are two machine C’s in the process, the company does not allow
transporting less than three units and the entire 12 units to every process.

IV. Three different material-handling units are available for moving items of materials. The costs of these
lifts are $3000, $2500, and $3300, respectively. These units must make five moves. Data on the
operating cost, Wij ($/hr), and the operating time, hij (hr.), are given in the table below. The capacities of
this equipment are 15 cubic meters, 10 cubic meters, and 18 cubic meters, respectively. Assume an
interest rate of 5% per annum and there are 260 days per year. Each equipment can be used for 5 years.
Where: i = material handling unit, j = move

Move W1j h1j W2j h2j W3j h3j

1 50 0.8 40 0.5 80 0.7
2 60 0.7 70 0.3 50 0.8
3 70 0.4 M - 30 0.9
4 80 0.5 100 0.3 60 0.2
5 40 0.2 M - M -

a. Determine which type of equipment should be used if these moves are to be done daily.
Machine Daily Cost NPV
3
A (capacity: 15 m )
B (capacity: 10 m3)
C (capacity: 18 m3)
Conclusion:

b. If there are seven hours available per day, the frequencies (fij) of each move and the amount of
products (Qij) to be transported per day for each move and per material handling unit are given in
the table below. Assume the overtime cost is $15 per hour.
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FACPLAD REVIEWER for Quiz 1
V. Five machines (A, B, C, D, E) located in a manufacturing cell are arranged in a “U” configuration. As
shown in the layout below. The material handling system employed is a bi-directional conveyor system.
For safety reason, machine C was mounted on the floor. These machines are to be used to produce four
products (1, 2, 3, and 4). The table below shows the product routing information and production rates.

A B
C
E D
Product Machine Prod. Rate M/C Distance M/C Distance
Sequence (ft.) (ft.)
1 BEAC 175 A-B 20 B-D 100
2 CED 225 A-C 70 B-E 120
3 BCEAD 500 A-D 120 C-D 50
4 ACEB 150 A-E 140 C-E 70
B-C 50 D-E 20

a. Develop a flow matrix for the five departments.

Flow\To A B C D E
A
B
C
D
E

b. Develop an activity relationship chart given the following basis for each relationship:
A = more than 800 O = 201 – 400
E =601 – 800 U = 0 – 200
I = 401 – 600 X = less than 0

Flow\To A B C D E
A
B
C
D
E

c. Find the total handling cost per week of the current layout.
d. Develop a layout of the processing areas using pair-wise exchange method. Limit computations
to one iteration.
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FACPLAD REVIEWER for Quiz 1

VI. XYZ Manufacturing Company produces and delivers a certain product and is planning to improve its
efficiency by re-layouting. Currently there are six (6) important departments identified by General
Manager. The table below shows the ratings between two activities.
A B C D E F
Painting (A) - E I U X A
Welding (B) - E E U U
Maintenance (C) - I U U
Machine Shop (D) - U U
Office (E) - E
Storage and shipping (F) -

a. Propose a layout to the General Manager using relationship diagramming. Assume a block size
of 20’ x 20’. What is the order of departments entering the layout? The area requirement for each
department is as follows:
Dept. A B C D E F
Area 2400 1600 800 1200 1200 2800
No. of blocks

Order of departments entering the layout:

Block layout:

b. Evaluate the current layout using normalized adjacency score (NAS).

A B C

F E D
Note: 4 – A, 3 – E, 2 – I, 1 – O, and 0 – U
c. Using the data presented in the table below, construct the final adjacency graph using graph
based construction procedures. Define the order of departments entering the layout. What is the
total score?
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FACPLAD REVIEWER for Quiz 1
Dept. A B C D E F
A - 9 7 8 5 5
B 0 - 4 0 6 7
C 0 0 - 2 6 8
D 0 0 0 - 8 5
E 0 0 0 0 - 0
F 0 0 0 0 0 -

Order of departments entering the layout:

Final adjacency graph:

Total score:
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FACPLAD REVIEWER for Quiz 1
Answers

I. II.
A B
1. 10-30% Space Relationship Diagram Back-to-Back
2. Physical Distribution Modifying Considerations End-to-End
3. Activity Relationship Practical Limitations Front-to-Front
4. Ergonomic Principle Develop Alternative Layout Circular
5. Stackability Odd-angle
6. Blister Packaging
7. Rectilinear C D
8. Flow Space Aim for the Theoretical Ideal System
9. Unit Load Flow Conceptualize the Ultimate Ideal System
10. Fixed Product Activity Relationship Design the technological workable Ideal
11. Richard Muther System
12. Work Principle Implement the Recommended System
13. Apple’s
14. S
15. Multidimensional
III.

Unit load size option 1: 6 units

41 minutes
Unit load size option 2: 4 units
36 minutes
Unit load size option 3: 3 units
35 minutes
Conclusion: unit load option 3 units

IV

a.
Machine Daily Cost NPV
3
A (capacity: 15 m ) $ 158 $ - 180,854.90
B (capacity: 10 m3) $ 71 $ -82,422.14
3
C (capacity: 18 m ) $ 135 $ - 155,264.63
Conclusion:
Choose B, having the greatest NPV and the least cost.
 INDUSTRIAL MANAGEMENT ENGINEERING SOCIETY
FACPLAD REVIEWER for Quiz 1
V

a.
Flow\To A B C D E
A - 0 325 500 675
B - 500 0 325
C - 0 875
b. D - 225
E -
Flow\To A B C D E
A - U O I E
B - I U O
C - U A
D - O
E -

c. 307,000

A E
C
B D
d.

Exchange B and E, having the least cost of 236, 500.

VI.

a.

Dept. A B C D E F
No. of blocks 6 4 2 3 3 7

Order of departments entering the layout:

A-F-B-C-D-E

Block layout:
F E E E F
F F F F F
A A A A A
A B B C C
B B D D D
 INDUSTRIAL MANAGEMENT ENGINEERING SOCIETY
FACPLAD REVIEWER for Quiz 1
b. 0.75

c.

Order of departments entering the layout:

A-B-F-C-E-D

Total score: 75