Sheet 4 FP

Zagazig University Course : Forecasting
Faculty of Engineering Code: IE 425 Sheet No. 4

Industrial Engineering Department Subject: Facility Planning
Year : 2014-2015, 1st term Dr. Yehya Mesalam
1- What are some of the important factors that should be taken into consideration when a
layout is being designed?
2- What kind of manufacturing environments are the following types of layout designs best
suited for?
a. Fixed product layout
b. Product layout
c. Group layout
d. Process layout
3- Four departments are to be located in a building of 600' X 1000'. The expected personnel
traffic flows and area requirements for the departments are shown in the tables below.
a-Develop a block layout using SLP.
b-Develop a block layout using Relationship diagramming.
4- XYZ Inc. has a facility with six departments (A, B, C, D, E, and F). A summary of the
processing sequence for 10 products and the weekly production forecasts for the products
are given in the tables below.
a. Develop the from-to chart based on the expected weekly production.
b. Develop a block layout using SLP.
c-Develop a block layout using Relationship diagramming.
Page 1 of 7
Sheet No. 4 Facility Planning
5- A toy manufacturing company makes 10 different types of products. There are 15 equal-
sized departments involved. Given the following product routings and production
forecasts,
a. Construct a from-to chart for the facility.
b. Develop a block layout using SLP.
c-Develop a block layout using Relationship diagramming.
6- Shown below is the activity relationship chart along with the space requirements for each of the six
cells in a small auto parts manufacturing facility.
a. Construct relationship and space relationship diagrams.
b. Design the corresponding block layout using SLP.
C. Construct a corresponding block layout using relationship diagrams
7- An activity relationship chart is shown below for the American Mailbox Company. Construct a
relationship diagram for the manufacturing facility. Given the space requirements (in ft2),
a. Construct a block layout using SLP diagrams.
b. Develop a block layout using relationship diagramming
Page 2 of 7
8- In an assembly plant, material handling between departments is performed using a unidirectional

closed-loop conveyor. The figure below shows the layout for the modular facility, which consists of
three equal-sized assembly modules (A, B, and C), one administrative module (D), and one
warehouse module (E).
P/D points for each module are also shown in the figure. The administrative and warehouse
activities are not to be moved; however, assembly areas A, B, C can be relocated. The distance
between P/D points and the number of pallet loads moved between departments are given
below.
Using the pairwise exchange method, determine new locations for assembly modules A, B, and
C that minimize the sum of the products of pallet flows and conveyor travel distances.
9- Four equal-sized machines are served by an automated guided vehicle (AGV) on a linear
bidirectional track, as shown in the figure below. Each machine block is 30' X 30'. The product
routine information and required production rate are given in the table below. Determine a layout
arrangement based on the pairwise exchange method. Assume that the pickup/delivery stations are
located at the midpoint of the machine edge along the AGV track.
Page 3 of 7
10- Using the data from Problem 9 but assuming that the locations of the P/D points for
machines A and B are 5 feet from the lower righthand corner of each machine and the P/D
points for machines C and D are 10 feet from the lower-lefthand corner of machines C and
D, develop an improved layout using the pairwise exchange method.
11- A mobile robot is serving two cells located at either sides of the AGV track, as shown by
the figure below. There are three machines placed in each cell. Given the from-to chart in
the table below, find the best machine arrangements for both cells. Rearrangement is
limited only to machines within each cell. Assume that the P/D point of each machine is
located at the midpoint of the machine edge along the AGV track.
12- Five machines located in a manufacturing cell are arranged in a “U” configuration as
shown in the layout below. The material handling system employed is a bidirectional
conveyor system. Determine the best machine arrangement given the product routing
information and production rates in the table.
Page 4 of 7
13- The ABC Cooling and Heating Company manufactures several different types of air
conditioners. Five departments are involved in the processing required for the products. A
summary of the processing sequences required for the five major products and the weekly
production volumes for the products are shown in the tables below along with the
department area. Based on the graph-based construction method, develop a block layout.
14- The activity relationship chart for Walter’s machine shop is shown in the figure below.
The space requirements are in square feet. Construct the relationship diagram and
develop a block layout using the graph-based method.
Page 5 of 7
15- The from-to material flow matrix for an eight-department facility is given in the table
below. Construct a relationship diagram based on the material flow matrix, and construct
a block layout using the graph-based method.
16- Consider the layout of five equal-sized departments. The material flow matrix is given in
the figure below.
a. Develop the final adjacency graph using the graph-based procedure.
b. Develop a block layout based on the final adjacency graph obtained in part a.
17- The material flow matrix for 10 departments is given below.
Page 6 of 7
The area requirements are
a. Determine a final adjacency graph using the graph-based procedure.

b. Construct a block layout based on the adjacency graph in part a.
Page 7 of 7

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Zagazig University Course : Forecasting

Faculty of Engineering Code: IE 425 Sheet No. 4

8- In an assembly plant, material handling between departments is performed using a unidirectional

17- The material flow matrix for 10 departments is given below.

The area requirements are

a. Determine a final adjacency graph using the graph-based procedure.

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