Process Design

Process

Must Exist for

Assists the Manage
organization to
Operations of Operations of
function
an organization an organization
properly
Process
 Process Design ?

Determines the structure of

a process
Focus on the
The sequence of design of
operations product/service
process
The workflow
 Process Design ?

Layout of
Product/ Facility
Service Major &
Process Implications
Design of
Design work/job
Important in Product/Service
Process Design
Make or Buy decision

Production/Inventory Strategies

Make-to-stock (Standardized products)

Make-to-order (variety)

Assemble-to-order (from standardized sub-components)

 Process Types

Job Shop Repetitive

Batch Continuous
 Job Shop

• Equipment very flexible (does

many things)
• Skilled Workers
 Batch

• Equipment less flexible

• Less skilled workers
 Repetitive

• Higher Quantities
• Equipment less flexible
• Less skilled workers
 Continuous
• Very high volumes of non-discrete
goods (gasoline, steel)
• Used when high volume of highly
standardized output is required and
product is in continuous motion in
production
Process Characteristics
Product-Process Matrix (What to Select)

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 Productive Activity
Process Flow
Diagram: Show
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Symbols
operations and vit
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movements of e A
material tiv
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Process Flow Diagram of ordering a product on the phone

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si on ) Wa
si on No)
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De o r N D el a D e es o r
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Process Flow Diagram: Each function/Role activity in its row
Assembly Line Balancing
 Assembly Line Balancing

n c ing
B a la id le
Line ize the line
inim g the
m a lo n r
e g he
tim  Hi on
l i zati
Uti
Line Balancing: Cycle Time

e r
e p
Tim unit
Line Balancing Formulas

up
n d
u
Ro min.
N
Useful tool in Line Balancing: Precedence
Network
How to balance a line

We need to assign tasks to

workstations
No optimal solution:
Managers use heuristics
Intuitive Rules
Line Balancing Heuristic Rules (Precedent
Network)

Assign the task with longest time.

Assign the task with the most followers.

Assign the task with the largest positional weight (the

sum of the task’s time plus the time of all the following
tasks).
Line balancing on the network below. Example 1
Perform line balancing on the network below, assuming CT of 1 minute and using the
‘the most followers rule.’

N = 2.5/1.0 = 2.5
= 3 workstations
Workstati Time Eligible Will Fit Task Idle
on
Left (min) activity Time Time
1 1.0 a,c a,c a(0.1)

Eligible act We
Time left ivies are choose We
before activities “a” calculate at
because the end of
choosing whom
first predecess
ors have it has the
activity
been more workstation
assigned
followers
 Line balancing. Example 1
Perform line balancing on the network below, assuming CT of 1 minute and using the
‘the most followers rule.’

Workstati Time Eligible Will Fit Task Idle

on
Left (min) activity Time Time
1 1.0 a,c a,c a(0.1)
1 0.9 b,c c c(0.7)

Time left Even b

after and c are
choosing eligible,
first we can
activity only fit c
 Line balancing. Example 1
Perform line balancing on the network below, assuming CT of 1 minute and using the
‘the most followers rule.’

Workstati Time Eligible Will Fit Task Idle

on
Left (min) activity Time Time
1 1.0 a,c a,c a(0.1)
1 0.9 b,c c c(0.7)
1 0.2 b No 0.2

Time left Calculate

after Idle Time
choosing Can’t fit because
two “b” workstation
activities is exhausted
above 1-0.8=0.2
 Line balancing . Example 1
Perform line balancing on the
network below, assuming CT of 1 Workstati Time Eligible Will Fit Task Idle
minute and using the ‘the most on
Left (min) activity Time Time
followers rule.’ 1 1.0 a,c a,c a(0.1)
1 0.9 b,c c c(0.7)
1 0.2 b No 0.2
2 1.0 b b b(1.0)

“b” because
Time left
its
before
preceding
doing
activities
anything
have been
= CT
assigned
 Line balancing . Example 1
Perform line balancing on the
network below, assuming CT of 1 Workstati Time Eligible Will Fit Task Idle
minute and using the ‘the most on
Left (min) activity Time Time
followers rule.’ 1 1.0 a,c a,c a(0.1)
1 0.9 b,c c c(0.7)
1 0.2 b -- 0.2
2 1.0 b b b(1.0)
2 0 d -- 0.0

