2014 - Solved Problems in Facility Planning

SOLVED PROBLEMS IN
FACILITY PLANNING & DESIGN
2014
Solved Problems in Facility Planning & Design 2014
FORMULAS IN FACILITY PLANNING & DESIGN
Facility Planning: determines how an activity’s tangible fixed assets best support achieving the activity’s
objectives.
Facility Location: is the placement of a facility with respect to customers, suppliers, and other facilities
with which it interfaces.
Structural Design: consists of the building and services (e.g., gas, water, power, heat, light, air,
sewage).
Layout Design: consists of all equipment, machinery, and furnishings within the structure.
Handling System Design: consists of the mechanism by which all interactions required by the layout are
satisfied (e.g., materials, personnel, information, and equipment handling
systems).
FACILITY LOCATION
Factor Analysis Technique
WS = WxS
Where:
WS = weighted score for each factor for each facility plan or location
W= appropriate weight to each factor (typically between 0 to 1) based on the relative importance of
each.
S= assigned score to each facility plan or location (typically between 0 to 100) with respect to each
factor identified.
Compute the sum of the weighted scores for each facility plan or location and choose a facility
plan or location with the highest score.
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Center-Of-Gravity Technique
n
X Wi i
i=1
X= _________________
n
W i
i=1
n
Y W i i
i=1
Y= _________________
n
W i
i=1
Where:
X, Y = coordinates of the new facility at the center of gravity.
Xi, Yi = coordinates of the existing facility i.
Wi = annual weight shipped from facility i.
Load-Distance Technique
n
LD = l d
i i
i=1
Where:
LD = the load distance value
li = the load expressed as a weight, number of trips, or units being shipped from the proposed site to
location i.
di = the distance between the proposed site and location i.
di = (xi – x)2 + (yi – y)2
Where:
(x, y) = coordinates of the proposed site
(x i,yi) = coordinates of the existing facility
FACILITY DESIGN – SCHEDULE DESIGN
Scrap Estimate
Ok = Ik - PkIk
Ok = Ik (1 - Pk)
Ik = Ok/ (1- Pk)
I1 = On/ (1- P1) (1- P2)… (1- Pn)
Where:
Ok = desired output of non-defective product from operation k
Ik = production input to operation k
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Pk = % of scrap produced in operation k
Yield with Reworking
Ok or Yield = (Total Input) (%Good Units) + (Total Input) (1 – %Good Units) (%Reworked)
Yield = (I) (%G) + (I) (1 – %G) (%R)
Where
I = planned number of units of product started in the production process

%G = percentage of good units produced
%R = percentage of defective units that are successfully reworked
Equipment Fraction
F= _____Total Time Required to Perform the Operation_______

Net Available Time to Complete the Operation per Machine
F= SQ/ EHR
Where:
F= number of machines required per period
S= standard time per unit produced
Q= number of units to be produced period
E= efficiency or actual performance expressed as percentage of standard time
R= reliability of the machine expressed as percentage of ―up time‖
LAYOUT DESIGN
Product Layout – Line Balancing
D = OT / CT
CT = OT / D
Where:
D= desired output rate
OT = operating time per period
CT = cycle time
N= __(D)(t)___
OT
Where:
N= minimum number of work stations
t = sum of task times
D= desired output rate
OT = operating time per period
E= __t___
N x CT
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Where:
E= efficiency of the assembly line
t = sum of task times
N= minimum number of work stations
CT = cycle time
Line Balancing Based on Incremental Utilization Method
 Add tasks to a workstation in order of task precedence one at a time until utilization is 100% or is
observed to fall
 Then the above procedure is repeated at the next workstation for the remaining tasks
 Pro – Appropriate when one or more task times is equal to or greater than the cycle time
 Con – Might create the need for extra equipment
Line Balancing Based on the Largest Number of Following Tasks
 Assign tasks to station 1, then 2, etc. in sequence. Keep assigning to a workstation ensuring that
precedence is maintained and total work is less than or equal to the cycle time. Use the following
rules to select tasks for assignment.
 Primary: Assign tasks in order of the largest number of following tasks
 Secondary (tie-breaking): Assign tasks in order of the longest operating time
Line Balancing Based on the Longest Task Time
 Adds tasks to a workstation one at a time in the order of task precedence.

 If two or more tasks tie for order of precedence, the one with the longest task time is added
 Conditions for its use:
◦ No task time can be greater than the cycle time
◦ There can be no duplicate workstations
Process Layout – Block Diagramming
 Develop the load summary chart

 Rank the composite movements from highest to lowest
 Prepare the initial layout on the grid by placing one-by-one the two-way movements based on its
rank.
 Compute the initial total number of non-adjacent loads
 Develop alternative layouts eliminating or minimizing the number of non-adjacent loads
Process Layout – Systematic Layout Planning
 Determine the total flow

 Rank the flows
 Combine flow and non-flow relationships
 Rank the combined points
 Develop the combined relationship chart
 Develop the relationship diagram
 Measure the effectiveness of the relationship diagram
 Develop the space relationship diagram
 Develop the layout
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Measuring Effectiveness of the Relationship Diagram
Min Z =   Lij x Dij

i j
Where:
Z= the least value of the product between Lij and Dij
Lij = Load between departments i & j, often measured by the value of the vowel letter.
A = 4, E = 3, I = 2, O = 1, U = 0, X = -1 X = -2
Dij = Distance between departments i & j
Adjacent (Straight) – 1, Partial Adjacent (Diagonal) – 2, Non-Adjacent – 3
Process Layout - Manual CORELAP Algorithm
 Computerized Relationship Layout Planning (CORELAP) is a construction algorithm to create an

activity relationship (REL) diagram or block layout from a REL chart.
 Each department (activity) is represented by a unit square.
 Numerical values are assigned to Corelap Values (CV’s):
V(A) = 10,000, V(O) = 10,
V(E) = 1,000, V(U) = 1,
V(I) = 100, V(X) = -10,000.
 For each department, the Total Closeness Rating (TCR) is the sum of the absolute values of the
relationships with other departments.
Procedure to Select Departments
 The first department placed in the layout is the one with the greatest TCR value. If a tie exists,
choose the one with more A’s.
 If a department has an X relationship with the first one, it is placed last in the layout. If a tie
exists, choose the one with the smallest TCR value.
 The second department is the one with an A relationship with the first one. If a tie exists, choose
the one with the greatest TCR value.
 If a department has an X relationship with the second one, it is placed next-to-the-last or last in
the layout. If a tie exists, choose the one with the smallest TCR value.
 The third department is the one with an A relationship with one of the placed departments. If a tie
exists, choose the one with the greatest TCR value.
 The procedure continues until all departments have been placed.
Procedure to Place Departments
 Consider the figure below. Assume that a department is placed in the middle (position 0). Then,
if another department is placed in position 1, 3, 5 or 7, it is ―fully adjacent‖ with the first one. If it
is placed in position 2, 4, 6 or 8, it is ―partially adjacent‖.
 For each position, Weighted Placement (WP) is the sum of the numerical values for all pairs of
adjacent departments.
 The placement of departments is based on the following steps:
o The first department selected is placed in the middle.
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o The placement of a department is determined by evaluating all possible locations around

the current layout in counterclockwise order beginning at the ―western edge‖.
o The new department is located based on the greatest WP value.
Cellular Layout – Direct Clustering Algorithm
 Form the Parts-Machines Matrix.

 Order the rows and columns. Sum the Xs in each column (machine) and in each row (part) of the
machine-part matrix. Order the rows (top to bottom) in descending order of the number of Xs in
the rows and order the columns (left to right) in ascending order of the number of Xs in each.
Where ties exist, break the ties in descending numerical sequence.
 Sort the columns. Beginning with the first row of the matrix, shift to the left of the matrix all
columns having an X in the first row. Continue the process row-by-row until no further opportunity
exists for shifting columns.
 Sort the rows. Column-by-column, beginning with the leftmost column, shift rows upward when
opportunities exist to form blocks of Xs
 Form cells. Look for opportunities to form cells such that all processing for each part occurs in a
single cell.
Facility Planning & Design Acronyms:
ALDEP - Automated Layout Design Program

PLANET - Plant Layout Analysis and Evaluation Technique
CORELAP - Computerized Relationship Layout Planning
CRAFT - Computerized Relative Allocation of Facilities Technique
DCA – Direct Clustering Algorithm
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ANSWER SHEET 1
PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE
NAME: _____________________________________ DATE: ____________________
1. _______ 21. _________ 41. _________ 61. _________ 81. _________
2. _______ 22. _________ 42. _________ 62. _________ 82. _________
3. _______ 23. _________ 43. _________ 63. _________ 83. _________
4. _______ 24. _________ 44. _________ 64. _________ 84. _________
5. _______ 25. _________ 45. _________ 65. _________ 85. _________
6. _______ 26. _________ 46. _________ 66. _________ 86. _________
7. _______ 27. _________ 47. _________ 67. _________ 87. _________
8. _______ 28. _________ 48. _________ 68. _________ 88. _________
9. _______ 29. _________ 49. _________ 69. _________ 89. _________
10. _______ 30. _________ 50. _________ 70. _________ 90. _________
11. _______ 31. _________ 51. _________ 71. _________ 91. _________
12. _______ 32. _________ 52. _________ 72. _________ 92. _________
13. _______ 33. _________ 53. _________ 73. _________ 93. _________
14. _______ 34. _________ 54. _________ 74. _________ 94. _________
15. _______ 35. _________ 55. _________ 75. _________ 95. _________
16. _______ 36. _________ 56. _________ 76. _________ 96. _________
17. _______ 37. _________ 57. _________ 77. _________ 97. _________
18. _______ 38. _________ 58. _________ 78. _________ 98. _________
19. _______ 39. _________ 59. _________ 79. _________ 99. _________
20. _______ 40. _________ 60. _________ 80. _________ 100. _________
SCORE: __________ /100 X 100 = __________%
PASSING RATE: 75%
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PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE
1. Using this space determination method, the present space requirements are converted to those
required for the proposed layout.
a. Roughed-Out Layout Method b. Production-Center Method

c. Space-Standards Method d. Converting Method
2. It is the most complex Flexible Manufacturing System layout which allows material to move among the
machine centers in any order and typically includes several support stations such as tool interchange
stations, pallet or fixture build stations, inspection stations, and chip/ coolant collection systems.
a. Progressive Layout b. Open-Field Layout

c. Closed-Loop Layout d. Ladder Layout
3. Which of the following is a walking industrial vehicle?
a. Tractor Trailer b. Straddle Carrier

c. Pallet Truck d. Hand Truck
4. How many lavatories do you need if a business organization has 41 to 60 employees?
a. 2 b. 3
c. 4 d. 5
5. Drawing on the use of adjacency in the graph-based procedure, the _________________ is

determined by summing the numerical values for all pairs of adjacent departments.
a. Total Closeness Rating b. Weighted Placement Value

c. Total Adjacent Loads d. Total Flow
6. What is the objective of designing the product, process, and schedule in relation to facilities planning?
a. An effective production facility b. An efficient operations management

c. An efficient production system d. An effective operations management
7. A principle of material handling which a material handling facility should be the result of a cohesive and
structured unit of specific courses of action to determine what material needs to be moved, when, and
where it will be moved, and how it will be moved.
a. Planning Principle b. System Principle

c. Standardization Principle d. Work Principle
8. Cellular layout is a type of layout which –
a. Groups machines into department according to their function.

b. Groups machines into small assembly lines that produce families of parts.
c. Allows production of larger lots by reducing set-up time.
d. Encourages the use of larger and efficient machinery.
9. What is the preferred area requirement of the President’s Office?
a. 80 – 110 sq. ft. b. 100 – 150 sq. ft.

c. 150 – 250 sq. ft. d. 250 – 400 sq. ft.
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10. The arrangement of all equipment, machinery, and furnishings within the structure.
a. Facility Planning b. Facility Location

c. Layout Design d. Handling System Design
11. Which of the following is not a characteristic of product layouts?
a. Standardized product b. Sequential arrangements of machines

c. High material handling costs d. Continuous production system
12. A graph is ___________ if it can be drawn so that its vertices are points in the plane and each edge
can be drawn so that it intersects no other edges and passes through no other vertices.
a. Open b. Close
c. Planar d. Non-Planar
13. How many urinals do you need if a church has 401 to 700 members?
a. 2 b. 3
c. 4 d. 5
14. This program is used to generate and evaluate plant layout which does not restrict the final layout to
uniform shape, nor does it allow fixing departments to certain locations, resulting in unrealistic
layouts.
a. ALDEP - Automated Layout Design Program

b. PLANET - Plant Layout Analysis and Evaluation Technique
c. CORELAP - Computerized Relationship Layout Planning
d. CRAFT - Computerized Relative Allocation of Facilities Technique
15. A __________ is the quantity in which material is normally moved.
a. Distance b. Unit Load

c. Block d. Grid
16. It is an analog model of the operations and inspections required in assembling a product.
a. Operation Process Chart b. Precedence Diagram

c. Assembly Chart d. Route Sheet
17. Which is not an automatic identification and recognition equipment?
a. Bar Coding b. Radio Frequency Tag

c. Magnetic Stripe d. Voice Headset
18. Which of the following assumptions is not associated with planar location models?
a. A plane is an adequate approximation of a sphere.

b. Any point in the plane is a valid location to consider.
c. Fixed costs can be ignored.
d. Travel costs are indirectly proportional to the planar distance used.
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19. The algorithm in Relationship Diagramming for determining the placement of the new activity begins
at the ____________ of the partial layout and evaluates all possible locations in counterclockwise
order.
a. Northeastern Edge b. Northwestern Edge

c. Eastern Edge d. Western Edge
20. A product layout is characterized by –
a. Narrow aisle ways b. Organized by function

c. Uses of general purpose equipment d. Produces goods to customer order
21. An approach to scoring models in computerized layout evaluation which attempts to approximate the
―cost‖ of flow between activities.
a. Adjacency-Based Scoring b. Distance-Weighted Adjacency-Based Scoring

c. Sequence-Based Scoring d. Distance-Based Scoring
22. Which is not a characteristic of a process layout?
a. Varied skills b. General purpose

c. Low in-process d. Machine location layout
23. In a __________________ layout, work stations are arranged according to the general function they
perform without regard to any particular product.
a. Product b. Process
c. Fixed Position d. Group Technology
24. A layout procedure which is based on the space relationship diagram, modifying considerations, and
practical limitations, a number of alternative layouts are designed and evaluated.
a. Immer’s Basic Steps b. Apple’s Plant Layout Procedure

c. Reed’s Plant Layout Procedure d. Muther’s Systematic Layout Planning
25. It is a form of flow pattern that is applicable when it is desired to terminate the flow very near the point
where the flow originated.
a. Straight Line Flow b. L-Shaped Flow

c. U-Shaped Flow d. Circular Flow
26. It determines how an activity’s tangible fixed assets best support achieving the activity’s objectives.

