Session 5 - Important Slides

Question 1

What are the General Space Calculation ratios for Industrial Plants?

Answer 1

Gross Area 100% = 90% Net Area + 10% Building Construction

Net Area 90% = 58% Effective Area + 28% Logistics (Routing) + 4% Area for Technical Functions

Effective Area 58% = 
28% Production
14% Inventory
8% Support
5% Personnel Requirements
2% Administration
1% Other

Question 2

What are the General Objectives in Facility Layout Planning?

Answer 2

1) Min material handling
2) Maintaining flexibility operation
3) Promote high turnover of WIP
4) Hold-down investment in equipment
5) Economical use of floor space
6) Utilise labour
7) Ensure safety, comfort, convenience

Question 3

What are the 4 steps of Product Design?

Answer 3

1) R&D
2) Engineering & Design
3) Production Design
4) Processing & Tooling, null series

Question 4

What are 4 steps of Layout Design?

Answer 4

1) Location & Size of area
2) General Overall Layout
3) Detailed layout plants
4) Installation

Question 5

What are the 3 steps to Full Operations?

Answer 5

1) Production tests = TESTING
2) Ramp-Up = INCREASING
3) Operations = STEADY STATE

Question 6

What kind of a process is Effective Flow Planning?

Answer 6

Effective flow planning is a hierarchical process

Question 7

What is effective flow within a facility contingent upon?

Answer 7

Contingent upon Effective Flow between Departments, which depends on Effective Flow within Workstations.

Question 8

What 3 main flows should be aligned?

MMP

Answer 8

1) Material Flow
2) Product Flow
3) Personnel Flow

Question 9

Where are Macro and Micro Flows pictured?

Answer 9

1) Macro pictured in the Block Layout

2) Micro pictured in the Detailed Layout

Question 10

What are the 5 Basic Input Data of Systematic Layout Planning?

Answer 10

1) P Product / Material
2) Q Quantity / Volume
3) R Routing (process sequence)
4) S Supporting Service
5) T Timing

Question 11

What are the 11 SLP Process Steps?

Answer 11

1) Input Data: P,Q,R,S,T & Activities
2) Flow of Materials
3) Activity Relationship
4) Relationship Diagram
5) Space Requirements
6) Space Available
7) Space Relationship Diagram
8) Modifying Constraints
9) Practical Limitations
10) Develop Layout Alternatives
11) Evaluation

Question 12

What is MULTIPLE?

Answer 12

Multifloor Plant Layout Evaluation

Question 13

What are the Characteristics of MULTIPLE?

Answer 13

1) Starting Point: Construction or Improvement
2) Relationship Inputs: From-to chart (Quantitative)
3) Objective: Distance Based
4) Representation: Discrete

Question 14

How does MULTIPLE work?

Answer 14

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Uses SFC (space filling curves), for example: the Hilbert Curve o	Each grid is visited exactly once o	Generation of curves as TSP
Departments are arranged according to a sequence
Two-Way / Pairwise Exchanges of departments
Selection of the exchange is made to lead to the Lowest Transportation Costs
Distance is measured rectilinearly along the grid between departments’ centroids

Question 15

What is the Hilbert Curve?

Answer 15

The Hilbert curve is a space filling curve that visits every center-point in a square grid

Question 16

What is the MULTIPLE Heuristic Algorithm?

Answer 16

X: Number of non-fixed Departments with 1 to X referring to the sequence
T: refers to the iteration starting
1) Set:
a. MIN = cmin (cost of the current layout)
b. T = T+1
2) Exchange Departments I & J:
a. I = 1 to X-1
b. J = I+1 to X
3) Set cij = cost of layout with the I & J exchanged
4) Is cij < MIN ?
a. If YES, then Set MIN = cmin = cij and go to 5
b. If NO, then go to 5
5) Is this the LAST exchange for T?
a. If YES, then go to 6
b. If NO, then go to 2
6) Is AT LEAST ONE exchange IMPROVING the current layout cost?
a. If YES, then go to 7
b. If NO, Then END = NO FURTHER IMPROVEMENTS POSSIBLE FOR CURRENT LAYOUT
7) Layout cost MIN becomes current layout for next iteration, go to 1