Time left
Calculate
after It will not
Idle time;
fitting fit “d”
1-1=0
“b”
 Line balancing . Example 1
Perform line balancing on the
network below, assuming CT of 1 Workstati Time Eligible Will Fit Task Idle
minute and using the ‘the most on
Left (min) activity Time Time
followers rule.’ 1 1.0 a,c a,c a(0.1)
1 0.9 b,c c c(0.7)
1 0.2 b -- 0.2
2 1.0 b b b(1.0)
2 0 d -- 0.0
3 1.0 d d d(0.5)

Only “d” eligible

because all
preceding activities
have been assigned
 Line balancing . Example 1
Perform line balancing on the
network below, assuming CT of 1 Workstati Time Eligible Will Fit Task Idle
minute and using the ‘the most on
Left (min) activity Time Time
followers rule.’ 1 1.0 a,c a,c a(0.1)
1 0.9 b,c c c(0.7)
1 0.2 b -- --- 0.2
2 1.0 b b b(1.0)
2 0 d -- -- 0.0
3 1.0 d d d(0.5)
3 0.5 e e e(0.2)
3 0.3 --- --- --- 0.3

Total Idle Time = 0.3 + 0 + 0.2 = 0.5

Line balancing example, let’s calculate the effectiveness of the result.
 Line balancing Effectiveness. Example 2
Calculate the effectiveness of the results you’ve gotten in Example 1

Total Idle Time = 0.5

CT = 1.0

N = No. of
workstations = 3.0
Line Balancing Steps in General (Recap)
 Line Balancing. Example 3.
Perform line balancing on the network below, assuming CT of 1 minute and using
the ‘the most followers rule then longest time.’

Workstati Time Eligible Will Fit Task Idle

N = 3.7/1.0 = 3.7 on
Left (min) activity Time Time
= 4 workstations 1 1.0 a,c a,c a(0.2)

We
choose
“a”
because
it has
more
followers
 Line Balancing. Example 3.
Perform line balancing on the network below, assuming CT of 1 minute and using
the ‘the most followers rule then longest time.’

Workstati Time Eligible Will Fit Task Idle

N = 3.7/1.0 = 3.7 on
Left (min) activity Time Time
= 4 workstations 1 1.0 a,c a,c a(0.2)
1 0.8 c,b c,b c(0.8)

“c” and “b” have the same number of

followers but “c” has a longer time so
we choose “c” because of the next
criteria: “c” has longest time
 Line Balancing. Example 3.
Perform line balancing on the network below, assuming CT of 1 minute and using
the ‘the most followers rule then longest time.’

Workstati Time Eligible Will Fit Task Idle

on
Left (min) activity Time Time
1 1.0 a,c a,c a(0.2)
1 0.8 c,b c,b c(0.8)
1 0 0
2 1.0 b,d b,d b(0.1)

We choose “b” because it

has more followers
 Line Balancing. Example 3.
Perform line balancing on the network below, assuming CT of 1 minute and using
the ‘the most followers rule then longest time.’

Workstati Time Eligible Will Fit Task Idle

on
Left (min) activity Time Time
1 1.0 a,c a,c a(0.2)
1 0.8 c,b c,b c(0.8)
1 0 0
2 1.0 b,d b,d b(0.1)
2 0.9 e,d e,d d(0.6)

“d” and “e” have the same

no. of followers but “d” has
longer time: choose “d”
 Line Balancing. Example 3.
Perform line balancing on the network below, assuming CT of 1 minute and using
the ‘the most followers rule then longest time.’

Workstati Time Eligible Will Fit Task Idle

on
Left (min) activity Time Time
2 1.0 b,d b,d b(0.1) more
followers

2 0.9 e,d e,d d(0.6) tie

but
longest
2 0.3 e,f e,f e(0.3)

We choose “e” because it

has more followers
 Line Balancing. Example 3.
Perform line balancing on the network below, assuming CT of 1 minute and using
the ‘the most followers rule then longest time.’

