Course:

Operations
Management and
Research
Module 4
FACILITY LAYOUT : SESSION 2 : NUMERICAL
EXAMPLES
Type of Plant Layouts :
Questions
PROCESS LAYOUT
PRODUCT LAYOUT
FIXED POSITION LAYOUT
HYBRID LAYOUT
CELLULAR MANUFACTURING
Sums related to
Process Layout
and Product
Layout
P R O C E S S L AYO U T: ( 1 ) LOA D S U M M A RY C H A RT O R B LO C K D I AG RA M M I N G
( 2 ) R E L AT I O N S H I P D I AG RA M A N D M U T H E R ’ S G R I D
P R O D U C T L AYO U T: L I N E B A L A N C I N G P R O B L E M S
Process Layout: Load
summary chart or block
diagramming
Q1 Solve Together
Q1. Analyse what should be the facility Steps of Load Summary Type of
layout using the travel chart method Questions:
(from-to-chart) for a given facility. 1. Take a random layout if not already given
A B C ( lot of times we take 2x 3).
2. Calculate the composite load to be
D E F
transported from one location to the other.
3. Aim is to minimize the load travelled over
From Number of moves to longer distances or in other words reduce
A B C D E F non-adjacent movements.
A - 7 - - - 5
B - - - 4 10 - 4. Note: Adjacent movements are those
C - 7 - - 2 - which you can travel directly either
D - - 8 - - - vertically, horizontally or diagonally.
E 4 - - - -3 -
5. Reduce the non-adjacent movement zero
F - 6 - - 10 -
or limited.
Q2
Mohawk Valley Furniture Warehouse
has purchased a retail outlet with six A B C
departments as shown below. The
anticipated number of customers D E F
that move between the departments
each week is given in the load
From Number of moves to
summary chart. A B C D E F
A - 70 - - - 50
(a) Calculate the non-adjacent loads B - - - - 100 -
for the layouts shown below. C - 70 - - -- -
D - - 80 - - -
E 40 - - - - 30
(b) Revise Mowhawk's layout such
F - 60 - - 100 -
that non-adjacent loads are
minimised.
Q3 Solve Together
Maureen Marcy is designing the layout
for a new business in town, The
Collegiate Spa. From visiting spas in the 1 2 3
neighbouring towns, she has compiled 4 5 6
the following data on movement between
spa activities. Help Maureen determine
where to locate each activity on 2x3 grid
so that non-adjacent distances are 1 2 3 4 5 6
1-Relaxation Lounge - 50 25 - 75 -
minimised. (Question from Russell and 2-Facial 10 - - - - 75
3-Massage 30 - - 50 - 50
taylor) 4-Power Shower - - - - - 25
5-Mineral Bath - 50 - - - 50
6-Sauna - - - - - -
Q4 Solve Together
Given the following load summary chart, design a layout on a 2x3 grid that will
minimise the non-adjacent loads.
1 2 3
4 5 6

From/To 1 2 3 4 5 6
1 - - 125 40 - -
2 - - 45 75
3 - - - 20 235 200
4 60 30 10 - 85 50
5 - - - - - 10
6 - - 40 30 150 -
Process Layout: Relationship
diagram and Muther’s grid
Q5 Let us understand together :
Muther’s Grid
Q5 Let us understand together :
Relationship Diagram
Q6 Draw the Relationship
Diagram from the Muther’s
Grid
Q7 Draw the Relationship
Diagram from the Muther’s
Grid
Product Layout:
Assembly Line Balancing
Q8: Let’s Solve Together
The Basic Block Company needs to produce 4000 boxes of blocks per 40-hour week
to meet upcoming holiday demand. The process of making blocks can be broken
down into six work elements. The precedence and time requirements for each
element are as follows. Draw and label a precedence diagram for the production
process. Set up a balanced assembly line and calculate the efficiency of the line.
Work Element Precedence Performance Time(min)
A - 0.10
B A 0.40
C A 0.50
D - 0.20
E C,D 0.60
F B,E 0.40
Formulae for Line Balancing
Problems
Steps for Line Balancing
Problems
1. Draw and label precedence diagram.
2. Calculate the desired cycle time required for the line.
3. Calculate the theoretical minimum number of workstations.
4. Group elements into workstations, recognizing cycle time and precedence
constraints.
5. Calculate the efficiency of the line.
6. Determine if the theoretical minimum number of workstations or an
acceptable efficiency level has been reached.
Q10: Let’s Solve Together
Professional Image Briefcases is an exclusive producer of handcrafted stylish cases.
The company assembles each case with care and attention to detail. This laborious
process requires the completion of 6 primary work elements listed here.
Work Element Description Precedence Performance Time(min)
A Tan Leather - 30
B Dye Leather A 15
C Shape Case B 10
D Mold hinges and - 5
fixtures
E Install hinges and C,D 10
fixtures
F Assemble case E 10

a. Construct a precedence diagram for manufacturing