IE4516 Final f2021Key (1)
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Louisiana State University *
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Course
4516
Subject
Industrial Engineering
Date
Dec 6, 2023
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Uploaded by GrandRainHare29
IE 4516 Final Exam – Fall 2021
NAME:______________________
CLOSE BOOK/NOTE (Two-page formula-sheet allowed)
I.
True/False Questions (15 points total, 1 point each)
1.
Facility planning is a continuous exercise.
T
/F
2.
Minimizing WIP is a goal of effective manufacturing systems
T
/F
3.
Flexible automation is best suited for large product volume with low variety
T/
F
4.
Material handling is a means by which total manufacturing costs are reduced
through more efficient material flow control, lower inventory and improved
safety.
T
/F
5.
U-shaped layout is not the most desirable manufacturing cell configuration.
T/
F
6.
Unit load refers to a single item that can be stored or moved at one time and it
will not change throughout the flow
T/
F
7.
Use of containers with good stacking and nesting features can increase material
handling cost.
T/
F
8.
Material Handling Planning Chart (MHPC) is usually developed after the
Operation Process Chart.
T
/F
9.
Key to pallet loading of mixed-sized containers is using progressive container
systems
T
/F
10. Fast moving items should be located far away from the entrance/exit.
T/
F
11. Unit load design should be completed before design of material handling system
T/
F
12. Muther’s Systematic Layout Planning procedure uses activity relationship chart
as its foundation, including from-to chart
T
/F
13. The values given in a From-to chart indicates equivalent flow volumes
T
/F
14. Picking takes up the most of order picker’s time.
T/
F
15. Order picking is the most costly warehousing operation.
T
/F
II.
Multiple choice questions for Concepts (40 points total, 2 points each)
1.
Once the make or buy decision is made, decisions as to how many products will be made are
made primarily by
a)
Facility planner
b)
Process engineer
c)
Industrial engineer
d)
Production planner
2.
Which chart below should be constructed last?
a)
Precedence diagram
b)
Assembly chart
c)
Operation process chart
1
d)
Material handling planning chart
3.
Which term in the below list has the widest scope than others
a)
Facility design b) Facility planning
c) Facility location
d) Facility layout
4.
Which factor below might not decrease the number of machines needed?
a)
Run more shifts
b)
Use machine cells
c)
Shorten setup time
d)
Implement preventive maintenance
5.
Which tool below is best suited for evaluating alternative facility design?
a)
Prioritization matrix
b)
Affinity diagram
c)
Tree diagram
d)
Activity network diagram
6.
Which JIT concept below does not impact facility design?
a)
Reduction of inventory
b)
Deliveries to points of use
c)
Quality at the source
d)
Better communication, line balancing, and multifunctional workers
e)
None of the above
7.
Zero defect process is not easy to achieve. If defective products are not considered, then the
major consequence is
a)
Material cost might be underestimated
b)
Labor cost might be underestimated
c)
Insufficient good products will be produced.
d)
Machine cost might be underestimated.
e)
All of the above
8.
Pertaining to from-to chart, which statement below is true?
a)
The departments listed down the row and across the column should be identical.
b)
The order should follow the overall flow pattern.
c)
The values given measure frequency of equivalent unit-load-moves per day and others.
d)
The values below the diagonal represent backtracking.
e)
All of the above
9.
Which below statement about qualitative measures of activity relationships is not true?
a)
It can be used to arrange departments having large volumes of materials, information,
and people movements.
b)
The departments listed can be in any order.
c)
The scale consists of six closeness values, with “X” indicating undesirable.
d)
Each closeness value should be given along with the reason.
10.
Which order picking method involve multiple pickers per order, single line item per pick and
multiple periods per shift?
2
a)
Zone
b) Batch
c) Wave
d) Zone-Wave
e) Zone-Batch-Wave
11.
In the notation of waiting line analysis (x|y|z):(u|v|w), which one denotes system capacity?
a)
x
b) y
c) z
d) u
e) v
12.
The most common arrival distribution in waiting line analysis is
a) Binomial
b) Poisson
c) Gaussian
d) General
13.
The most common service time distribution in waiting line analysis is
a)
Exponential
b) Binomial
c) Gaussian
d) General
14.
Which warehousing functions will not be needed if cross-docking is implemented
a)
Receiving & Shipping
b)
Storage
c)
Order picking
d)
Storage & Order picking
15.