Workstati Time Eligible Will Fit Task Idle

on
Left (min) activity Time Time
2 0.3 e,f e,f e(0.3)
2 0 -- -- -- 0
3 1.0 f f f(1.0) 0
3 0 -- -- -- 0
4 1.0 g g g(0.4) 0
4 0.6 h h h(0.3)
4 0.3 --- --- --- 0.3
 Line Balancing. Example 3.
Perform line balancing on the network below, assuming CT of 1 minute and using
the ‘the most followers rule then longest time.’
Workstation Time Left (min) Eligible activity Will Fit Task Time Idle Time

1 1.0 a,c a,c a(0.2)

1 0.8 c,b c,b c(0.8)
1 0 0
2 1.0 b,d b,d b(0.1)
2 0.9 e,d e,d d(0.6)
2 0.3 e,f e,f e(0.3)
2 0 -- -- -- 0
3 1.0 f f f(1.0) 0
3 0 -- -- -- 0
4 1.0 g g g(0.4) 0
4 0.6 h h h(0.3)
4 0.3 --- --- --- 0.3
 Line Balancing. Example 4.
What’s the efficiency of the network below, which used a minimum work station
method. Use example 3 data.

% of Idle Time = 0.3/(4*1)

Efficiency= 100 – 7.5= 92.5%
=0.075=7.5%
 Variable Task/Activity Time

It’s convenient to assume the same time for each

repetition of task Reality shows task times
are variable

Worker Fatigue
Reasons for Variations Material Shortage
Product
Boredom Differences Mechanical
Defects Problems
Solutions to Variable Task/Activity Time

Reduce Variability
Use higher Do preventive
Design the jobs better maintenance
quality material

Use buffer inventory between workstations

Leave some idle time in workstations

Cross-train workers
Bottlenecks

k
n ec
ttle
Also

Bo
called
“choke
point”
 Bottleneck

One process (or activity/task) of limited capacity

Which limits the capacity of
the whole system
 Bottleneck: Because of the bottleneck in the process
below: process runs at 30 units per hour opposed to 60 units per
hour

The cycle time for the line will be dictated by

the bottleneck (2 min) and hence output =
60/2 = 30 units per hour
If use parallel stations where the
bottleneck: Problem Solved
 Solutions for Bottlenecks

Parallel Workstations

Automate Tasks

Task done offline or by “floaters”

Floaters: special crew of workers who
Offline: e.g. outside operational
move around to assist in bottleneck areas
hours
 m ajor
n ce of
u e s flow
Seq tions (pro c es

a
oper diagra
m)

ro c es s ,
e P eople
i t y, , ro totypresources-pent)
p ac ype P mine quipm
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Ca ss t h,
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o
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Mo o c es s s
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Layout: Location/arrangement of departments, work centers,
equipment, etc..

Two Types of Layout

 Designing Process (Functional) Layout

• Arrange production resources according to function.

• Processes items that have variety of product requirements.

• Relates more to Job shop dynamics

• Promotes the use of general purpose equipment
 Process Layout

in es
a ch ent
e m pm
L i k e q u i p ed
& grou her
Resources are to get

arranged according
to similarity of b l e: t y
l exi arie
function al
F e v c ts
n dl du es
r
ne se Ha f pro rvic
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G rpo nt o se
d
p u ip m e an
u
eq
Process Layout
Designing Process (Functional) Layout

Involves determining the position of the departments

on the facility floor

Arrange work centers so as to minimize transportation

cost, distance or time.
General Rule: Locate departments
with high interdepartmental flow as
close as possible
Designing Process (Functional) Layout:
Minimize transportation cost, distance or time.

v
Designing Process (Functional) Layout:
Complexity

In practice, for layouts, there are a large number of

possible assignments:
Example, 14 departments/locations produce more than
87 billion different ways for assignments.
Designing Process (Functional) Layout:
Minimize transportation cost, distance or time.

A reasonable heuristic is
to locate department
with high
interdepartmental
workflow close together
Designing Process Layout. Example 5
For the data below (distances and loads between departments). Design the layout with
high interdepartmental workflows close together.

Location A and
Closest two locations are A and B B should be
assigned b e Ato
1
u ld ?
dept.
ts
ho B1??and
he
r3
Bu o r fu r t n
ed tio
Ne s p e c
in
Dept. Workflow Workflow total
Pair
3-1 90 170 Highest
Interdepartmental
1-3 80 workflow

3-2 70 100
2-3 30
2-1 20 30
1-2 10
Designing Process Layout. Example 5
So dept. 1 and 3
should be located
close to eachother;
while 1 and 2 could
Look for second be farthest
highest interdept.
workflow

Dept. Workflow Workflow total

Pair
3-1 90 170
1-3 80
3-2 70 100 2nd Highest
Interdepartmental
2-3 30 workflow
2-1 20 30
1-2 10
 Designing Process Layout. Example 6
Compute transportation costs for example 5 with $1 transportation cost per meter per load