27. Which of the following is not a type of crane?
a. Jib b. Gantry
c. Hoist d. Stacker
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28. A type of layout used when the product is too large or cumbersome to move through the various
processing steps. Consequently, rather than take the product to the processes, the processes are
brought to the product.
a. Fixed Position Layout b. Product Layout

c. Group Layout d. Process Layout
29. It allows the storage location for a particular product to change or ―float‖ over time.
a. Shared Storage b. Randomized Storage

c. Dedicated Storage d. Class-Based Dedicated Storage
30. It is the design verification phase of product development and is used to demonstrate or prove
aspects of a design.
a. Prototyping b. Bill of Materials

c. Component part drawings d. Assembly drawing
31. Typically, layout design problems do not have well-defined, unique, and optimum solutions. We are
interested in obtaining a/ an ___________________.
a. Absolute solution b. Most favorable solution

c. Best possible solution d. Satisfactory solution
32. How many lavatories do you need if a school has 101 to 200 students?
a. 2 b. 3
c. 4 d. 5
33. This method evaluates different locations based on the load being transported and the distance. A
single set of location coordinates is not identified. Instead, various locations are evaluated using a
value that is measure of weight and distance.
a. Factor Analysis Technique b. Center of Gravity Technique

c. Load-Distance Technique d. Relationship Diagram Technique
34. A programmable equipment connected by an automated material handling system and controlled by a
central computer.
a. Flexible Manufacturing System b. Group Technology

c. Mixed Model Assembly Lines d. Computer Method for Sequencing Operations
35. A layout construction program that uses the total closeness rating, which is the sum of all numerical
values, assigned to the closeness relationships in a relationship chart between a department and all
other departments.

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36. It is the sum of the weighted ratings between the new activity to be placed in the layout and its
neighbors in the layout.
a. Boundary Length b. Shape Ratio

c. Corner Count d. Placing Rating
37. It is the maximum work station time on the line.
a. Desired Cycle Time b. Lead Time

c. Actual Cycle Time d. Balanced Time
38. Regions defined by a graph are referred to as ____________.
a. Faces b. Edges
c. Adjacents d. Duals
39. A scale plan or model on which a thread is used to trace and measure the path of workers, materials
or equipment during a specified sequence of events.
a. String Diagram b. Plant Layout

c. Relationship Chart d. Block Diagram
40. What is the recommended range of stall width for standard car use?
a. 8.5 to 9 ft. b. 8 to 8.5 ft.

c. 9 to 10 ft. d. 10 to 11 ft.
41. Which of the items below is not a container?
a. Pallet b. Skid
c. Tote Pan d. Stretchwrap
42. It involves the assignment of specific storage locations or storage addresses for each product stored.

43. The arrangement of desired machinery of a plant, established or contemplated, in the way which will
permit the easiest flow of materials, at the lowest cost and with the minimum of handling, in processing
the product from the receipt of raw materials to the dispatch of the finished product.
a. Line Balancing b. Block Diagram

c. Plant Layout d. Relationship Chart
44. A tabular record for presenting quantitative data about the movements of workers, materials or
equipment between any number of places over any given period of time.
a. String Diagram b. From-To Chart

c. Flow Diagram d. Travel Chart
45. It tells us how much to produce and when to produce.
a. Product Design b. Schedule Design

c. Process Design d. Facility Design
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46. A layout procedure composed of three simple steps, which can be applied to any type of layout
problem. These steps are: put the problem on paper, show lines of the flow, and convert flow lines to
machine lines.

47. The term ____________ is interpreted to mean adjacent.
a. Open b. Close
c. Line d. Circle
48. How many water closets do you need if a business organization has 51 to 80 employees?
a. 2 b. 3
c. 4 d. 5
49. What is the preferred area requirement of partitioned open for space—supervisor or manager?
a. 80 – 110 sq. ft. b. 100 – 150 sq. ft.

c. 150 – 250 sq. ft. d. 250 – 400 sq. ft.
50. A method of determining space requirements where each work station is a production facility having
its own receiving, shipping, production, and storage space requirements.
a. Space Standards Method b. Conversion Method

c. Calculation Method d. Flexible Method
51. How much space area requirements do you need if you will serve meals to 200 to 400 employees?
a. 500 – 1000 sq. ft. b. 800 – 1600 sq. ft.

c. 1,400 – 2,800 sq. ft. d. 2,400 – 3,900 sq. ft.
52. Which of these conveyors is not a belt conveyor?
a. Chute Conveyor b. Flat Conveyor

c. Telescoping Conveyor d. Magnetic Conveyor
53. It summarizes whether a part will be purchased or produced, how the production of a part will be
achieved, what equipment will be used, and how long it will take to perform each operation.

54. A principle of material handling which material handling flow should be as low as possible within the
requirements for effectiveness and efficiency of a material handling system.

55. A type of layout used when production volumes for individual products are not sufficient thereby
grouping products into logical product families.

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56. It provides information about the component parts of the product, make or buy decisions, part
number, number of parts per product, and drawing references.
a. Parts List b. Bill of Materials

57. It consists of mechanism by which all interactions required by the layout are satisfied.

58. This a space determination method where templates or models are placed on the layout to obtain an
estimate of the general configuration and space requirements.

59. A type of layout used when processes are located according to the processing sequence for the
product. Material flows directly from a workstation to the adjacent workstation.

60. This location policy is referred to as _______________ if one particular time, different products use
the same storage slot, albeit only one product occupies the slot when it is occupied.

61. It identifies the significant material flows and their corresponding paths.
a. Factory Flow Analysis b. Group Analysis

c. Line Analysis d. Tooling Analysis
62. It is the simplest form of flow pattern which when employed in a plant, separate receiving and
shipping crews are normally required.

63. It contains the information concerning the structure of the product.

c. Assembly Chart d. Engineering Drawing
64. Detailed design of individual products is influenced by?
a. Function b. Material
c. Manufacturing d. All of these
65. It is reduced if the assembly process occurs in a single dimension.
a. Product Dimension b. Parts Standard

c. Cost of Assembly d. Number of Parts
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66. It depicts the probable movement of materials by corresponding lines superimposed on the floor plan
of the area under study.
a. Flow Process Chart b. Multiproduct Process Chart

c. Flow Diagram d. From-To Chart
67. They denote assembly operations or sub-assemblies.
a. Lines with single link b. Lines with several links

c. Circles with several links d. Circles with single link
68. It consists of the mechanism by which all interactions required by the layout are satisfied e.g.
materials, personnel, information, and equipment handling systems.
a. Structure Design b. Handling System Design

c. Layout Design d. Facility Location
69. Which of the following tools is used primarily in determining machine location for a product layout?

c. Assembly Diagram d. Flow Diagram
70. Machines within a manufacturing cell are organized by –
a. CORELAP b. Relationship Diagramming

c. Direct Clustering Algorithm d. Block Diagramming
71. Cycle time is not –
a. Daily operating time divided by the desired production

b. The maximum allowable time at each work station
c. How often items roll off the assembly
d. The time required to complete a product from start to finish
72. A common goal in designing process layouts is –
a. Minimizing the number of workers

b. Minimizing the idle time
c. Minimizing material handling costs
d. Balancing the work at each station
73. Mixed model assembly lines ---
a. Are simple to balance than single model assembly lines.

b. Are usually U-shaped or S-shaped layouts.
c. Require a more specialized workforce.
d. Are most efficient when production of one type is completely finished before another type of
model is introduced.
74. This drawing provides part specifications and dimensions in sufficient detail for manufacturing.
a. Perspective Drawing b. Exploded Drawing

c. Engineering Drawing d. Photograph of the Product
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75. It establishes the prerequisite assembly steps that must be completed before performing a given
assembly step.

76. It refers to the overall design concepts or morphologies embedded within the facilities plan
a. Parametric design b. Conceptual design

c. Detailed design d. Design Program
77. What is the recommended range of stall width for luxury and elderly car use?
a. 8.5 to 9 ft. b. 8 to 8.5 ft.

c. 9 to 10 ft. d. 10 to 11 ft.
78. A principle of material handling which you try to reduce the ratio of equipment weight to product
weight and suggest not to buy equipment that is bigger than necessary.
a. Capacity Principle b. Standardization Principle

c. Unit Load Principle d. Dead Weight Principle
a. 500 – 1000 sq. ft. b. 800 – 1600 sq. ft.

c. 1,400 – 2,800 sq. ft. d. 2,400 – 3,900 sq. ft.
80. What is the recommended reception area that can accommodate a reception and 6 – 8 people?
a. 125 – 200 sq. ft. b. 200 – 300 sq. ft.

c. 300 – 400 sq. ft. d. 400 – 500 sq. ft.
81. It is obtained by dividing the usable cube by the exterior envelope of the container.
a. Container Nesting Ratio b. Container Space Utilization

c. Trailer Space Utilization d. Storage Space Efficiency
82. It is determined by dividing the overall container height by the nested height.

83. It is the ratio of usable cube divided by the storage cube.

84. The total number of containers along the length and width of the trailer and the container stacked
vertically.

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85. A space determination method consists of a single machine plus all the associated equipment and
space required for its operation. Work space, additional maintenance space, and storage space are
added to the space requirements for the machine.

86. Which of the following is not an automated industrial vehicle?
a. Unit Load Carrier b. Mobile Yard Crane

c. Sorting Transfer Vehicle d. Automated Electrified Vehicle
87. Which of the following is a type of an Operator-to-Stock Retrieval Equipment?
a. Picking Cart b. Carousels

c. Vertical Lift Module d. Automatic Dispenser
88. It is a quantitative method of locating a facility at the center of the movement in a geographic area
based on weight and distance. It identifies a set of coordinates designating a central location on a
map relative to all other locations.

89. Are physical restrictions on the order in which operations are performed on the assembly line?
a. Precedence Requirements b. Station Times

c. Balance Delays d. Production Time Available
90. It is generally agreed that effective facilities planning can reduce material handling costs by ---
a. 5 – 10% b. 10 – 30%
c. 30 – 40% d. 50 – 70%
91. The quantity of equipment required for an operation.
a. Equipment Effectiveness b. Equipment Efficiency

c. Equipment Fraction d. Equipment Planning
92. Which of the following is/ are way/s that we can accommodate a 20 second task in an 18 second
cycle time?
a. Share the task b. Use parallel work stations

c. Use a more skilled worker d. All of these
93. The term _____________ is used as a measure of the number of storages and retrievals performed
per time period.
a. Space b. Cost
c. Size d. Throughput
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94. It takes a load summary chart and block diagram as input and then makes pair wise exchanges of
departments until no improvements in cost or non-adjacency score can be found.

95. It is an adaptation of the familiar mileage chart appearing on most road maps which normally contains
numbers representing some measure of the material flow between two machines, departments,
buildings, or sites.

96. It is the placement of a facility with respect to customers, suppliers, and other facilities with which it
interfaces.

97. It is the time required to complete an item.

98. It is a mechanized device to move materials in relatively large quantities between specific locations
over a fixed path.
a. Conveyor b. Unit Load Carrier

c. Pallet Truck d. Automated Guided Vehicle
99. It is a way to visualize the amount of movement that occurs between departments.
a. Relationship Diagramming b. Block Diagramming

c. Line Balancing d. Digital Clustering Algorithm
100. It covers the system’s ability to be changed to produce new product types and ability to change the
order of operations executed on a part.
a. Routing Flexibility b. Material Flexibility

c. Machine Flexibility d. Flow Flexibility
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SOLVED PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE
1. Using this space determination method, the present space requirements are converted to those
required for the proposed layout.

Answer: d. Converting Method
2. It is the most complex Flexible Manufacturing System layout which allows material to move among the
machine centers in any order and typically includes several support stations such as tool interchange
stations, pallet or fixture build stations, inspection stations, and chip/ coolant collection systems.
a. Progressive Layout b. Open-Field Layout

c. Closed-Loop Layout d. Ladder Layout
Answer: b. Open-Field Layout
3. Which of the following is a walking industrial vehicle?
a. Tractor Trailer b. Straddle Carrier

c. Pallet Truck d. Hand Truck
Answer: d. Hand Truck
4. How many lavatories do you need if a business organization has 41 to 60 employees?
a. 2 b. 3
c. 4 d. 5
Answer: b. 3
5. Drawing on the use of adjacency in the graph-based procedure, the _________________ is

determined by summing the numerical values for all pairs of adjacent departments.
a. Total Closeness Rating b. Weighted Placement Value

c. Total Adjacent Loads d. Total Flow
Answer: c. Total Adjacent Loads
6. What is the objective of designing the product, process, and schedule in relation to facilities planning?
a. An effective production facility b. An efficient operations management

c. An efficient production system d. An effective operations management
Answer: c. An efficient production system
7. A principle of material handling which a material handling facility should be the result of a cohesive and
structured unit of specific courses of action to determine what material needs to be moved, when, and
where it will be moved, and how it will be moved.

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Answer: a. Planning Principle
8. Cellular layout is a type of layout which –
a. Groups machines into department according to their function.

b. Groups machines into small assembly lines that produce families of parts.
c. Allows production of larger lots by reducing set-up time.
d. Encourages the use of larger and efficient machinery.
Answer: b. Groups machines into small assembly lines that produce families of parts.
9. What is the preferred area requirement of the President’s Office?
a. 80 – 110 sq. ft. b. 100 – 150 sq. ft.

c. 150 – 250 sq. ft. d. 250 – 400 sq. ft.
Answer: d. 250 – 400 sq. ft.
10. The arrangement of all equipment, machinery, and furnishings within the structure.

Answer: c. Layout Design
11. Which of the following is not a characteristic of product layouts?
a. Standardized product b. Sequential arrangements of machines

c. High material handling costs d. Continuous production system
Answer: c. High material handling costs
12. A graph is ___________ if it can be drawn so that its vertices are points in the plane and each edge
can be drawn so that it intersects no other edges and passes through no other vertices.
a. Open b. Close
c. Planar d. Non-Planar
Answer: c. Planar
13. How many urinals do you need if a church has 401 to 700 members?
a. 2 b. 3
c. 4 d. 5
Answer: c. 4
14. This program is used to generate and evaluate plant layout which does not restrict the final layout to
uniform shape, nor does it allow fixing departments to certain locations, resulting in unrealistic
layouts.

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Answer: b. PLANET
15. A __________ is the quantity in which material is normally moved.
a. Distance b. Unit Load

c. Block d. Grid
Answer: b. Unit Load
16. It is an analog model of the operations and inspections required in assembling a product.

