Operations Management
Operations Management
13th Edition
ISBN: 9781259667473
Author: William J Stevenson
Publisher: McGraw-Hill Education
Question
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Chapter 6, Problem 15P
Summary Introduction

To determine: The new placement of departments that will minimize the total transportation costs.

Introduction:

Product layouts:

Product layout is a production system where the equipment and workstations are placed along the production and assembly lines.  A conveyor is used to move the production units along the line. Product layouts have specialized labor to perform specific functions with the help of equipment (programmed to do a specific tasks in a repetitive manner). The layout is mostly based on the processing sequence.

Process layouts:

Process layout is a production system where the equipment is placed in a system based on their functions. The production line is planned to eliminate wastes.  In certain process layouts, the machineries and work settings are not arranged as per the standardized production sequence. However, there would be an assembly having similar machineries and operational activities depending on the requirement. For example, paint department.

Expert Solution & Answer
Check Mark

Answer to Problem 15P

Arrangement:

Operations Management, Chapter 6, Problem 15P , additional homework tip  1

The total transportation cost for the arrangement is $143, 650 per day.

Explanation of Solution

Given information:

  • Work centers 1 and 3 are assigned in two locations and cannot be moved.
  • There are 8 work centers.
  • Cost is $1 per load per meter.
  • The departments are 1, 2, 3, 4, 5, 6, 7, and 8.
  • The locations are A, B, C, D, E, F, G, and H.

Distances between locations (meters):

To A B C D E F G H
From
A 40 40 60 120 80 100 110
B 60 40 60 140 120 130
C 45 85 40 70 90
D 40 50 40 45
E 90 50 40
F 40 60
G 40
H

Number of load per day between departments:

To 1 2 3 4 5 6 7 8
From
1 10 5 90 370 135 125 0
2 360 120 40 115 45 120
3 350 110 40 20 190
4 190 70 50 200
5 10 40 10
6 50 20
7 20
8

Locations:

Operations Management, Chapter 6, Problem 15P , additional homework tip  2

Arrangement of departments:

The numbers of trips between work centers is shown and are ranked from high to low.

Work centers pair Number of loads Ranking
1–2 10
1–3 5
1–4 90 11
1–5 370 1
1–6 135 6
1–7 125 7
1–8 0
2–3 360 2
2–4 120 8 (Tied)
2–5 40
2–6 115 9
2–7 45
2–8 120 8 (Tied)
3–4 350 3
3–5 110 10
3–6 40
3–7 20
3–8 200 4
4–5 190 5 (Tied)
4–6 70 12
4–7 50
4–8 190 5 (Tied)
5–6 10
5–7 40
5–8 10
6–7 50
6–8 20
7–8 20

The table clearly indicates that work centers 1-5 have the highest number of trips between them. After that the following work centers have the most number of trips: 2-3, 3-4, 3-8, 4-5, 4-8, 1-6, 1-7, 2-4, 2-8 and others. After continuous trial and error method the following assignment is reached. It is to be noted that, except the pre assigned work centers, slight variations are reasonable in the assignment as long as work centers 2,4 and 8 are nearer to 3, 4 is nearer to 5 and 5 is nearer to 1.

Operations Management, Chapter 6, Problem 15P , additional homework tip  3

Calculation of cost for each work center pair:

The cost for each department pair is calculated by multiplying the number of loads with the distance with the cost per load per meter.

Department 1-2:

Cost=10×100×1=$1,000

Department 1-3:

Cost=5×120×1=$600

Department 1-4:

Cost=90×60×1=$5,400

Department 1-5:

Cost=370×40×1=$14,800

Department 1-6:

Cost=135×80×1=$10,800

Department 1-7:

Cost=125×40×1=$5,000

Department 2-3:

Cost=360×50×1=$18,000

Department 2-4:

Cost=120×40×1=$4,800

Department 2-5:

Cost=40×120×1=$4,800

Department 2-6:

Cost=115×40×1=$4,600

Department 2-7:

Cost=45×70×1=$3,150

Department 2-8:

Cost=120×40×1=$4,800

Department 3-4:

Cost=350×40×1=$14,000

Department 3-5:

Cost=110×60×1=$6,600

Department 3-6:

Cost=40×90×1=$3,600

Department 3-7:

Cost=20×85×1=$1,700

Department 3-8:

Cost=200×40×1=$8,000

Department 4-5:

Cost=190×40×1=$7,600

Department 4-6:

Cost=70×50×1=$3,500

Department 4-7:

Cost=50×45×1=$2,250

Department 4-8:

Cost=190×45×1=$8,550

Department 5-6:

Cost=10×140×1=$1,400

Department 5-7:

Cost=40×60×1=$2,400

Department 5-8:

Cost=10×130×1=$1,300

Department 6-7:

Cost=50×40×1=$2,000

Department 6-8:

Cost=20×60×1=$1,200

Department 7-8:

Cost=20×90×1=$1,800

Calculation of total cost:

The total cost is calculated by adding the cost of individual work center pairs.

Cost=1,000+600+5,400+14,800+10,800+5,000+18,000+4,800+4,800+4,600+3,150+4,800+14,000+6,600+3,600+1,700+8,000+7,600+3,500+2,250+8,550+1,400+2,400+1,300+2,000+1,200+1,800=$143,650

The total transportation cost for the arrangement is $143,650.

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Chapter 6 Solutions

Operations Management

Ch. 6.5 - Prob. 1.1RQCh. 6.5 - Prob. 1.2RQCh. 6 - Explain the importance of process selection in...Ch. 6 - Briefly describe the five process types, and...Ch. 6 - Prob. 3DRQCh. 6 - Briefly describe computer-assisted approaches to...Ch. 6 - What is a flexible manufacturing system, and under...Ch. 6 - Prob. 6DRQCh. 6 - Why might the choice of equipment that provides...Ch. 6 - Prob. 8DRQCh. 6 - Prob. 9DRQCh. 6 - Briefly describe the two main layout types.Ch. 6 - Prob. 11DRQCh. 6 - Prob. 12DRQCh. 6 - What is the goal of Line balancing? What happens...Ch. 6 - Why are routing and scheduling continual problems...Ch. 6 - Prob. 15DRQCh. 6 - Prob. 16DRQCh. 6 - The City Transportation Planning Committee must...Ch. 6 - Identify the fixed-path and variable-path...Ch. 6 - Prob. 19DRQCh. 6 - Prob. 20DRQCh. 6 - Prob. 21DRQCh. 6 - Prob. 22DRQCh. 6 - What is cellular manufacturing? What are its main...Ch. 6 - Prob. 24DRQCh. 6 - Prob. 25DRQCh. 6 - Prob. 1TSCh. 6 - What trade-offs are involved when deciding how...Ch. 6 - Who needs to be involved in process selection?Ch. 6 - Prob. 4TSCh. 6 - Prob. 5TSCh. 6 - Prob. 1CTECh. 6 - Prob. 2CTECh. 6 - What are the risks of automating a production...Ch. 6 - Consider an assembly line such as the burrito...Ch. 6 - Prob. 1PCh. 6 - A manager wants to assign tasks to workstations as...Ch. 6 - A manager wants to assign tasks to workstations as...Ch. 6 - A producer of inkjet printer is planning to add a...Ch. 6 - As part of a major plant renovation project, the...Ch. 6 - Twelve tasks, with times and precedence...Ch. 6 - For the given set of tasks, do the following: a....Ch. 6 - A shop works a 400-minute day. The manager of the...Ch. 6 - Arrange six departments into a 2 3 grid so that...Ch. 6 - Using the information given in the preceding...Ch. 6 - Using the information in the following grid,...Ch. 6 - Arrange the eight departments shown in the...Ch. 6 - Arrange the departments so they satisfy the...Ch. 6 - a. Determine the placement of departments fix a...Ch. 6 - Prob. 15PCh. 6 - Develop a process layout that will minimize the...Ch. 6 - Prob. 17PCh. 6 - Rebalance the assembly line in Problem 7. This...
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