$ 1 st
o n co ,
s e d o n ad
ti
Ba orta er lo te
nsp ter p mpu
tra r me n co al st
t o
pe e ca e to on c
w th tati
o r
ns p
tr a
Designing Process (Functional) Layout
Heuristic
 Product Line Layout

for r m on eve id
ed ve o i
s
U titi us com than h
Ac th ra e
p
pe nuo g o re ods s o o lu m
e
R nti sin M go ice sm gh vo w
Co oces for serv hi flo
pr
Product Line Layout
Cellular Layout

u p :
o y
G r o l og s w i t h d
h n item sign an
Tectifying es (de g) andnto
n iti in i
Ide ilar factur hem
sim anu ng t ies
i l
m
up fami
gro
Difference between Functional and
Cellular Layout
n of
o
e rsi yout
a l l v c t la
Sm odu
pr

u p :
o y
G r o l og s w i t h d
h n item sign an
Tectifying es (de g) andnto
n iti in i
Ide ilar factur hem
sim anu ng t ies
i l
m
up fami
gro
Cellular Layouts
• Benefits:
• Faster processing time and reduced setup times
• Increased capacity
• Less material handling and work-in-process inventory

 Disadvantage
 Conversion of group technology is a major
undertaking

68
Other Layout Types
• Warehouse layouts
• Important consideration: frequency of order
• Retail layouts
• Important consideration: traffic flow
• Office layouts
• Objective: optimize the physical transfer of information or
paperwork
• New trend: create an image of openness (low rise
partitions)

69
Other Layout Types

• Restaurant Layout
• Important consideration: process workflow

• Hospital Layout
• Important considerations: patient care & safety, easy
access to critical resources such
as X-ray, CAT scan, & MRI equipment

70
 Other Service Layout

ti ve
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v
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i Offi ctive orta d tim
b j
e c id p uld er/ re je nsp , an
e o u t d ou t b
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T yo
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 Example 7a
A manager want to assign tasks to workstations to achieve an hourly output rate of 33
units. Assume that the shop works 60 minutes per hour (i.e. no breaks). A) Assign the
tasks shown in the following network (times are on the nodes and are in minutes) to
workstations using the following rules: i) Assign the task with the most followers; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists, choose randomly.

D= 33 OT= 60 𝑂𝑇
𝐶𝑇 =
𝐷
 Example 7a
A manager want to assign tasks to workstations to achieve an hourly output rate of 33
units. Assume that the shop works 60 minutes per hour (i.e. no breaks). A) Assign the
tasks shown in the following network (times are on the nodes and are in minutes) to
workstations using the following rules: i) Assign the task with the most followers; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists, choose randomly.
 Example 7a
A manager want to assign tasks to workstations to achieve an hourly
output rate of 33 units. Assume that the shop works 60 minutes per
hour (i.e. no breaks). A) Assign the tasks shown in the following
network (times are on the nodes and are in minutes) to workstations
using the following rules: i) Assign the task with the most followers; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists,
choose randomly.

𝐶𝑇 =1.82
 Example 7a
A manager want to assign tasks to workstations to achieve an hourly
output rate of 33 units. Assume that the shop works 60 minutes per
hour (i.e. no breaks). A) Assign the tasks shown in the following
network (times are on the nodes and are in minutes) to workstations
using the following rules: i) Assign the task with most followers; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists,
choose randomly.

𝐶𝑇 =1.82

Tie on # of followers, e has longest time

 Example 7a
𝐶𝑇 =1.82
A manager want to assign tasks to workstations to achieve an hourly
output rate of 33 units. Assume that the shop works 60 minutes per
hour (i.e. no breaks). A) Assign the tasks shown in the following
network (times are on the nodes and are in minutes) to workstations
using the following rules: i) Assign the task with the most followers; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists,
choose randomly.

Tie on # of followers, d has longest time

C has more followers
 Example 7b
A manager want to assign tasks to workstations to achieve an hourly output rate of 33
units. Assume that the shop works 60 minutes per hour (i.e. no breaks). A) Assign the
tasks shown in the following network (times are on the nodes and are in minutes) to
workstations using the rules. B) What is the efficiency?