Answer: c. Assembly Chart
17. Which is not an automatic identification and recognition equipment?
a. Bar Coding b. Radio Frequency Tag

c. Magnetic Stripe d. Voice Headset
Answer: d. Voice Headset
18. Which of the following assumptions is not associated with planar location models?
a. A plane is an adequate approximation of a sphere.

b. Any point in the plane is a valid location to consider.
c. Fixed costs can be ignored.
d. Travel costs are indirectly proportional to the planar distance used.
Answer: d. Travel costs are indirectly proportional to the planar distance used.
19. The algorithm in Relationship Diagramming for determining the placement of the new activity begins
at the ____________ of the partial layout and evaluates all possible locations in counterclockwise
order.
a. Northeastern Edge b. Northwestern Edge

c. Eastern Edge d. Western Edge
Answer: d. Western Edge
20. A product layout is characterized by –
a. Narrow aisle ways b. Organized by function

c. Uses of general purpose equipment d. Produces goods to customer order
Answer: a. Narrow aisle ways
21. An approach to scoring models in computerized layout evaluation which attempts to approximate the
―cost‖ of flow between activities.
a. Adjacency-Based Scoring b. Distance-Weighted Adjacency-Based Scoring

c. Sequence-Based Scoring d. Distance-Based Scoring
Answer: d. Distance-Based Scoring
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22. Which is not a characteristic of a process layout?
a. Varied skills b. General purpose

c. Low in-process d. Machine location layout
Answer: c. Low in-process
23. In a __________________ layout, work stations are arranged according to the general function they
perform without regard to any particular product.
a. Product b. Process
c. Fixed Position d. Group Technology
Answer: a. Product
24. A layout procedure which is based on the space relationship diagram, modifying considerations, and
practical limitations, a number of alternative layouts are designed and evaluated.

Answer: d. Muther’s Systematic Layout Planning
25. It is a form of flow pattern that is applicable when it is desired to terminate the flow very near the point
where the flow originated.

Answer: d. Circular Flow
26. It determines how an activity’s tangible fixed assets best support achieving the activity’s objectives.

Answer: a. Facility Planning
27. Which of the following is not a type of crane?
a. Jib b. Gantry
c. Hoist d. Stacker
Answer: c. Hoist
28. A type of layout used when the product is too large or cumbersome to move through the various
processing steps. Consequently, rather than take the product to the processes, the processes are
brought to the product.

Answer: a. Fixed Position Layout
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29. It allows the storage location for a particular product to change or ―float‖ over time.

Answer: b. Randomized Storage
30. It is the design verification phase of product development and is used to demonstrate or prove
aspects of a design.
a. Prototyping b. Bill of Materials

c. Component part drawings d. Assembly drawing
Answer: a. Prototyping
31. Typically, layout design problems do not have well-defined, unique, and optimum solutions. We are
interested in obtaining a/ an ___________________.
a. Absolute solution b. Most favorable solution

c. Best possible solution d. Satisfactory solution
Answer: d. Satisfactory solution
32. How many lavatories do you need if a school has 101 to 200 students?
a. 2 b. 3
c. 4 d. 5
Answer: a. 2
33. This method evaluates different locations based on the load being transported and the distance. A
single set of location coordinates is not identified. Instead, various locations are evaluated using a
value that is measure of weight and distance.

Answer: c. Load-Distance Technique
34. A programmable equipment connected by an automated material handling system and controlled by a
central computer.
a. Flexible Manufacturing System b. Group Technology

c. Mixed Model Assembly Lines d. Computer Method for Sequencing Operations
Answer: a. Flexible Manufacturing System
35. A layout construction program that uses the total closeness rating, which is the sum of all numerical
values, assigned to the closeness relationships in a relationship chart between a department and all
other departments.

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Answer: c. CORELAP
36. It is the sum of the weighted ratings between the new activity to be placed in the layout and its
neighbors in the layout.
a. Boundary Length b. Shape Ratio

c. Corner Count d. Placing Rating
Answer: d. Placing Rating
37. It is the maximum work station time on the line.

Answer: c. Actual Cycle Time
38. Regions defined by a graph are referred to as ____________.
a. Faces b. Edges
c. Adjacents c. Duals
Answer: a. Faces
39. A scale plan or model on which a thread is used to trace and measure the path of workers, materials
or equipment during a specified sequence of events.
a. String Diagram b. Plant Layout

c. Relationship Chart d. Block Diagram
Answer: a. String Diagram
40. What is the recommended range of stall width for standard car use?
a. 8.5 to 9 ft. b. 8 to 8.5 ft.

c. 9 to 10 ft. d. 10 to 11 ft.
Answer: a. 8.5 to 9 ft.
41. Which of the items below is not a container?
a. Pallet b. Skid
c. Tote Pan d. Stretchwrap
Answer: d. Stretchwrap
42. It involves the assignment of specific storage locations or storage addresses for each product stored.

Answer: c. Dedicated Storage
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43. The arrangement of desired machinery of a plant, established or contemplated, in the way which will
permit the easiest flow of materials, at the lowest cost and with the minimum of handling, in processing
the product from the receipt of raw materials to the dispatch of the finished product.

c. Plant Layout d. Relationship Chart
Answer: c. Plant Layout
44. A tabular record for presenting quantitative data about the movements of workers, materials or
equipment between any number of places over any given period of time.
a. String Diagram b. From-To Chart

c. Flow Diagram d. Travel Chart
Answer: d. Travel Chart
45. It tells us how much to produce and when to produce.
a. Product Design b. Schedule Design

c. Process Design d. Facility Design
Answer: b. Schedule Design
46. A layout procedure composed of three simple steps, which can be applied to any type of layout
problem. These steps are: put the problem on paper, show lines of the flow, and convert flow lines to
machine lines.

Answer: a. Immer’s Basic Steps
47. The term ____________ is interpreted to mean adjacent.
a. Open b. Close
c. Line d. Circle
Answer: b. Close
48. How many water closets do you need if a business organization has 51 to 80 employees?
a. 2 b. 3
c. 4 d. 5
Answer: c. 4
49. What is the preferred area requirement of partitioned open for space—supervisor or manager?
a. 80 – 110 sq. ft. b. 100 – 150 sq. ft.

c. 150 – 250 sq. ft. d. 250 – 400 sq. ft.
Answer: a. 80 – 110 sq. ft.
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50. A method of determining space requirements where each work station is a production facility having
its own receiving, shipping, production, and storage space requirements.
a. Space Standards Method b. Conversion Method

c. Calculation Method d. Flexible Method
Answer: c. Calculation Method
a. 500 – 1000 sq. ft. b. 800 – 1600 sq. ft.

c. 1,400 – 2,800 sq. ft. d. 2,400 – 3,900 sq. ft.
Answer: b. 800 – 1600 sq. ft.
52. Which of these conveyors is not a belt conveyor?
a. Chute Conveyor b. Flat Conveyor

c. Telescoping Conveyor d. Magnetic Conveyor
Answer: a. Chute Conveyor
53. It summarizes whether a part will be purchased or produced, how the production of a part will be
achieved, what equipment will be used, and how long it will take to perform each operation.

Answer: d. Route Sheet
54. A principle of material handling which material handling flow should be as low as possible within the
requirements for effectiveness and efficiency of a material handling system.

Answer: d. Work Principle
55. A type of layout used when production volumes for individual products are not sufficient thereby
grouping products into logical product families.

Answer: c. Group Layout
56. It provides information about the component parts of the product, make or buy decisions, part
number, number of parts per product, and drawing references.

Answer: a. Parts List
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57. It consists of mechanism by which all interactions required by the layout are satisfied.

Answer: d. Handling System Design
58. This a space determination method where templates or models are placed on the layout to obtain an
estimate of the general configuration and space requirements.

Answer: a. Roughed-Out Layout Method
59. A type of layout used when processes are located according to the processing sequence for the
product. Material flows directly from a workstation to the adjacent workstation.

Answer: b. Product Layout
60. This location policy is referred to as _______________ if one particular time, different products use
the same storage slot, albeit only one product occupies the slot when it is occupied.

Answer: a. Shared Storage
61. It identifies the significant material flows and their corresponding paths.
a. Factory Flow Analysis b. Group Analysis

c. Line Analysis d. Tooling Analysis
Answer: a. Factory Flow Analysis
62. It is the simplest form of flow pattern which when employed in a plant, separate receiving and
shipping crews are normally required.

Answer: a. Straight Line Flow
63. It contains the information concerning the structure of the product.

c. Assembly Chart d. Engineering Drawing
Answer: b. Bill of Materials
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64. Detailed design of individual products is influenced by?
a. Function b. Material
c. Manufacturing d. All of these
Answer: d. All of these
65. It is reduced if the assembly process occurs in a single dimension.
a. Product Dimension b. Parts Standard

c. Cost of Assembly d. Number of Parts
Answer: c. Cost of Assembly
66. It depicts the probable movement of materials by corresponding lines superimposed on the floor plan
of the area under study.

Answer: c. Flow Diagram
67. They denote assembly operations or sub-assemblies.
a. Lines with single link b. Lines with several links

c. Circles with several links d. Circles with single link
Answer: c. Circles with several links
68. It consists of the mechanism by which all interactions required by the layout are satisfied e.g.
materials, personnel, information, and equipment handling systems.
a. Structure Design b. Handling System Design

c. Layout Design d. Facility Location
Answer: b. Handling System Design
69. Which of the following tools is used primarily in determining machine location for a product layout?

c. Assembly Diagram d. Flow Diagram
Answer: a. Line Balancing
70. Machines within a manufacturing cell are organized by –
a. CORELAP b. Relationship Diagramming

c. Direct Clustering Algorithm d. Block Diagramming
Answer: c. Direct Clustering Algorithm
71. Cycle time is not –
a. Daily operating time divided by the desired production

b. The maximum allowable time at each work station
c. How often items roll off the assembly
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d. The time required to complete a product from start to finish
Answer: d. The time required to complete a product from start to finish
72. A common goal in designing process layouts is –
a. Minimizing the number of workers

b. Minimizing the idle time
c. Minimizing material handling costs
d. Balancing the work at each station
Answer: c. Minimizing material handling costs
73. Mixed model assembly lines ---
a. Are simple to balance than single model assembly lines.

b. Are usually U-shaped or S-shaped layouts.
c. Require a more specialized workforce.
d. Are most efficient when production of one type is completely finished before another type of
model is introduced.
Answer: b. Are usually U-shaped or S-shaped layouts.
74. This drawing provides part specifications and dimensions in sufficient detail for manufacturing.
a. Perspective Drawing b. Exploded Drawing

c. Engineering Drawing d. Photograph of the Product
Answer: c. Engineering Drawing
75. It establishes the prerequisite assembly steps that must be completed before performing a given
assembly step.

Answer: b. Precedence Diagram
76. It refers to the overall design concepts or morphologies embedded within the facilities plan
a. Parametric design b. Conceptual design

c. Detailed design d. Design Program
Answer: a. Parametric design
77. What is the recommended range of stall width for luxury and elderly car use?
a. 8.5 to 9 ft. b. 8 to 8.5 ft.

c. 9 to 10 ft. d. 10 to 11 ft.
Answer: c. 9 to 10 ft.
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78. A principle of material handling which you try to reduce the ratio of equipment weight to product
weight and suggest not to buy equipment that is bigger than necessary.
a. Capacity Principle b. Standardization Principle

c. Unit Load Principle d. Dead Weight Principle
Answer: d. Dead Weight Principle
a. 500 – 1000 sq. ft. b. 800 – 1600 sq. ft.

c. 1,400 – 2,800 sq. ft. d. 2,400 – 3,900 sq. ft.
Answer: c. 1,400 – 2,800 sq. ft.
80. What is the recommended reception area that can accommodate a reception and 6 – 8 people?
a. 125 – 200 sq. ft. b. 200 – 300 sq. ft.

c. 300 – 400 sq. ft. d. 400 – 500 sq. ft.
Answer: b. 200 – 300 sq. ft.
81. It is obtained by dividing the usable cube by the exterior envelope of the container.

Answer: b. Container Space Utilization
82. It is determined by dividing the overall container height by the nested height.

Answer: a. Container Nesting Ratio
83. It is the ratio of usable cube divided by the storage cube.

Answer: d. Storage Space Efficiency
84. The total number of containers along the length and width of the trailer and the container stacked
vertically.

Answer: c. Trailer Space Utilization
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85. A space determination method consists of a single machine plus all the associated equipment and
space required for its operation. Work space, additional maintenance space, and storage space are
added to the space requirements for the machine.

Answer: b. Production-Center Method
86. Which of the following is not an automated industrial vehicle?
a. Unit Load Carrier b. Mobile Yard Crane

c. Sorting Transfer Vehicle d. Automated Electrified Vehicle
Answer: b. Mobile Yard Crane
87. Which of the following is a type of an Operator-to-Stock Retrieval Equipment?
a. Picking Cart b. Carousels

c. Vertical Lift Module d. Automatic Dispenser
Answer: a. Picking Cart
88. It is a quantitative method of locating a facility at the center of the movement in a geographic area
based on weight and distance. It identifies a set of coordinates designating a central location on a
map relative to all other locations.

Answer: b. Center of Gravity Technique
89. Are physical restrictions on the order in which operations are performed on the assembly line?
a. Precedence Requirements b. Station Times

c. Balance Delays d. Production Time Available
Answer: a. Precedence Requirements
90. It is generally agreed that effective facilities planning can reduce material handling costs by ---
a. 5 – 10% b. 10 – 30%
c. 30 – 40% d. 50 – 70%
Answer: b. 10 – 30%
91. The quantity of equipment required for an operation.
a. Equipment Effectiveness b. Equipment Efficiency

c. Equipment Fraction d. Equipment Planning
Answer: c. Equipment Fraction
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92. Which of the following is/ are way/s that we can accommodate a 20 second task in an 18 second
cycle time?
a. Share the task b. Use parallel work stations

c. Use a more skilled worker d. All of these
Answer: d. All of these
93. The term _____________ is used as a measure of the number of storages and retrievals performed
per time period.
a. Space b. Cost
c. Size d. Throughput
Answer: d. Throughput
94. It takes a load summary chart and block diagram as input and then makes pair wise exchanges of
departments until no improvements in cost or non-adjacency score can be found.

Answer: d. CRAFT
95. It is an adaptation of the familiar mileage chart appearing on most road maps which normally contains
numbers representing some measure of the material flow between two machines, departments,
buildings, or sites.

Answer: d. From-To Chart
96. It is the placement of a facility with respect to customers, suppliers, and other facilities with which it
interfaces.

Answer: b. Facility Location
97. It is the time required to complete an item.