Which statement about randomized vs. dedicated storage policy is not true?
a)
Randomized storage requires less space.
b)
Randomized storage can better handle seasonal and fluctuating demands.
c)
If designed well, dedicated storage has greater throughput.
d)
The turnover based storage location assignment is for designing dedicated storage.
e)
Dedicated storage requires less information to design and less management
.
16.
Line balancing results are not affected by which item below?
a)
Precedence relationships
b)
Processing time
c)
Production rate
d)
Line balancing method
e)
None of the above
17.
Raw material cost is most likely
a)
Direct fixed cost
b) Direct variable
c) Indirect fixed
d) Indirect variable
18.
The cost of a piece of material handling equipment used in making a product is most likely
a)
Direct fixed cost
b) Direct variable
c) Indirect fixed
d) Indirect variable
19.
A firm estimates that the fixed cost of producing a line of footwear is $30,000 with a $10
variable cost for each pair produced. If each pair sells for $25, how many pairs must they sell
to break-even?
a)
1,000
b) 2,000
c) 3,000
d) 4,000
20.
For assigning the three departments, with flow matrix given below on the left, to three sites
with distance matrix given below on the right, the total cost lower bound is
a)
67
b) 76
c) 83
d) 38
e) None of the above
3
Flow
A
B
C
A
-
5
2
B
0
-
3
C
0
4
-
Dist
1
2
3
1
-
5
10
2
4
-
6
3
6
5
-
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III.
Computational Problems (45 points)
1.
(15 points) Consider a workstation with buffer size N = 4. Parts arrive at a Poisson rate of 1
per minute if the buffer is not full; else diverted. Workstation service time is exponentially
distributed with mean = 50 seconds. Compute the followings: system empty probability,
average number in line, average number in system, utilization of the workstation, average
waiting time in line, and average waiting time in system.
Ans:
=
/
=
1
1
(
50
60
)
=
5
/
6
=> P
0
=(1-
)/(1-
N+1
) = 0.2786
L
q
= 0.9192
L= 1.6405
U=
ρ
−
ρ
N
+
1
1
−
ρ
N
+
1
=
0.7214
W
q
= 1.0618
W= 1.8952
4
2.
(15 points) Consider the problem of locating four machines along a straight aisle. Assume
that each machine P/D point is located at the midpoint along the edge of the machine work
area parallel to the aisle. Let c
ij
= a
ij
= 1. The machine dimensions are 4
×
4 for machine 1,
3
×
3 for machine 2, 5
×
5 for machine 3, and 2
×
2 for machine 4. The loaded material
handling trips between machines are
1
2
3
4
1
-
10
2
15
2
8
-
5
4
3
2
4
-
9
4
10
5
9
-
Determine the best location of machines along the aisle and the associated total cost.
Ans:
f
ij
1
2
3
4
1
-
18
4
25
2
-
9
9
3
-
18
4
-
Pick 1-4
Compute RPC of
2-1-4 = 18
4.5 + 9
8.5=157.5
1-4-2 = 18
7.5 + 9
3.5=166.5
3-1-4 = 4
5.5 +18
9.5 = 193
1-4-3 = 4
8.5 + 18
4.5= 115 Selected
Compute RPC of
2-1-4-3 = 18*4.5 + 9*8.5 + 9*13= 274.5 The best
1-4-3-2 = 18*13.5 +9*9.5 +9*5= 373.5
Total cost of 2-1-4-3 = 18*4.5+4*8.5+25*4+9*13+9*8.5+18*4.5=489.5
d
ij
1
2
3
4
1
-
4.5
8.5
4
2
-
13
8.5
3
-
4.5
4
-
5
3.
(15 points) Consider a warehouse with 12 10’
10’ bays as shown below with an I/O point in
the middle on either end with w
1
=0.6 and w
2
=0.4.
P
1
P
2
Determine the best storage location of each of the products: A, B, and C with storage space
required and load rates given.
Product
Area (ft
2
)
Rate of loads
A
500
500
B
400
600
C
300
150
Ans:
S
A
=500/100=5, S
B
=400/100=4, S
C
=300/100=3
T
B
/S
B
>=T
A
/S
A
>= T
C
/S
C
F
k
matrix
=>
6
27
29
31
33
17
19
21
23
27
29
31
33
A
A
A(C
)
C
B
B
B
B
A
A
C(A
)
C
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