𝐶𝑇 =1.82 N

𝑇𝑜𝑡𝑎𝑙𝐼𝑑𝑙𝑒𝑇𝑖𝑚𝑒=1.28
 Example 8a
A large manufacturer of sharpeners have asked to
balance the assembly line, given the following task
times and precedence relationships. Assume that
the cycle time is 1.3 minutes per unit. Task Duration Immediate
(minutes) Followers
A) i. Draw the precedence network a 0.2 b
ii. Assign the task with the most followers; b 0.4 d
Tiebreaker: Assign the task with the longest time c 0.3 d
iii. Determine the percentage of idle time d 1.3 g
iv. Calculate the rate of output that could be e 0.1 f
expected for this lines assuming a 420- minute f 0.8 g
working day g 0.3 h
h 1.2 ---
Example 8a
Task Duration Immediate
(minutes) Followers
a 0.2 b
b 0.4 d
c 0.3 d
d 1.3 g
e 0.1 f
f 0.8 g
g 0.3 h
h 1.2 ---
 Example 8a
A large manufacturer of sharpeners have asked to balance the assembly line, given the
following task times and precedence relationships. Assume that the cycle time is 1.3
minutes per unit. A) i. Draw the precedence network. ii. Assign the task with the most
followers; Tiebreaker: Assign the task with the longest time. iii. Determine the percentage
of idle time. iv. Calculate the rate of output that could be expected for this lines assuming a
420- minute working day 𝐶𝑇 =1.3
 Example 8a
A large manufacturer of sharpeners have asked to balance the assembly line, given the
following task times and precedence relationships. Assume that the cycle time is 1.3
minutes per unit. A) i. Draw the precedence network. ii. Assign the task with the most
followers; Tiebreaker: Assign the task with the longest time. iii. Determine the percentage
of idle time. iv. Calculate the rate of output that could be expected for this lines assuming a
420- minute working day 𝐶𝑇 =1.3
 Example 8b
A large manufacturer of sharpeners have asked to balance the assembly line, given the
following task times and precedence relationships. Assume that the cycle time is 1.3
minutes per unit. B) Answer the following questions: i. What’s the shortest cycle time that
will permit the use of only two workstations? Identify the tasks you would assign to each
workstations. ii. Determinee the percentage idle time that would result if two workstations
Task Duration Immedia
were used. iii. What is the daily output under this arrangement? (minutes te
N ) Follower
s
a 0.2 b
b 0.4 d
c 0.3 d
d 1.3 g
e 0.1 f
f 0.8 g
g 0.3 h
h 1.2 ---
 Example 8b
A large manufacturer of sharpeners have asked to balance the assembly line, given the
following task times and precedence relationships. Assume that the cycle time is 1.3
minutes per unit. B) Answer the following questions: i. What’s the shortest cycle time that
will permit the use of only two workstations? Identify the tasks you would assign to each
workstations. ii. Determinee the percentage idle time that would result if two workstations
were used. iii. What is the daily output under this arrangement?
More Exercises
 Example A
Determine the minimum number of workstations needed for this situation:
Operating time is 450 minutes per day. Desired output is 80 units per day. The sum of task
times is 56 minutes.
Sum of task
𝐶𝑇 =
𝑂𝑇
𝑁 𝑚𝑖𝑛 =
∑ 𝑡 OT= 450 D= 80 times = 56
𝐷 𝐶𝑇

= 5.625

= 9.96, so 10 stations needed

 Example B
With the data below, determine the percentage idle time?

∑ 𝐼𝑑𝑙𝑒𝑇𝑖𝑚𝑒
CT= 5.1 N= 4

% 𝑜𝑓 𝐼𝑑𝑙𝑒𝑡𝑖𝑚𝑒=
𝑁 𝑎𝑐𝑡𝑢𝑎𝑙 ∗𝐶𝑦𝑐𝑙𝑒𝑇𝑖𝑚𝑒 Station StationTime
(min)
1 4.2
2 4.7 Cycle time = 5.1
3 4.4 min
4 4.8
 Example B
With the data below, determine the percentage idle time?

% 𝑜𝑓 𝐼𝑑𝑙𝑒𝑡𝑖𝑚𝑒=
∑ 𝐼𝑑𝑙𝑒𝑇𝑖𝑚𝑒 CT= 5.1 N= 4

𝑁 𝑎𝑐𝑡𝑢𝑎𝑙 ∗𝐶𝑦𝑐𝑙𝑒𝑇𝑖𝑚𝑒
Compute the idle time for each work station (CT minus station-time),
then sum all the idle times
Station Stationtime Idle Time
1 4.2 .9
2 4.7 .4
3 4.4 .7
4 4.8 .3
2.3
 Example B
With the data below, determine the percentage idle time?