Answer: b. Lead Time
98. It is a mechanized device to move materials in relatively large quantities between specific locations
over a fixed path.
a. Conveyor b. Unit Load Carrier

c. Pallet Truck d. Automated Guided Vehicle
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Answer: a. Conveyor
99. It is a way to visualize the amount of movement that occurs between departments.
a. Relationship Diagramming b. Block Diagramming

c. Line Balancing d. Digital Clustering Algorithm
Answer: b. Block Diagramming
100. It covers the system’s ability to be changed to produce new product types and ability to change the
order of operations executed on a part.
a. Routing Flexibility b. Material Flexibility

c. Machine Flexibility d. Flow Flexibility
Answer: c. Machine Flexibility
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ANSWER SHEET 2
PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE
NAME: _____________________________________ DATE: ____________________
1. _______ 21. _________ 41. _________ 61. _________ 81. _________
2. _______ 22. _________ 42. _________ 62. _________ 82. _________
3. _______ 23. _________ 43. _________ 63. _________ 83. _________
4. _______ 24. _________ 44. _________ 64. _________ 84. _________
5. _______ 25. _________ 45. _________ 65. _________ 85. _________
6. _______ 26. _________ 46. _________ 66. _________ 86. _________
7. _______ 27. _________ 47. _________ 67. _________ 87. _________
8. _______ 28. _________ 48. _________ 68. _________ 88. _________
9. _______ 29. _________ 49. _________ 69. _________ 89. _________
10. _______ 30. _________ 50. _________ 70. _________ 90. _________
11. _______ 31. _________ 51. _________ 71. _________ 91. _________
12. _______ 32. _________ 52. _________ 72. _________ 92. _________
13. _______ 33. _________ 53. _________ 73. _________ 93. _________
14. _______ 34. _________ 54. _________ 74. _________ 94. _________
15. _______ 35. _________ 55. _________ 75. _________ 95. _________
16. _______ 36. _________ 56. _________ 76. _________ 96. _________
17. _______ 37. _________ 57. _________ 77. _________ 97. _________
18. _______ 38. _________ 58. _________ 78. _________ 98. _________
19. _______ 39. _________ 59. _________ 79. _________ 99. _________
20. _______ 40. _________ 60. _________ 80. _________ 100. _________
SCORE: __________ /100 X 100 = __________%
PASSING RATE: 75%
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PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE
1. Belinda Fashion Wear is a small chain of stores specializing in fashion clothing. The company currently
has five stores in Manila, Quezon City, and Caloocan, and it wants to open new store in of four new
mall locations in the other nearby cities. A consulting firm has been hired to help the company decide
where to locate new store. The company has indicated five factors that are important to its decision,
including proximity of a college, community median income, mall vehicle traffic flow and parking,
quality and number of stores in the mall, and proximity of other malls or shopping areas. The
consulting firm had the company weight the importance of each factor. The consultant had visited each
potential location and rated them according to each factor, as follows:
Location factors Weight Mall 1 Mall 2 Mall 3 Mall 4

College proximity 0.30 40 60 90 60
Median income 0.25 75 80 65 90
Vehicle traffic 0.25 60 90 79 85
Mall quality and size 0.10 90 100 80 90
Proximity of other shopping 0.10 80 30 50 70
Given that all sites have basically the same leasing cost and labor and operating cost, what is the
recommended location based on rating factors?
a. Mall 1 b. Mall 2
c. Mall 3 d. Mall 4
2. Zachtech Computers manufacture computer components such as chips, circuit boards, motherboards,
keyboards, LCD panels, and the like and sells them around the world. It wants to construct a new
warehouse/distribution center in Asia to serve emerging Asian markets. It has identified sites in
Shanghai, Hong Kong and Singapore and has rated the important location factors for each site as
follows:
Location Factors Weight Shanghai Hong Kong Singapore

Political Stability 0.25 50 60 90
Economic Growth 0.18 90 70 75
Port Facilities 0.15 60 95 90
Container support 0.10 50 80 90
Land and construction cost 0.08 90 20 30
Transportation/Distribution 0.08 50 80 70
Duties and tariffs 0.07 70 90 90
Trade regulations 0.05 70 95 95
Airline Service 0.02 60 80 70
Area roads 0.02 60 70 80
Recommend a site including its total score rating based on these location factors and ratings.
a. Hongkong, 72 b. Hongkong, 82
c. Singapore, 81 d. Shanghai, 79
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3. Cradle University is going to construct a new student center and athletic complex that will include a
bookstore, post office, theaters, markets, mini-mall, meeting rooms, swimming pool, and weight and
exercise rooms. The university administration has hired a site selection specialist has identified four
sites on campus and has rated important location factors for each site as follows:
Location Factors Weight South West A West B East

Proximity to housing 0.23 70 90 65 85
Student traffic 0.22 75 80 60 85
Parking availability 0.16 90 60 80 70
Plot size, terrain 0.12 80 70 90 75
Infrastructure 0.10 50 60 40 60
Off-campus accessibility 0.06 90 70 70 70
Proximity dining facilities 0.05 60 80 70 90
Visitor traffic 0.04 70 80 65 55
Landscape/aesthetics 0.02 50 40 60 70
Recommend a best site based on these location factors and ratings.

a. South b. West A
c. West B d. East
4. Zhan Electronics is going to construct new P1.2 billion semi-conductor plant and has selected four
Export Processing Zone Areas as potential sites. The important location factors and ratings for each
town are as follows:
Location Factors Weight Sta. Rosa Lipa Bataan Subic

Work Ethics 0.18 80 90 70 75
Quality of Life 0.16 75 85 95 90
Labor Laws/Unionization 0.12 90 90 60 70
Education 0.08 80 90 85 95
Labor skill & Education 0.07 75 65 70 80
Cost of Living 0.06 70 80 85 75
Taxes 0.05 60 70 55 60
Incentive Package 0.05 90 95 70 80
Government Regulation 0.03 40 50 65 55
Environmental 0.03 65 60 70 80
Regulation
Transportation 0.03 90 80 95 80
Space for Expansion 0.02 90 95 90 90
Urban Proximity 0.02 60 90 70 80
Recommend a site based on these location factors and ratings.
a. Sta. Rosa b. Lipa

c. Bataan c. Subic
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5. Joehanna Drug Store Chain wishes to build a new warehouse to serve the whole Quezon. At the
moment, it is looking at three possible locations. The factors, weights, and ratings being considered
are given below:
Ratings
Factor Weights Candelaria Lucena Lukban
Nearness to markets 20 4 7 5
Labor cost 5 8 8 4
Taxes 15 8 9 7
Nearness to suppliers 10 10 6 10
Which city should they choose?
a. Candelaria, 340 b. Lucena, 375

c. Lukban 325 d. Lukban, 385
6. The Charlie Forwarding Company wants to build a new distribution center in Central Luzon. The center
needs to be in the vicinity of uncongested Aurora, Bataan, and Nueva Ecija. The coordinates of this sites
and the number of weekly packages that flow to each are as follows:
Aurora Bataan Nueva Ecija

X = 17 X = 20 X = 30
Y = 30 Y=8 Y = 14
W = 17,000 W = 12,000 W = 9,000
What are the coordinates of the center of these 3 provinces?
a. (25, 22) b. (18, 22)

c. (24, 17) d. (21, 19)
7. James Company is attempting to determine the location for a new outlet mall. The region where the
outlet mall will be constructed includes four towns, which together have a sizable population base. The
grid map coordinates of the four towns in Cavite and the populations of each are as follows:
Town X Y Population (10,000s)

Rosario 30 60 6.5
Dasmarinas 50 40 4.2
Trece 10 70 5.9
Martirez
Silang 40 30 3.5
Determine best location for the outlet mall using the center-of-gravity method.
a. (32, 56) b. (33, 55)

c. (30, 54) d. (31, 52)
8. Ray-Mart, a discount store chain, wants to build a new superstore in an area in Batangas near four
small towns with population between 8,000 and 42,000. The coordinates (in miles) of these four towns
and the market population in each are as follows:
Bauan Ibaan Mabini Laurel

X = 12 X = 18 X = 30 X = 32
Y = 20 Y = 18 Y=7 Y = 25
W = 26,000 W = 14,000 W = 9,500 W = 12,000
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Determine the coordinates of the best site using the center of gravity technique.
a. (24, 21) b. (21, 20)

b. (23, 22) d. (20, 19)
9. Caloy Distribution Center in Quezon City is due to be replaced with a much larger, more modern facility
that can handle the tremendous needs that have developed with the city’s growth. Fresh produce
travels to the seven store locations several times a day making site selection critical for efficient
distribution. Using the data in the following table, determine the map coordinates for the proposed
new distribution center.
Store Locations Map Coordinates (x,y) Truck Round Trips per Day
Timog Avenue (10, 5) 3
Banawe St. (3, 8) 3
West Avenue (4, 7) 2
Tomas Morato St. (15, 10) 6
Visayas Avenue (13, 3) 5
Libis (1, 12) 3
Cubao (5, 5) 10
a. (8, 7) b. (9, 7)
c. (7, 9) d. (7, 8)
10. The following table gives the map coordinates and the shipping loads for a set of cities that we wish to
connect though a central ―hub.‖ Near what map coordinates should the hub be located?
City Map Coordinate (x,y) Shipping Load

A (5, 10) 5
B (6, 8) 10
C (4, 9) 15
D (9, 5) 5
E (7, 9) 15
F (3, 2) 10
G (2, 6) 5
a. (7, 5) b. (8, 4)
c. (4, 8) d. (5, 7)
11. The Inah Burger restaurant chain uses a distribution center to prepare the food ingredients it provides
its individual restaurants. The company is attempting to determine the location for new distribution
center that will service five restaurants. The grid-map coordinates of the five restaurants and the annual
numbers of 40-foot trailer trucks transported to each restaurant are as follows:
Restaurants X Y Annual Truck Shipments

1 100 300 30
2 210 180 25
3 250 400 15
4 300 150 20
5 400 200 18
Determine the coordinates of the location using the center-of-gravity method.
a. (233, 242) b. (236, 244)

c. (243, 231) c. (245, 230)
39 | P a g e
12. The Inah Burger restaurant chain in the previous problem is considering three potential sites. With the
following grid-map coordinates for its new distribution center: A(350, 300). B. (150, 250), and C (250,
300). Determine the best location using the load-distance formula.
a. Site A, LD = 15,205 b. Site B, LD = 15,325

c. Site C, LD = 15,570 c. Site C, LD = 15,255
13. Marla Homes, a home improvement/ building supply chain, is going to build a new warehouse facility
to serve its stores in six Metro Manila Cities - Taguig, Pasig, Mandaluyong, Makati, Pasay, and
Quezon City. The coordinates of this cities (in miles), using Manila, as the origin (0,0) of a set of
coordinates, and the annual truck loads that supply each city as shown as follows. Determine the best
site using the center- gravity technique.
Pasig Taguig Mandaluyong Makati Pasay Quezon

City
X = 15 X =42 X = 88 X = 125 X = 135 X = 180
Y = 85 Y = 145 Y = 145 Y = 140 Y = 125 Y = 18
W = 160 W = 90 W = 105 W = 35 W = 60 W = 75
a. (77, 104) b. (80, 107)

c. (79, 106) d. (81, 105)
14. Refer to problem no. 13, Marla Homes base has two parcel of land, Site A & B in Metro Manila. Use
the load-distance technique to determine which would be the best site with its load-distance value.
Given:
Site X Y
A 88 80
B 13 127
a. Site A with LD = 38,986 b. Site A with LD = 40,391

c. Site B with LD = 44,121 d. Site B with LD = 43,542
15. Roy Automobile Accessories, a manufacturer of automobile fan belts is considering three locations—
Subic, Clark, and Laguna for a new plant. Cost studies indicate that fixed costs per year at the sites
are P30,000.00, P60,000.00, and P110,000.00, respectively; and variable cost are P75.00 per unit,
P45.00 per unit, and P25.00 per unit, respectively. The expected selling price of the fan belt produced
is P120.00. The company wishes to find the most economical location for an expected volume of
2,000 units per year.
a. Subic, P180,000.00 b. Subic, P140,000.00

c. Clark, P150,000.00 d. Laguna, P160,000.00
16. A plastic firm has four work centers (A, B, C, and D) in series with individual capacities (units per day) and
actual output as shown.
A B C D
450 390 360 400 actual output = 306/ day
What is the process capacity?
a. 306 b. 360
c. 450 d. 1,600
40 | P a g e
17. Refer to Problem no. 16, what is the process efficiency?
a. 19% b. 22.5%
c. 68% d. 85%
18. Dennis Furniture Company manufactures four-drawer oak cabinets in six stages. In the first stage, the
boards forming the walls of the cabinets are cut; in the second stage the front drawer panels are
woodworked; in the third stage the boards are sanded and finished; in the fourth stage the boards are
cleaned, stained, and painted with a clear finish; in the fifth stage the hardware for pulls, runners, and
fittings is installed; and in the final stage the cabinets are assembled. Inspection occurs at each stage
of the process, and the average percentages of good-quality units are as follows:
Stage Average Percentage

Good Quality
1 87%
2 91%
3 94%
4 93%
5 93%
6 96%
The cabinets are produced in weekly production runs with a product input for 300 units. Determine
the weekly product yield of good-quality cabinets.
a. 186 b. 288
c. 312 d. 486
19. Refer to problem no. 18, what would weekly product input have to be in order to achieve a final
weekly product yield of 300 cabinets?
a. 186 b. 288
c. 312 d. 486
20. The Jelo Motor Company, motors are produced in a three-stage process. Motors are inspected
following each stage with percentage yields of good quality in process units as follows:

Good Quality
1 0.96
2 0.98
3 0.95
The company wants to know the daily product yield for product input of 250 units per day.
a. 263 b. 238
c. 223 d. 280
21. Refer to problem no. 20, how many input units it would have to start with each day to result in a final
daily yield of 250 good quality units?
a. 263 b. 238
c. 223 d. 280
41 | P a g e
22. Rafael Metals Company manufactures of wood burning stove. What is the product input for 15,000
stoves if the good quality of each stove is 88%?
a. 13,200 b. 1,800
c. 125,000 d. 17,045
23. Lara Company operates a small telephone order system for a catalog of its clothing products. The
catalog orders are processed in four stages. Errors can be made in orders at any of these stages,
and the average percentages of errors that occur at each stage are as follows.
Stage %Error
1 19%
2 16%
3 10%
4 8%
If an average of 460 telephone orders is processed each day, how many errorless orders will result?
a. 112 b. 259
c. 244 d. 129
24. Liam Manufacturing Company has a weekly product input of 2,800 units. The average percentage of
good-quality product is 87 percent. Of the poor quality products 60 percent can be reworked and sold
as good-quality products. Determine the weekly product output?
a. 2,654 b. 5,364
c. 1,462 d. 3,218
25. Assume that production volume is 1,600 pieces per day, the standard time is 0.004 hour per piece, 8
working hours per day, setup time at 0.2 hr per day, and scrap rate of 0.10. Find the fractional
machine number.
a. 1.12 b. 0.85
c. 0.91 d. 1.21
26. A product requires two sequential machine operations. The first takes 3.5 minutes and the defect
percentage is 12. The second takes 6.0 minutes and the defect percentage is 7. In another similar
plant belonging to the same company, past annual data on identical operations and working
conditions indicate that a total of 2,198 hours due to set up of machines and 2,052 hours due to
machine unavailability due to maintenance per year. Assuming 250 work days per year and a daily
shift of 10 hours, it is desired to determine the minimum fractional number of machines to
manufacture 50,000 units per year.
a. 4 b. 5
c. 6 d. 7
27. Eric Explosives Company is considering the expansion of a solid-propellant manufacturing process by
adding more 1-ton capacity curing furnaces. Each batch (1 ton) of propellant must undergo 30 minutes of
furnace time, including load and unload operations. However, the furnace is used only 80 percent of the
time due to power restrictions in the other parts of the system. The required output for the new layout is to
be 16 tons per shift (8 hours). Plant (system) efficiency is estimated at 50 percent of system capacity.
Determine the number of furnaces required.
a. 3 b. 4
c. 1 d. 5
42 | P a g e
28. Refer to problem no. 27, estimate the percentage of time the furnaces will be idled.
a. 20% b. 25%
c. 33% d. 67%
29. Charmz Developing Agency must determine how many photo-enlarger cubicles are required to maintain
an output of 200 good prints per hour. The set-up and exposure time can theoretically be done in 2
minutes per print, but operators are on the average only 90 percent efficient and, in addition, 5 percent of
the prints must be scrapped and redone. Also, the cubicles can be utilized for enlarging only 70 percent of
the time. What is the required process capacity in prints per hour?
a. 212 b. 250
c. 211 d. 200
30. Refer to problem no. 29, what average output per hour can be expected from each cubicle, taking its use
factor and efficiency into account?
a. 211 b. 30
c. 19 d. 200
31. Refer to problem no. 29, how many enlarger cubicles are required?
a. 14 b. 10
c. 16 d. 12
32. Dason Plastics manufacturer must acquire some molding machines capable of producing 160,000 good
parts per year. They will be installed in a production line that normally produces 20 percent rejects
because of the tight aerospace specifications. Assume that it takes 90 seconds to mold each part and the
plant operates 2,000 hours per year. If the molding machines are used only 50 percent of the time and
are 90 percent efficient, what actual (usable) molding machine output per hour would be achieved?
a. 40 b. 18
c. 45 d. 20
33. Refer to problem no. 32, how many molding machines would be required?
a. 4 b. 8
c. 6 d. 12
34. Given:
Year Demand (units)
i. 220,000
ii. 275,000
iii. 380,000
iv. 420,000
v. 565,000
% Scrap: 3%
Standard Time: 2 minutes per unit
Target Machine Efficiency: 90%
Machine Breakdown: 30 minutes per day
Operation Schedule: 8am – 4pm daily schedule/ 20 working days per month
How many machines you will acquire/ buy on Year 1?
a. 5 b. 7
c. 2 d. 9
43 | P a g e
35. Refer to problem 34, how many machines you will acquire/ buy on Year 2?
a. 5 b. 7
c. 1 d. 9
36. Refer to problem no. 34, how many machines you will acquire/ buy on Year 3?
a. 5 b. 7
c. 3 d. 9
a. 1 b. 10
c. 2 d. 9
a. 1 b. 10
c. 3 d. 13
39. A team of Industrial Engineers conducted a work sampling of identical machines being used for a
manufacturing company and they have observed the following:
% Idleness
Machine 1 20%
Machine 2 35%
Machine 3 15%
Machine 4 55%
The machines are running based on the schedule of operation per shift.
Shift Schedule: 6am – 2pm/ 2pm – 10pm/ 10pm – 6am
Break Time: 1-hr meal break and 15 minutes coffee or short break per shift.
Compute for the number of machines required in a given shift.
a. 1 b. 2
c. 3 d. 4
40. Mandy Garments produces T-shirts for road races. They need to acquire some new stamping
machines to produce 30,000 good T-shirts per month. Their plant operates 200 hours per month, but
the new machines will be used for T-shirts only 60 percent of the time and the output usually includes
5 percent that are ―seconds‖ and unusable. The stamping operation takes 1 minute per T-shirt, and
the stamping machines are expected to have 90 percent efficiency when considering adjustments,
changeover of patterns, and unavoidable downtime. How many machines are required?
a. 5 b. 6
c. 7 d. 8
41. During one-8-hour shift, 770 non-defective parts are desired from a fabrication operation. The
standard time for the operation is 12 minutes. Because the machine operators are unskilled, the
actual time it takes to perform the operation is 25 minutes and, on the average, one-sixth of the parts
that begin fabrication are scrapped. Assuming that each of the machines used for this operation will
not be available for 45 minutes each shift and there is a probability of 0.05 that each machine will
breakdown, determine the number of machines required.
a. 50 b. 52
c. 54 d. 56
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42. Nestor Briefcases is an exclusive producer of handcrafted, stylish cases. Priding itself on its earlier
reputation, the company assembles each case with care and attention to detail. This laborious
process requires the completion of six primary work elements, which are listed here.
Work Element Precedence Time (min)

A Tan leather - 30
B Dye leather A 15
C Shape case B 10
D Mold hinges and fixtures - 5
E Install hinges and fixtures C, D 10
F Assemble case E 10
If the demand is 50 cases per 40-hour week, compute the cycle time for the process.
a. 30 b. 40
c. 46 d. 48
43. Refer to problem no. 42, compute the lead time required for assembling one briefcase.
a. 30 b. 48
c. 80 d. 45
44. Refer to problem no. 42, calculate the theoretical minimum number of workstations.
a. 3 b. 2
c. 4 d. 1
45. Refer to problem no. 42, balance the line based on the most number of followers.
a.
35 45
AD BCEF
b.
45 35
AB CDEF
c.
30 30 20
A BCD EF
45 | P a g e
d.
30 25 25
A BC DEF
46. Refer to problem no. 42, compute the line’s efficiency.
a. 89% b. 83%
c. 81% d. 93%
47. Refer to problem no. 42, suppose the demand for briefcases increases to 80 cases per week.
Calculate a new cycle time.
a. 30 b. 35
c. 50 d. 45
48. Refer to problem no. 47, balance the line based on the longest task time
a.
35 45
AD BCEF
b.
45 35
AB CDEF
c.
30 30 20
A BCD EF
d.
30 25 25
A BC DEF
49. Refer to problem no. 47, calculate the new efficiency of the manufacturing process.
a. 89% b. 83%
c. 81% d. 93%
46 | P a g e
a. 3 b. 2
c. 4 d. 1
51. Pepper & Mys Bakeshop has set a production quota of 600 party cakes per 40-hour workweek. Use
the following information to compute for the cycle time.
Work Predecessor Performance Time (min)

Element
A - 1
B A 2
C B 2
D A, E 4
E - 3
F C, D 4
a. 3 b. 16
c. 4 d. 13
52. Refer to problem no. 51, compute the theoretical minimum number of workstations.
a. 5 b. 3
c. 2 d. 4
53. Refer to problem no. 51, balance the line using incremental utilization method
a.
3 3.25 3.25 3.25
AB CDEF CDEF CDEF
b.
2.5 2.5 5.5 5.5
ABC ABC DEF DEF
c.
3 3.25 3.25 3.25
3.25
AB CEDF CEDF CEDF CEDF
47 | P a g e
d.
3.0 3.0 3.25 3.25 3.25
AB AB CEDF CEDF CEDF
54. Refer to problem no. 51, calculate the efficiency of the assembly line.
a. 95% b. 90%
c. 80% d. 83%
55. The Hanzel Pizza is revamping its order processing and pizza-making procedures. In order to deliver
fresh pizza fast, six elements must be completed.
Work Element Precedence Time

(min)
A Receive order - 2
B Shape dough A 1
C Prepare toppings A 2
D Assemble pizza B, C 3
E Bake pizza D 3
F Deliver pizza E 3
If the demand is 120 pizzas per night (5:00 p.m. to 1:00 a.m.), compute the cycle time for the process.
a. 4 b. 3
c. 14 d. 13
56. Refer to problem no. 55, compute the lead time for the process.
a. 4 b. 3
c. 14 d. 13
57. Refer to problem no. 55, Calculate the theoretical minimum number of workstations.
a. 2 b. 3
c. 4 d. 5
58. Refer to problem no. 55, balance the line using the most number of followers method.
a.
3 5 3 3
AB CD E F
b.
3 2 3 3 3
AB C D E F
48 | P a g e
c.
4 1 3 3 3
AC B D E F
d.
4 4 3 3
AC BD E F
59. Refer to problem no. 55, compute the efficiency of the line.
a. 88% b. 91%
c. 89% d. 93%
60. Refer to problem no. 55, suppose demand increases to 160 pizzas per night. What is the new cycle
time?
a. 4 b. 3
c. 14 d. 13
61. Refer to problem no. 60, balance the line based on the longest task time method.
a.
3 5 3 3
AB CD E F
b.
3 2 3 3 3
AB C D E F
c.
4 1 3 3 3
AC B D E F
49 | P a g e
d.
4 4 3 3
AC BD E F
62. Refer to problem no. 60, calculate the new theoretical minimum number of workstations.
a. 2 b. 3
c. 4 d. 5
63. Neren’s Eye Care, Inc., is a full-service optical supplier that sells eyeglasses, contact lenses,
protective eye apparel to opticians. Bogs’ job is to assemble custom-ordered lenses into eyeglasses
for customers. Sales have been good lately, and Bogs has been assembling 100 glasses a day. The
manager of Neren’s asked Bogs to write down the precedence requirements and approximate
assembly times for each step in the assembly process. The data are shown here.
Element Description Precedence Time

(min)
A Inspect right and left lens for scratches and - 1.0
proper match
B Pop lens into frame A 1.0
C Position right side piece and attach to frame B 0.4
D Position left side piece and attach to frame B 0.4
E Package C, D 2.0
Assuming an 8-hour workday, how long does it take Bogs to assemble one pair of glasses?
a. 2 b. 2.4
c. 4 d. 4.8
64. Refer to problem no. 63, Neren’s anticipates a surge in demand with the opening of its own retail
outlets. If the assembly process is set up as an assembly line, what is the maximum number of
eyeglasses that can be assembled in one day, regardless of the number of workers hired?
a. 200 b. 240
c. 100 d. 480
65. Refer to problem no. 64, what is the efficiency of the line?
a. 80% b. 91%
c. 100% d. 95%
50 | P a g e
66. Prof. Jone has assigned 15 cases in his Seminar class to be completed in a 15 week semester. The
students, of course, are moaning and groaning that the caseload cannot possibly be completed in the
time allotted. Prof. Jone sympathetically suggests that the students work in groups and learn to
organize their work efficiently. Knowing when a situation is hopeless, the students make a list of the
tasks that have to be completed in preparing a case. These tasks are listed here, along with
precedence requirements and estimated time in days. Assuming students will work 5 days a week on
this assignment, how many students should be assigned to each group?
Element Description Precedence Time (days)

A Read case - 1
b Gather data a 4
c Search literature a 3
d Load in data b 1
e Run computer analysis d 4
f Write/type case c, e 4
a. 3 b. 4
c. 5 d. 6
67. The precedence diagram and task times (in minutes) for assembling Reyson’s Stamp Pad are shown
here. Set up an assembly line to produce 125 stamp pads in a 40-hour week. What is the cycle time?
8 5
A B F 4 J 9
C D E H 7 K 3
6 10 2
G I
5 2
a. 10 b. 19.2
c. 61 d. 2
a.
19 19 11 12
ABC DFG EHI JK
b.
19 19 18 5
ACB DGF EHJ IK
51 | P a g e
c.
19 17 13 12
ABC DEG FHI JK
d.
19 16 14 12
ACB DFE GHI JK
69. The work elements, precedence requirements, and time requirements to assemble a picture frame
are shown here. What is the cycle time capable of producing 1,600 frames per 40-hour week?

(min)
A Attach left frame side to top of frame - 0.35
B Attach right frame side to bottom of frame - 0.35
C Attach left and right frame subassemblies A, B 0.70
D Cut 8-inch x 10-inch glass - 0.50
E Cut 8-inch x 10-inch cardboard - 0.50
F Place glass into frame C, D 0.20
G Place cardboard into frame E, F 0.20
H Secure cardboard and glass F, G 0.50
I Apply descriptive label to glass D 0.10
a. 1.5 b. 0.70
c. 0.10 d. 3.4
70. Refer to problem no. 69, balance the assembly line based on the computed cycle time using
incremental utilization method
a.
1.4 1.2 .80
ABC DEG FIH
b.
1.30 1.40 0.70
DABI CEF GH
52 | P a g e
c.
1.40 1.40 0.60
ABC DEFG HI
d.
1.45 1.45 0.50
DEAI BCFG H
71. Refer to Problem No. 70, what is the maximum output per week?
a. 1,600 b. 1,715
c. 1,750 d. 1,656
72. Refer to problem no. 69, balance the assembly line based on the computed cycle time using most
number of followers method.
a.
1.4 1.2 .80
ABC DEG FIH
b.
1.30 1.40 0.70
DABI CEF GH
c.
1.40 1.40 0.60
ABC DEFG HI
d.
1.45 1.45 0.50
DEAI BCFG H
a. 1,600 b. 1,715
c. 1,750 d. 1,656
53 | P a g e
74. Refer to problem no. 69, balance the assembly line based on the computed cycle time using longest
task time method.
a.
1.4 1.2 .80
ABC DEG FIH
b.
1.30 1.40 0.70
DABI CEF GH
c.
1.40 1.40 0.60
ABC DEFG HI
d.
1.45 1.45 0.50
DEAI BCFG H
a. 1,600 b. 1,715
c. 1,750 d. 1,656
76. Refer to problem no. 69, calculate the maximum number of frames that can be assembles each week.
a. 2,557 b. 2,452
c. 3,567 d. 3,429
77. Refer to problem no. 76, rebalance the line for maximum production. Assuming one worker per
workstation. How many workers would be required?
a. 5 b. 4
c. 6 d. 3
78. Refer to problem no. 76, assume the company can sell as many frames as can be produced. If
workers are paid P60.00 an hour. What is the total cost per frame?
a. 1.67 b. 1.47
c. 6.17 d. 7.14
54 | P a g e
79. The Racela Finance Corporation has set a processing quota of 80 insurance claims per 8-hour day.
The claims process consists of five elements, which are detailed in the following table. Racela has
decided to use an assembly line arrangement to process the forms and would like to make sure they
have set up the line in the most efficient fashion. Calculate the cycle time required to meet the
processing quota.
Element Precedence Performance Time (min)