% 𝑜𝑓 𝐼𝑑𝑙𝑒𝑡𝑖𝑚𝑒=
∑ 𝐼𝑑𝑙𝑒𝑇𝑖𝑚𝑒 CT= 5.1 N= 4
Sum of Idle
time= 2.3

𝑁 𝑎𝑐𝑡𝑢𝑎𝑙 ∗𝐶𝑦𝑐𝑙𝑒𝑇𝑖𝑚𝑒 Station Stationtime

1 4.2
Idle Time
.9
2 4.7 .4
3 4.4 .7
4 4.8 .3
2.3

= 0.1127 or 11.27%
 Example C
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). What is the total flow between departments B and D?
From/To 1 2 3 4From/To A B C D
1 - 50 100 150A - 10 40 50
2 - 50 100B 30 - 10 70
3 - 50C 60 10 - 40
4 -D 30 50 20 -

From table, load flow from B to D is 70

From table, load flow from D to B is 50

So total flow between B and D is (70+50)=120

 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $0.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4From/To A B C D
1 - 50 100 150A - 10 40 50
2 - 50 100B 30 - 10 70
3 - 50C 60 10 - 40
4 -D 30 50 20 -

Let’s figure out the layout first

Dept. Pair Workflow Workflow total Dept. Pair Workflow Workflow total

A-B 10 40 B-C
B-A 30 C-B
A-C B-D
C-A D-B
A-D C-D
D-A D-C
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4From/To A B C D
1 - 50 100 150A - 10 40 50
2 - 50 100B 30 - 10 70
3 - 50C 60 10 - 40
4 -D 30 50 20 -

Let’s figure out the layout first

Dept. Pair Workflow Workflow total Dept. Pair Workflow Workflow total

A-B 10 40 B-C
B-A 30 C-B
A-C 40 100 B-D
C-A 60 D-B
A-D C-D
D-A D-C
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4From/To A B C D
1 - 50 100 150A - 10 40 50
2 - 50 100B 30 - 10 70
3 - 50C 60 10 - 40
4 -D 30 50 20 -

Let’s figure out the layout first

Dept. Pair Workflow Workflow total Dept. Pair Workflow Workflow total

A-B 10 40 B-C 10 20
5 Highest
th
6th Highest
B-A 30 C-B 10
A-C 40 100 B-D 70 120
C-A 60 2 Highest
nd
D-B 50 Highes
t

A-D 50 80 C-D 40 60
D-A 30 3 Highest
rd
4th Highest
D-C 20
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4
1 - 50 100 150 Location 1 Location 2 Location 3 Location 4
2 - 50 100
3 - 50 C A D B
4 -

Let’s figure out the locations

Dept. Pair Workflow Workflow total Dept. Pair Workflow Workflow total

A-B 10 40 B-C 10 20
5 Highest
th
6th Highest
B-A 30 C-B 10
A-C 40 100 B-D 70 120
C-A 60 2 Highest
nd
D-B 50 1st High
est

A-D 50 80 C-D 40 60
D-A 30 3 Highest
rd
4th Highest
D-C 20
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4
1 - 50 100 150 Location 1 Location 2 Location 3 Location 4
2 - 50 100
3 - 50 C A D B
4 -

Let’s figure out the transportation cost

Dept. Pair Loads Distance Distance*Load
Dept. Pair Loads Distance Distance*Loads

A-B (2,4) 10 B-C 10

B-A (2,4) 30 C-B 10
A-C (1,2) 40 B-D 70
C-A (1,2) 60 D-B 50
A-D (2,3) 50 C-D 40
D-A (2,3) 30 D-C 20
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4
1 - 50 100 150 Location 1 Location 2 Location 3 Location 4
2 - 50 100
3 - 50 C A D B
4 -

Let’s associate locations with departments

Dept. Pair Loads Distance Distance*Load
Dept. Pair Loads Distance Distance*Loads

A-B (2,4) 10 100 B-C 10

B-A (2,4) 30 100 C-B 10
A-C (1,2) 40 B-D 70
C-A (1,2) 60 D-B 50
A-D (2,3) 50 C-D 40
D-A (2,3) 30 D-C 20
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4
1 - 50 100 150 Location 1 Location 2 Location 3 Location 4
2 - 50 100
3 - 50 C A D B
4 -

Let’s associate locations with departments

Dept. Pair Loads Distance Distance*Load
Dept. Pair Loads Distance Distance*Loads

A-B (2,4) 10 100 B-C 10

B-A (2,4) 30 100 C-B 10
A-C (1,2) 40 50 B-D 70
C-A (1,2) 60 50 D-B 50
A-D (2,3) 50 C-D 40
D-A (2,3) 30 D-C 20
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in
four areas (1, 2, 3, and 4). If transportation costs are $0.25 per load per foot moved, what
are total monthly costs for an optimum layout?
From/To 1 2 3 4
1 - 50 100 150 Location 1 Location 2 Location 3 Location 4
2 - 50 100
3 - 50 C A D B
4 -

Let’s associate locations with departments

Dept. Pair Loads Distance Distance*Load
Dept. Pair Loads Distance Distance*Loads

A-B (2,4) 10 100 1000 B-C (1,4) 10 150 1500

B-A (2,4) 30 100 3000 C-B (1,4) 10 150 1500
A-C (1,2) 40 50 2000 B-D (3,4) 70 50 3500
C-A (1,2) 60 50 3000 D-B (3,4) 50 50 2500
A-D (2,3) 50 50 2500 C-D (1,3) 40 100 4000
D-A (2,3) 30 50 1500 D-C (1,3) 20 100 2000
 Example D
Given the following process layout data for locating four departments (A, B, C, and D) in four
areas (1, 2, 3, and 4). If transportation costs are $0.25 per load per foot moved, what are
total monthly costs for an optimum layout? Dept. Pair Loads Distance Distance*Loads

A-B (2,4) 10 100 1000

Sum all the “distances * Loads
B-A (2,4) 30 100 3000
(4th column) ”
A-C (1,2) 40 50 2000
C-A (1,2) 60 50 3000
The sum is $28000 A-D (2,3) 50 50 2500
D-A (2,3) 30 50 1500
B-C (1,4) 10 150 1500
We multiply sum by the $0.25 C-B (1,4) 10 150 1500
rate per load per ft. B-D (3,4) 70 50 3500
D-B (3,4) 50 50 2500
C-D (1,3) 40 100 4000
Total Cost = $28000*0.25 = $7000 D-C (1,3) 20 100 2000
 Example E
A manger want to assign tasks to workstations in order to achieve an hourly output rate of 4
units. The department uses a working time of 56 minutes per hour. The department uses a
working time of 56 minutes per hours. A) Assign the tasks showing in the network below
using the following heuristic: : i) Assign the task with the largest positional weight; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists, choose randomly.
B) What’s the efficiency?
 Example E
A manger want to assign tasks to workstations in order to achieve an hourly output rate of 4
units. The department uses a working time of 56 minutes per hour. The department uses a
working time of 56 minutes per hours. A) Assign the tasks showing in the network below
using the following heuristic: : i) Assign the task with the largest positional weight; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists, choose randomly.
B) What’s the efficiency?

To the right is
the positional
weight of all
the tasks
(written in
“[…]” )
 Example E
A manger want to assign tasks to workstations in order to achieve an hourly output rate of 4
units. The department uses a working time of 56 minutes per hour. The department uses a
working time of 56 minutes per hours. A) Assign the tasks showing in the network below
using the following heuristic: : i) Assign the task with the largest positional weight; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists, choose randomly.
B) What’s the efficiency?
 Example E
A manger want to assign tasks to workstations in order to achieve an hourly output rate of 4
units. The department uses a working time of 56 minutes per hour. The department uses a
working time of 56 minutes per hours. A) Assign the tasks showing in the network below
using the following heuristic: : i) Assign the task with the largest positional weight; ii)
Tiebreaker: Assign the task with the longest time, if a tie still exists, choose randomly.
B) What’s the efficiency?
 Example F
For the below network, perform line balancing using the heuristic rule of “assign the task
with the most followers”. If a tie exists, use the rule of “assign the task with the longest
time.” The output rate is 240 units per day (8 hours work day)
Task Duration Immedia
(minutes te
) Follower
s
a 0.2 b
b 0.4 d
c 0.2 d
d 0.4 g
e 1.2 f
f 1.2 g
g 1.0 -
 Example F
For the below network, perform line balancing using the heuristic rule of “assign the task
with the most followers”. If a tie exists, use the rule of “assign the task with the longest
time.” The output rate is 240 units per day (8 hours work day)