A - 4
B A 5
C B 2
D A 1
E C, D 3
a. 5 b. 6
c. 15 d. 16
80. Refer to problem no. 79, determine how many claims can actually be processed on your line.
a. 60/ day b. 70/ day

c. 80/ day d. 90/ day
81. A firm must produce 40 units/day during an 8-hour workday. Tasks, times, and predecessor activities
are given below.
Task Time (Minutes) Predecessor(s)

A 2 -
B 2 A
C 8 -
D 6 C
E 3 B
F 10 D, E
G 4 F
H 3 G
Total 38 minutes
Determine the cycle time to produce the 40 units per day.
a. 10 b. 38
c. 12 d. 20
82. Thomas Santos, manager of a metropolitan branch office of the state department of motor vehicles,
attempted to perform an analysis of the driver’s license renewal operations. He identified the steps
and associated times required to perform each step as follows:
Job Average Time to perform (seconds)

A. Review renewal application for correctness 15
B. Process and record payment 30
C. Check file violations and restrictions 60
D. Conduct eye test 40
E. Photograph applicant 20
F. Issue temporary license 30
Santos found that each step was assigned to a different person. Santos also found that jobs A, B, C,
and D were handled by general clerks who were each paid P270.00 per hour. Job E was by a
photographer paid P360.00 per hour. Job F, the issuing of temporary licenses, was required by state
55 | P a g e
policy to be handled by a uniformed motor vehicle officer. Officers were paid P405.00 per hour, but
they could be assigned to any job except photography.
A review of the jobs indicated that job A, reviewing the application for correctness, had to be
performed before any other step could be taken. Similarly, job F, issuing the temporary license, could
not be performed until all the other steps were completed. The checking of file violations and
restrictions could be performed while the applicant is having his eye test. The branch offices were
charged P450.00 per hour for each camera to perform photography.
Determine the maximum number of applications per hour that can be handled by the present
configuration of the process?
a. 60 b. 90
c. 120 d. 180
83. Refer to problem no. 82, how many applications can be processed per hour if a second clerk is added
to check for violations?
a. 60 b. 90
c. 120 d. 180
84. In addition to problem no. 83, assuming one more clerk is added to job D, what is the maximum
number of applications the process can handle?
a. 60 b. 90
c. 120 d. 180
85. Refer to problem no. 82, what is the required cycle time of the process to accommodate 180
applications per hour?
a. 15 b. 20
c. 40 d. 60
86. Refer to problem no. 82, compute for the costs per application per hour involved in the current
process.
a. 30.60 b. 18.90
c. 23.40 d. 38.25
87. Refer to problem no. 84, for the costs per application per hour involved in the alternative process.
a. 30.60 b. 18.90
c. 23.62 d. 38.25
88. Given:
From/To A B C D E F
A 15 50 125
B 20 75
C 50 120 120
D
E 50 100
F 110 100
56 | P a g e
Design a layout on a 3x3 grid that will minimize nonadjacent load. What is the layout of your building?
a.
A B C
D E F
b.
C B E
F A D
c.
B A F
E C D
d.
D B E
C F A
89. Given:
Number of loads per week

Department 1 2 3 4 5 6
1 50 100 20
2 30 50 10
3 20 100
4 50
5
6
57 | P a g e
a.
1 2 6
4 3 5
b.
5 2 1
4 3 6
c.
2 6 5
3 4 1
d.
6 3 4
1 5 2
90. Given:

1. Administration 3 6 5 6 10
2. Social services 8 1 1
3. Institutions 3 9
4. Accounting 2
5. Education 1
6. Internal audit
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a.
4 1 2
6 5 3
b.
3 6 4
2 5 1
c.
1 5 4
3 6 2
d.
6 3 2
5 1 4
91. Given:
Loads/day
From/To A B C D E
A 30 60 20
B 30 30
C 80
D 40
E
59 | P a g e
a.
C A
D E
b.
C B
D A
c.
B D
E A
d.
A E
C B
60 | P a g e
92. Matthew Design Company has been asked to design the layout for a newly constructed office
building of one of its clients. The closeness matrix showing the daily trips between its six department
offices is given below.
Trips between Departments

Department
1 2 3 4 5 6
1 25 90 165
2 105
3 125 125
4 25
5 105
6
a.
3 1 5
6 4 2
b.
2 5 3
4 1 6
c.
5 1 4
3 6 2
d.
1 6 2
3 5 4
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93. Given:
Flow between Departments (Number of Moves)
Departments 1 2 3 4 5 6 7 8
1. Shipping and receiving 175 150 80 20 75
2. Plastic molding stamping 90 100 125 120
3. Metal forming 350
4. Sewing department 25 25
5. Small toy assembly 180 187
6. Large toy assembly 374 103
7. Painting 7
8. Mechanism assembly
a.
5 1
2 6 4
3 7 8
b.
1 7
5 2 6
3 8 4
62 | P a g e
c.
4 5
6 1 3
2 8 7
d.
6 4
7 8 2
5 1 3
94. Given:
From/To Stores Turning Milling Press Plate Assembly Warehouse

Stores 6 12 9 1 4
Turning 3 4
Milling 7 2
Press 3 1 1
Plate 1 3 4 3
Assembly 1 7
Warehouse
a.
Press Warehouse
Warehouse Plate Milling
Stores Turning
63 | P a g e
b.
Turning Stores
Milling Press Warehouse
Plate Assembly
c.
Assembly Warehouse
Turning Plate Press
Assembly Stores
d.
Milling Assembly
Plate Warehouse Turning
Stores Press
95. Based on the relationship chart below, what is it recommended layout?
64 | P a g e
a.
4 6
1 5
2 3
b.
6 4
1 5
3 2
c.
2 3 6
1 5
d.
6 3 2
5 1
96. Based on the relationship chart below, what is its recommended layout?
65 | P a g e
a.
5 3 1
2 4
6 7
b. 1 3
4 2
5 6 7
c.
3 1
6 2 4
7 5
d.
1 3
6 2 4
5 7
97. Given:
Legend: CV Values Legend CV Values

A 10,000 E 1,000
I 100 O 10
U 0 X -1,000
Activity Area (sq. m)
1. W ood cutting 1,280
A
2. Receiving 560 E
I X
3. Framing 1,280 U U
E U
I
U U
4. Upholstery 1,120 X U
U I
E U U
5. Fabric storage 960 I I
A I U
E U
6. Fabric cutting 960 U
A U
7. Sewing 640 U U
U U
O
8. Shipping 800
E
9. Offices 800
O
10. General Storage 480
66 | P a g e
Distance between departments: Adjacent = 1, Partial Adjacent = 0.5, Non-Adjacent = 0
Using CORELAP, what is Total Closeness Rating (TCR) Value of Department 1?
a. 10,000 b. 11,000
c. 12,000 d. 14,000
98. In reference to problem no. 97, what activity is the first to be placed on the grid?
a. 7 b. 2
c. 5 d. 6
99. In reference to problem no. 98, what is your final layout?
a.
10 5 6
1 3 7
2 8 4 9
b.
10 1 7
3 5 6
4 8 9 2
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c.
10 1 4
8 9 2
7 3 5 6
d.
10 5 6
8 4 7
2 1 3 9
100. Given:
Parts-Machines Matrix
Parts
1 2 3 4 5 6 7 8
A x x x
B x x
C x x
D x x x x
E x
Machines F x x
G x x
H x x x
I x x
J x x
K x
L x x x
Using Digital Clustering Algorithm (DCA), prepare the final cell formation with additional machines, if
needed.
68 | P a g e
a. 5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
B X X
J X X
L X X X
G X X
K X
C X X
F X X
I X X
E X
b. 5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
B X X
J X X
L1 X X
G X X
K X
L2 X
C X X
F X X
I X X
E X
c. 5 6 1 4 7 3 2 8
D X X X X
A X X X
H X X X
B X X
J X X
C X X
F X X
I X X
E X X X
L X X
G X X
K X
d. 5 6 1 4 7 3 2 8
D X X X X
A X X X
H X X X
B X X
J X X
C X X
F X X
I X X
E1 X
E2 x x
L X X
G X X
K X
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SOLVED PROBLEMS IN FACILITY PLANNING & DESIGN - QUANTITATIVE
1. Belinda Fashion Wear is a small chain of stores specializing in fashion clothing. The company currently
has five stores in Manila, Quezon City, and Caloocan, and it wants to open new store in of four new
mall locations in the other nearby cities. A consulting firm has been hired to help the company decide
where to locate new store. The company has indicated five factors that are important to its decision,
including proximity of a college, community median income, mall vehicle traffic flow and parking,
quality and number of stores in the mall, and proximity of other malls or shopping areas. The
consulting firm had the company weight the importance of each factor. The consultant had visited each
potential location and rated them according to each factor, as follows:
Location factors Weight Mall 1 Mall 2 Mall 3 Mall 4

College proximity 0.30 40 60 90 60
Median income 0.25 75 80 65 90
Vehicle traffic 0.25 60 90 79 85
Mall quality and size 0.10 90 100 80 90
Proximity of other shopping 0.10 80 30 50 70
Given that all sites have basically the same leasing cost and labor and operating cost, what is the
recommended location based on rating factors?
a. Mall 1 b. Mall 2
c. Mall 3 d. Mall 4
Answer: d. Mall 4
Location factors Mall 1 Mall 2 Mall 3 Mall 4

College proximity 12.00 18.00 27.00 18.00
Median income 18.75 20.00 16.25 22.50
Vehicle traffic 15.00 22.50 19.75 21.25
Mall quality and size 9.00 10.00 8.00 9.00
Proximity of other shopping 8.00 3.00 5.00 7.00
TOTAL 62.75 73.50 76.00 77.75
2. Zachtech Computers manufacture computer components such as chips, circuit boards, motherboards,
keyboards, LCD panels, and the like and sells them around the world. It wants to construct a new
warehouse/distribution center in Asia to serve emerging Asian markets. It has identified sites in
Shanghai, Hong Kong and Singapore and has rated the important location factors for each site as
follows:
Location Factors Weight Shanghai Hong Kong Singapore

Political Stability 0.25 50 60 90
Economic Growth 0.18 90 70 75
Port Facilities 0.15 60 95 90
Container support 0.10 50 80 90
Land and construction cost 0.08 90 20 30
Transportation/Distribution 0.08 50 80 70
Duties and tariffs 0.07 70 90 90
Trade regulations 0.05 70 95 95
Airline Service 0.02 60 80 70
Area roads 0.02 60 70 80
70 | P a g e
Recommend a site including its total score rating based on these location factors and ratings.
a. Hongkong, 72 b. Hongkong, 82
c. Singapore, 81 d. Shanghai, 79
Answer: c. Singapore, 81
Location Factors Shanghai Hong Kong Singapore

Political Stability 12.50 15.00 22.50
Economic Growth 16.20 12.60 13.50
Port Facilities 9.00 14.25 13.50
Container support 5.00 8.00 9.00
Land and construction cost 7.20 1.60 2.40
Transportation/Distribution 4.00 6.40 5.60
Duties and tariffs 4.90 6.30 6.30
Trade regulations 3.50 4.75 4.75
Airline Service 1.20 1.60 1.40
Area roads 1.20 1.40 1.60
Total 64.70 = 65 71.90 = 72 80.55 = 81
3. Cradle University is going to construct a new student center and athletic complex that will include a
bookstore, post office, theaters, markets, mini-mall, meeting rooms, swimming pool, and weight and
exercise rooms. The university administration has hired a site selection specialist has identified four
sites on campus and has rated important location factors for each site as follows:
Location Factors Weight South West A West B East

Proximity to housing 0.23 70 90 65 85
Student traffic 0.22 75 80 60 85
Parking availability 0.16 90 60 80 70
Plot size, terrain 0.12 80 70 90 75
Off-campus accessibility 0.06 90 70 70 70
Proximity dining facilities 0.05 60 80 70 90
Visitor traffic 0.04 70 80 65 55
Landscape/aesthetics 0.02 50 40 60 70
Recommend a best site based on these location factors and ratings.

a. South b. West A
c. West B d. East
Answer: d. East
Location Factors South West A West B East

Proximity to housing 16.10 20.70 14.95 19.55
Student traffic 16.50 17.60 13.20 18.70
Parking availability 14.40 9.60 12.80 11.20
Plot size, terrain 9.60 8.40 10.80 9.00
Infrastructure 5.00 6.00 4.00 6.00
Off-campus accessibility 5.40 4.20 4.20 4.20
Proximity dining facilities 3.00 4.00 3.50 4.50
Visitor traffic 2.80 3.20 2.60 2.20
Landscape/aesthetics 1.00 0.80 1.20 1.40
Total 73.80 74.50 67.25 76.75
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4. Zhan Electronics is going to construct new P1.2 billion semi-conductor plant and has selected four
Export Processing Zone Areas as potential sites. The important location factors and ratings for each
town are as follows:
Location Factors Weight Sta. Rosa Lipa Bataan Subic

Work Ethics 0.18 80 90 70 75
Quality of Life 0.16 75 85 95 90
Labor Laws/Unionization 0.12 90 90 60 70
Education 0.08 80 90 85 95
Labor skill & Education 0.07 75 65 70 80
Cost of Living 0.06 70 80 85 75
Taxes 0.05 60 70 55 60
Incentive Package 0.05 90 95 70 80
Government Regulation 0.03 40 50 65 55
Environmental 0.03 65 60 70 80
Regulation
Transportation 0.03 90 80 95 80
Space for Expansion 0.02 90 95 90 90
Urban Proximity 0.02 60 90 70 80
Recommend a site based on these location factors and ratings.
a. Sta. Rosa b. Lipa

c. Bataan c. Subic
Answer: b. Lipa
Location Factors Sta. Rosa Lipa Bataan Subic

Work Ethics 14.4 16.2 12.6 13.5
Quality of Life 12.0 13.6 15.2 14.4
Labor Laws/Unionization 10.8 10.8 7.20 8.40
Infrastructure 6.00 5.00 6.00 7.00
Education 6.40 7.20 6.80 7.60
Labor skill & Education 5.25 4.55 4.90 5.60
Cost of Living 4.20 4.80 5.10 4.50
Taxes 3.00 3.50 2.75 3.00
Incentive Package 4.50 4.75 3.50 4.00
Government Regulation 1.20 1.50 1.95 1.65
Environmental Regulation 1.95 1.80 2.10 2.40
Transportation 2.70 2.40 2.85 2.40
Space for Expansion 1.80 1.90 1.80 1.80
Urban Proximity 1.20 1.80 1.40 1.60
Total 75.40 79.80 74.15 77.85
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5. Joehanna Drug Store Chain wishes to build a new warehouse to serve the whole Quezon. At the
moment, it is looking at three possible locations. The factors, weights, and ratings being considered
are given below:
Ratings
Factor Weights Candelaria Lucena Lukban
Nearness to markets 20 4 7 5
Labor cost 5 8 8 4
Taxes 15 8 9 7
Nearness to suppliers 10 10 6 10
Which city should they choose?
a. Candelaria, 340 b. Lucena, 375

c. Lukban 325 d. Lukban, 385
Answer: b. Lucena, 375
Ratings Weighted Ratings

Factor Weights Candelaria Lucena Lukban Candelaria Lucena Lukban
Nearness to
20 4 7 5 80 140 100
markets
Labor cost 5 8 8 4 40 40 20
Taxes 15 8 9 7 120 135 105
Nearness to
10 10 6 10 100 60 100
suppliers
Sum of Weighted ratings: 340 375 325
6. The Charlie Forwarding Company wants to build a new distribution center in Central Luzon. The center
needs to be in the vicinity of uncongested Aurora, Bataan, and Nueva Ecija. The coordinates of this sites
and the number of weekly packages that flow to each are as follows:
Aurora Bataan Nueva Ecija

X = 17 X = 20 X = 30
Y = 30 Y=8 Y = 14
W = 17,000 W = 12,000 W = 9,000
What are the coordinates of the center of these 3 provinces?
a. (25, 22) b. (18, 22)

c. (24, 17) d. (21, 19)
Answer: d. (21, 19)
X= (17) (17,000) + (20) (12,000) + (30) (9,000)

17,000 + 12,000 + 9,000
X= 21.03 = 21
Y= (30) (17,000) + (8) (12,000) + (14) (9,000)

17,000 + 12,000 + 9,000
Y= 19.26 = 19
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7. James Company is attempting to determine the location for a new outlet mall. The region where the
outlet mall will be constructed includes four towns, which together have a sizable population base. The
grid map coordinates of the four towns in Cavite and the populations of each are as follows:
Town X Y Population (10,000s)

Rosario 30 60 6.5
Dasmarinas 50 40 4.2
Trece 10 70 5.9
Martirez
Silang 40 30 3.5
Determine best location for the outlet mall using the center-of-gravity method.
a. (32, 56) b. (33, 55)

c. (30, 54) d. (31, 52)
Answer: c. (30, 54)
X = (30(6.5) + 50(4.2) + 10(5.9) + 40(3.5)) / (6.5 + 4.2 + 5.9 + 3.5)

X = 604/20.1
X = 30.05 = 30
Y = (60(6.5) + 40(4.2) + 70(5.9) + 30(3.5)) / (6.5 + 4.2 + 5.9 + 3.5)

Y = 1076/20.1
Y = 53.53 = 54
8. Ray-Mart, a discount store chain, wants to build a new superstore in an area in Batangas near four
small towns with population between 8,000 and 42,000. The coordinates (in miles) of these four towns
and the market population in each are as follows:
Bauan Ibaan Mabini Laurel

X = 12 X = 18 X = 30 X = 32
Y = 20 Y = 18 Y=7 Y = 25
W = 26,000 W = 14,000 W = 9,500 W = 12,000
Determine the coordinates of the best site using the center of gravity technique.
a. (24, 21) b. (21, 20)

b. (23, 22) d. (20, 19)
Answer: d. (20, 19)
X = (12(26,000) + 18(14,000) + 30(9,500) + 32(12,000)) / (26,000 + 14,000 + 9,500 + 12,000)

X = 1,233,000/61,500
X = 20.05 = 20
Y = (20(26,000) + 18(14,000) + 7(9,500) + 25(12,000)) / (26,000 + 14,000 + 9,500 + 12,000)

Y = 1,138,500/61,500
Y = 18.51 = 19
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9. Caloy Distribution Center in Quezon City is due to be replaced with a much larger, more modern facility
that can handle the tremendous needs that have developed with the city’s growth. Fresh produce
travels to the seven store locations several times a day making site selection critical for efficient
distribution. Using the data in the following table, determine the map coordinates for the proposed
new distribution center.
Store Locations Map Coordinates (x,y) Truck Round Trips per Day
Timog Avenue (10, 5) 3
Banawe St. (3, 8) 3
West Avenue (4, 7) 2
Tomas Morato St. (15, 10) 6
Visayas Avenue (13, 3) 5
Libis (1, 12) 3
Cubao (5, 5) 10
a. (8, 7) b. (9, 7)
c. (7, 9) d. (7, 8)
Answer: a. (8, 7)
New Distribution Center should be located at:
C x = (10 x 3) + (3 x 3) + (4 x 2) + (15 x 6) + (13 x 5) + (1 x 3) + (5 x 10) = 255 = 8

3 + 3 + 2 + 6 + 5 + 3 +10 32
Cy = (5 x 3) + (8 x 3) + (7 x 2) + (10 + 6) + (3 x 5) + (12 x 3) + (5 x 10) = 214 = 7

3 + 3 + 2 + 6 + 5 + 3 + 10 32
10. The following table gives the map coordinates and the shipping loads for a set of cities that we wish to
connect though a central ―hub.‖ Near what map coordinates should the hub be located?
City Map Coordinate (x,y) Shipping Load

A (5, 10) 5
B (6, 8) 10
C (4, 9) 15
D (9, 5) 5
E (7, 9) 15
F (3, 2) 10
G (2, 6) 5
a. (7, 5) b. (8, 4)
c. (4, 8) d. (5, 7)
Answer: d. (5, 7)
The new hub should be located close to:
C x= (5 x 5) + (6 x 10) + (4 x 15) + (9 x 5) + (7 x 15) + (3 x 10) + (2 x 5) = 335 = 5

5 +10 + 15 + 5 + 15 +10 + 5 65
Cy = (10 x 5) + (8 x 10) + (9 x 15) + (5 + 5) + (9 x 15) + (2 x 10) + (6 x 5) = 475 = 7

5 + 10 + 15 + 5 + 15 + 10 + 5 65
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11. The Inah Burger restaurant chain uses a distribution center to prepare the food ingredients it provides
its individual restaurants. The company is attempting to determine the location for new distribution
center that will service five restaurants. The grid-map coordinates of the five restaurants and the annual
numbers of 40-foot trailer trucks transported to each restaurant are as follows:
Restaurants X Y Annual Truck Shipments

1 100 300 30
2 210 180 25
3 250 400 15
4 300 150 20
5 400 200 18
Determine the coordinates of the location using the center-of-gravity method.
a. (233, 242) b. (236, 244)

c. (243, 231) c. (245, 230)
Answer: a. (233, 242)
X = (100(30) + 210(25) + 250(15) + 300(20) + 400(18)) / (30+25+15+20+18)
X = 25200/108
X = 233.33 = 233
Y = (300(30) + 180(25) + 400(15) + 150(20) + 200(18)) / (30+25+15+20+18)

Y = 26100/108
Y = 241.67 = 242
12. The Inah Burger restaurant chain in the previous problem is considering three potential sites. With the
following grid-map coordinates for its new distribution center: A(350, 300). B. (150, 250), and C (250,
300). Determine the best location using the load-distance formula.
a. Site A, LD = 15,205 b. Site B, LD = 15,325

c. Site C, LD = 15,570 c. Site C, LD = 15,255
Answer: b. Site B, LD = 15,325
Site A: d1= (X1 – Xa)2 + (Y1 – Ya)2

2 2
= (100 – 350) + (300 - 300) = 250
d2 = (X2 – Xa)2 + (Y2 – Ya)2

2 2
= (210 – 350) + (180 – 300) = 184.39
d3 = (X3 – Xa)2 + (Y3 – Ya)2
= (250 – 350)2 + (400 – 300)2 = 141.42
d4 = (X4 – Xa)2 + (Y4 – Ya)2
= (300 – 350)2 + (150 – 300)2 = 158.11
d5 = (X5 – Xa)2 + (Y5 – Ya)2

2 2
= (400 – 350) + (300 – 300) = 111.8
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2 2
Site B: d1 = (X1 – Xa) + (Y1 – Yb)
2 2
= (100 – 150) + (300 - 250) = 70.71
2 2
d2 = (X2 – Xb) + (Y2 – Yb)
2 2
= (210 – 150) + (180 – 250) = 92.20
2 2
d3 = (X3 – Xb) + (Y3 – Yb)
= (250 – 150)2 + (400 – 250)2 = 180.28
d4 = (X4 – Xb)2 + (Y4 – Yb)2
= (300 – 150)2 + (150 – 250)2 = 180.28

2 2
d5 = (X5 – Xb) + (Y5 – Yb)
= (400 – 150)2 + (200 – 250)2 = 254.95
Site C: d1 = (X1 – Xc)2 + (Y1 – Yc)2
= (100 – 350)2 + (300 - 300)2 = 150
d2 = (X2 – Xc)2 + (Y2 – Yc)2
= (210 – 250)2 + (180 – 366)2 = 126.49
d3 = (X3 – Xc)2 + (Y3 – Yc)2
= (250 – 250)2 + (400 – 300)2 = 100
d4 = (X4 – Xc)2 + (Y4 – Yc)2
= (300 – 250)2 + (150 – 300)2 = 158.11
d5 = (X5 – Xc)2 + (Y5 – Yc)2

2 2
= (400 – 250) + (200 – 300) = 180.28
LD (Site A) = 30(250) + 25(184.39) + 15(141.42) + 20(158.11) + 18(111.8)

= 19,405.65 = 19,406
LD (Site B) = 30(70.71) + 25(92.20) + 15(180.28) + 20(180.28) + 18(254.95)

= 15,325.20 = 15,325
LD (Site C) = 30(150) + 25(126.49) + 15(100) + 20(158.11) + 18(180.28)

= 15,569.49 = 15,570
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13. Marla Homes, a home improvement/ building supply chain, is going to build a new warehouse facility
to serve its stores in six Metro Manila Cities - Taguig, Pasig, Mandaluyong, Makati, Pasay, and
Quezon City. The coordinates of this cities (in miles), using Manila, as the origin (0,0) of a set of
coordinates, and the annual truck loads that supply each city as shown as follows. Determine the best
site using the center- gravity technique.
Pasig Taguig Mandaluyong Makati Pasay Quezon

City
X = 15 X =42 X = 88 X = 125 X = 135 X = 180
Y = 85 Y = 145 Y = 145 Y = 140 Y = 125 Y = 18
W = 160 W = 90 W = 105 W = 35 W = 60 W = 75
a. (77, 104) b. (80, 107)

c. (79, 106) d. (81, 105)
Answer: c. (79, 106)
X = 15(160) + 42(90) + 88(105) + 125(35) + 135(60) + 180(75)

160 + 90 + 105 + 35 + 60 + 75
= 78.85 = 79
Y = 85(160) + 145(90) + 145(105) + 140(35) + 125(60) + 18(75)

160 + 90 + 105 + 35 + 60 + 75
= 105.95 = 106
14. Refer to problem no. 13, Marla Homes base has two parcel of land, Site A & B in Metro Manila. Use
the load-distance technique to determine which would be the best site with its load-distance value.
Site X Y
A 88 80
B 13 127
a. Site A with LD = 38,986 b. Site A with LD = 40,391

c. Site B with LD = 44,121 d. Site B with LD = 43,542
Answer: b. Site A with LD = 40,391
For Site A:
2 2
d Pasig = (15 – 88) + (85 – 80) = 73.17
d Taguig = (42 – 88)2 + (145 – 80)2 = 79.63
d Mandaluyong = (88 – 88)2 + (145 – 80)2 = 65.00

2 2
d Makati = (125 – 88) + (140 – 80) = 70.49
2 2
d Pasay = (135 – 88) + (125 – 80) = 65.07
2 2
d Quezon City = (180 – 88) + (18 – 80) = 110.94
For Site B:
d Pasig = (15 – 13)2 + (85 – 127)2 = 42.05
2 2
d Taguig = (42 – 13) + (145 – 127) = 34.13
78 | P a g e
d Mandaluyong = (88 – 13)2 + (145 – 127)2 = 77.13

2 2
d Makati = (125 – 13) + (140 – 127) = 112.75
2 2
d Pasay = (135 – 13) + (125 – 127) = 122.00
2 2
d Quezon City = (180 – 13) + (18 – 127) = 199.42
Load Distance:
For Site A:
LD = 160(73.17) + 90(79.63) + 105(65.00) + 35(70.49) + 60(65.07) + 75(110.94)

= 40,390.75 = 40,391
For Site B:
LD = 160(42.05) + 90(34.13) + 105(77.13) + 35(112.75) + 60(122.00) + 75(199.42)
= 44,121.10 = 44,121
15. Roy Automobile Accessories, a manufacturer of automobile fan belts is considering three locations—
Subic, Clark, and Laguna for a new plant. Cost studies indicate that fixed costs per year at the sites
are P30,000.00, P60,000.00, and P110,000.00, respectively; and variable cost are P75.00 per unit,
P45.00 per unit, and P25.00 per unit, respectively. The expected selling price of the fan belt produced
is P120.00. The company wishes to find the most economical location for an expected volume of
2,000 units per year.
a. Subic, P180,000.00 b. Subic, P140,000.00

c. Clark, P150,000.00 d. Laguna, P160,000.00
Answer: c. Clark, P150,000.00
For Subic,
Total Cost = P30,000.00 + P75.00(2,000) = P180,000.00
For Clark,
Total Cost = P60,000.00 + P45.00(2,000) = P150,000.00
For Laguna,
Total Cost = P110,000.00 + P25.00(2000) = P160,000.00
With an expected volume of 2,000 units per year, Clark provides the lowest cost location.
16. A plastic firm has four work centers (A, B, C, and D) in series with individual capacities (units per day) and
actual output as shown.
A B C D
450 390 360 400 actual output = 306/ day
What is the process capacity?
a. 306 b. 360
c. 450 d. 1,600
Answer: b. 360
Process Capacity = capacity of most limited component in the line = 360 units/ day
79 | P a g e
17. Refer to Problem no. 16, what is the process efficiency?
a. 19% b. 22.5%
c. 68% d. 85%
Answer: d. 85%
Process Efficiency = actual output/ process capacity = 306/ 360 = 85%
18. Dennis Furniture Company manufactures four-drawer oak cabinets in six stages. In the first stage, the
boards forming the walls of the cabinets are cut; in the second stage the front drawer panels are
woodworked; in the third stage the boards are sanded and finished; in the fourth stage the boards are
cleaned, stained, and painted with a clear finish; in the fifth stage the hardware for pulls, runners, and
fittings is installed; and in the final stage the cabinets are assembled. Inspection occurs at each stage
of the process, and the average percentages of good-quality units are as follows:

Good Quality
1 87%
2 91%
3 94%
4 93%
5 93%
6 96%
The cabinets are produced in weekly production runs with a product input for 300 units. Determine
the weekly product yield of good-quality cabinets.
a. 186 b. 288
c. 312 d. 486
Answer: a. 186
O = (300)(0.87)(0.91)(0.94)(0.93)(0.93)(0.96) = 185.3 = 186
19. Refer to problem no. 18, what would weekly product input have to be in order to achieve a final
weekly product yield of 300 cabinets?
a. 186 b. 288
c. 312 d. 486
Answer: d. 486
I = 300 / (0.87)(0.91)(0.94)(0.93)(0.93)(0.96)
I = 485.5 = 486
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20. The Jelo Motor Company, motors are produced in a three-stage process. Motors are inspected
following each stage with percentage yields of good quality in process units as follows:

Good Quality
1 0.96
2 0.98
3 0.95
The company wants to know the daily product yield for product input of 250 units per day.
a. 263 b. 238
c. 223 d. 280
Answer: c. 223
O = (250)(0.96)(0.98)(0.95)
O = 223.44 = 224
21. Refer to problem no. 20, how many input units it would have to start with each day to result in a final
daily yield of 250 good quality units?
a. 263 b. 238
c. 223 d. 280
Answer: d. 280
I = 250 / (0.96)(0.98)(0.95)
I = 279.72 motors = 280
22. Rafael Metals Company manufactures of wood burning stove. What is the product input for 15,000
stoves if the good quality of each stove is 88%?
a. 13,200 b. 1,800
c. 125,000 d. 17,045
Answer: d.
I = O/(1 - P)
I = 15,000/(1 - 0.12)
I = 17,045.45 = 17,045
23. Lara Company operates a small telephone order system for a catalog of its clothing products. The
catalog orders are processed in four stages. Errors can be made in orders at any of these stages,
and the average percentages of errors that occur at each stage are as follows.
Stage %Error
1 19%
2 16%
3 10%
4 8%
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If an average of 460 telephone orders is processed each day, how many errorless orders will result?
a. 112 b. 259
c. 244 d. 129
Answer: b. 259
O = 460 (1 - 0.19)(1 - 0.16)(1 - 0.10)(1 - 0.08)

O = 460(0.81)(0.84)(0.90)(0.92)
O = 259.15 = 259
24. Liam Manufacturing Company has a weekly product input of 2,800 units. The average percentage of
good-quality product is 87 percent. Of the poor quality products 60 percent can be reworked and sold
as good-quality products. Determine the weekly product output?
a. 2,654 b. 5,364
c. 1,462 d. 3,218
Answer: 2,654
O = 2,800(0.87) + 2,800(0.13)(0.60)
O = 2,436 + 218.4
O = 2,654.4 = 2,654
25. Assume that production volume is 1,600 pieces per day, the standard time is 0.004 hour per piece, 8
working hours per day, setup time at 0.2 hr per day, and scrap rate of 0.10. Find the fractional
machine number.
a. 1.12 b. 0.85
c. 0.91 d. 1.21
Answer: c. 0.91
F = [(1600)/0.90](0.004)/ (8 – 0.2) = 0.91
26. A product requires two sequential machine operations. The first takes 3.5 minutes and the defect
percentage is 12. The second takes 6.0 minutes and the defect percentage is 7. In another similar
plant belonging to the same company, past annual data on identical operations and working
conditions indicate that a total of 2,198 hours due to set up of machines and 2,052 hours due to
machine unavailability due to maintenance per year. Assuming 250 work days per year and a daily
shift of 10 hours, it is desired to determine the minimum fractional number of machines to
manufacture 50,000 units per year.
a. 4 b. 5
c. 6 d. 7
Answer: b. 5
P2 = 50,000/0.93 = 53,763.44
P1 = 53,763.44/0.88 = 61,094.82
F = ((53,763.44)(6) + (61094.82)(3.5))/(60*250*10)(2,198/2,500)(2,052/2,500)) = 5
82 | P a g e
27. Eric Explosives Company is considering the expansion of a solid-propellant manufacturing process by
adding more 1-ton capacity curing furnaces. Each batch (1 ton) of propellant must undergo 30 minutes of
furnace time, including load and unload operations. However, the furnace is used only 80 percent of the
time due to power restrictions in the other parts of the system. The required output for the new layout is to
be 16 tons per shift (8 hours). Plant (system) efficiency is estimated at 50 percent of system capacity.
Determine the number of furnaces required.
a. 3 b. 4
c. 1 d. 5
Answer: a. 3
F = 30 mins per ton x 16 tons per shift/ 8 x 60 x 0.50 x 0.80 = 480/ 192 = 2.5 = 3
28. Refer to problem no. 27, estimate the percentage of time the furnaces will be idled.
a. 20% b. 25%
c. 33% d. 67%
Answer: d. 67%
Percentage of Idle Time:

Total hours available per shift = 3 furnaces @ 8 hours = 24 furnace hours
Total hours of actual use per shift = 16 tons (0.5 hr/ ton) = 8 furnace hours
Idle Time = 16 hours
Percentage of Idle Time = 16 hours idle/ 24 hours total = 67% idle time
29. Charmz Developing Agency must determine how many photo-enlarger cubicles are required to maintain
an output of 200 good prints per hour. The set-up and exposure time can theoretically be done in 2
minutes per print, but operators are on the average only 90 percent efficient and, in addition, 5 percent of
the prints must be scrapped and redone. Also, the cubicles can be utilized for enlarging only 70 percent of
the time. What is the required process capacity in prints per hour?
a. 212 b. 250
c. 211 d. 200
Answer: c. 211
Required process capacity = good output/ process efficiency = 200/ 0.95 = 211 prints/ hr
30. Refer to problem no. 29, what average output per hour can be expected from each cubicle, taking its use
factor and efficiency into account?
a. 211 b. 30
c. 19 d. 200
Answer: c. 19
Output/ hr = (unit capacity) (utilization) (efficiency)

Where unit capacity = 60 mins/ hr/ 2 mins/ print = 30 prints/ hr
Output/ hr = (30 prints/ hr) (0.70) (0.90) = 18.9 prints/ hr = 19
31. Refer to problem no. 29, how many enlarger cubicles are required?
a. 14 b. 10
c. 16 d. 12
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Answer: d. 12
Number of cubicles = 210.5 prints/ hr required/ 18.9 prints/ hr-cubicle = 11.4 or 12 cubicles
32. Dason Plastics manufacturer must acquire some molding machines capable of producing 160,000 good
parts per year. They will be installed in a production line that normally produces 20 percent rejects
because of the tight aerospace specifications. Assume that it takes 90 seconds to mold each part and the
plant operates 2,000 hours per year. If the molding machines are used only 50 percent of the time and
are 90 percent efficient, what actual (usable) molding machine output per hour would be achieved?
a. 40 b. 18
c. 45 d. 20
Answer: b. 18
Output/ hr = (unit capacity) (utilization) (efficiency)

Where, unit capacity = 60 mins/ hr/ 1.5 mins/ part = 40 parts/ hr
Output/ hr = (40 parts/ hr) (0.50) (0.90) = 18 parts/ hr
33. Refer to problem no. 32, how many molding machines would be required?
a. 4 b. 8
c. 6 d. 12
Answer: c. 6
Number of Molding Machines = (160,000/ 0.80)(1.5)/ (2000)(60)(0.50)(0.90)

= 300,000/ 54,000 = 5.56 = 6 machines
34. Given:
Year Demand (units)
1 220,000
2 275,000
3 380,000
4 420,000
5 565,000
% Scrap: 3%
Standard Time: 2 minutes per unit
Target Machine Efficiency: 90%
Machine Breakdown: 30 minutes per day
Operation Schedule: 8am – 4pm daily schedule/ 20 working days per month
How many machines you will acquire/ buy on Year 1?
a. 5 b. 7
c. 2 d. 9
Answer: a. 5
84 | P a g e
Given: H = 480
E = 0.85
R = 480-30 = 450/480 = 0.9375
T = 2 mins per unit
O1 = 220,000 per year
O2 = 275,000 per year
O3 = 380,000 per year
O4 = 420,000 per year
O5 = 565,000 per year
P = 3%
Solution:
Q1 = 220,000/ (1 – 0.03) = /12 = /20 = 945.017 per day
Q2 = 275,000/ (1 – 0.03) = /12 = /20 = 1,181.271 per day
Q3 = 380,000/ (1 – 0.03) = /12 = /20 = 1,632.302 per day
Q4 = 420,000/ (1 – 0.03) = /12 = /20 = 1,804.124 per day
Q5 = 565,000/ (1 – 0.03) = /12 = /20 = 2,426.976 per day
HER = 480 x 0.85 x 0.9375 = 382.5

F1 = 945.017 x 2 = 4.9 = 5 machines
382.5
35. Refer to problem 34, how many machines you will acquire/ buy on Year 2?
a. 5 b. 7
c. 1 d. 9
Answer: c. 1
F1 = 945.017 x 2 = 4.9 = 5 machines

382.5
F2 = 1,181.271 x 2 = 6.2 = 6 machines

382.5
Therefore, buy only 2 machines (6 – 5 = 1) in year 2
a. 5 b. 7
c. 3 d. 9
Answer: c. 3
F2 = 1,181.271 x 2 = 6.2 = 6 machines

382.5
F3 = 1,632.302 x 2 = 8.5 = 9 machines
382.5
a. 1 b. 10
c. 2 d. 9
Answer: a. 1
85 | P a g e
F3 = 1,632.302 x 2 = 8.5 = 9 machines

382.5
F4 = 1,804.124 x 2 = 9.4 = 10 machines
382.5
Therefore, buy only 1 machine (10 – 9 = 1) in year 4
a. 1 b. 10
c. 3 d. 13
Answer: c. 3
F4 = 1,804.124 x 2 = 9.4 = 10 machines

382.5
F5 = 2,426.976 x 2 = 12.7 = 13 machines
382.5
39. A team of Industrial Engineers conducted a work sampling of identical machines being used for a
manufacturing company and they have observed the following:
% Idleness
Machine 1 20%
Machine 2 35%
Machine 3 15%
Machine 4 55%
The machines are running based on the schedule of operation per shift.
Shift Schedule: 6am – 2pm/ 2pm – 10pm/ 10pm – 6am
Break Time: 1-hr meal break and 15 minutes coffee or short break per shift.
Compute for the number of machines required in a given shift.
a. 1 b. 2
c. 3 d. 4
Answer: c. 3
SQ = 405 (0.80) + 405 (0.65) + 405(0.85) + 405(0.45) = 1113.75 minutes

E = not given so considered 1
R = not given so considered 1
H = 8 x 60 = 480 – 60 –15 = 405 per shift
F = 1113.75/ 405 = 2.75 = 3 machines
40. Mandy Garments produces T-shirts for road races. They need to acquire some new stamping
machines to produce 30,000 good T-shirts per month. Their plant operates 200 hours per month, but
the new machines will be used for T-shirts only 60 percent of the time and the output usually includes
5 percent that are ―seconds‖ and unusable. The stamping operation takes 1 minute per T-shirt, and
the stamping machines are expected to have 90 percent efficiency when considering adjustments,
changeover of patterns, and unavoidable downtime. How many machines are required?
a. 5 b. 6
c. 7 d. 8
Answer: a. 5
86 | P a g e
Number of stamping machines = (30,000/ 0.95)(1 minute/ T-shirt)/ (200)(60)(0.60)(0.90)

= 31,578.95/ 6480 = 4.9 = 5 machines
41. During one-8-hour shift, 770 non-defective parts are desired from a fabrication operation. The
standard time for the operation is 12 minutes. Because the machine operators are unskilled, the
actual time it takes to perform the operation is 25 minutes and, on the average, one-sixth of the parts
that begin fabrication are scrapped. Assuming that each of the machines used for this operation will
not be available for 45 minutes each shift and there is a probability of 0.05 that each machine will
breakdown, determine the number of machines required.
a. 50 b. 52
c. 54 d. 56
Answer: d. 56
S = 12 mins.
E = 12/25 = 0.48
R = 1 – 0.05 = 0.95
H = 480 – 45 = 453 mins.
P = 1/6 = 0.167
Q= 770 = 924 Parts
1 – 0.167
Solution:
F = SQ = 12 x 924 = 55.90 = 56 machines

HER 435 x 0.48 x 0.95
42. Nestor Briefcases is an exclusive producer of handcrafted, stylish cases. Priding itself on its earlier
reputation, the company assembles each case with care and attention to detail. This laborious
process requires the completion of six primary work elements, which are listed here.
Work Element Precedence Time (min)

A Tan leather - 30
B Dye leather A 15
C Shape case B 10
D Mold hinges and fixtures - 5
E Install hinges and fixtures C, D 10
F Assemble case E 10
If the demand is 50 cases per 40-hour week, compute the cycle time for the process.
a. 30 b. 40
c. 46 d. 48
Answer: d. 48
87 | P a g e
30 15 10
A B C
D E F
5 10 10
total working hours (40 hours x 60 minutes/hour)

Cycle time= = = 48 minutes
desired units of output (50 cases)
43. Refer to problem no. 42, compute the lead time required for assembling one briefcase.
a. 30 b. 48
c. 80 d. 45
Answer: c. 80
Lead time= (30 + 15 + 10 + 5 + 10 + 10) = 80 minutes
a. 3 b. 2
c. 4 d. 1
Answer: b. 2
lead time (30 + 15 + 10 + 5 + 10 + 10)

N= = = 1.66 ≈ 2 workstations
cycle time 48
a.
35 45
AD BCEF
b.
45 35
AB CDEF
88 | P a g e
c.
30 30 20
A BCD EF
d.
30 25 25
A BC DEF
Answer: b
45 35
AB CDEF
Task Time Number of Followers

A 30 4
B 15 3
C 10 2
D 5 2
E 10 1
F 10 0
Station 1 Station 2
A (48 – 30 = 18) C (48 – 10 = 38)
B (18 – 15 = 3) D (38 – 5 = 33)
E (33 – 10 = 23)
F (23 – 10 = 13)
ST1 = 45 mins ST2 = 35 mins
46. Refer to problem no. 42, compute the line’s efficiency.
a. 89% b. 83%
c. 81% d. 93%
Answer: b. 83%
lead time (30 + 15 + 10 + 5 + 10 + 10)

Efficiency = = = 83.33%
no. of workstations x cycle time 2(48)
47. Refer to problem no. 42, suppose the demand for briefcases increases to 80 cases per week.
Calculate a new cycle time.
a. 30 b. 35
c. 50 d. 45
Answer: a. 30
89 | P a g e
total working hours (5 days x 8 hours/day x 60 minutes/hour)

Cycle time = = = 30 minutes
48. Refer to problem no. 47, balance the line based on the longest task time
a.
35 45
AD BCEF
b.
45 35
AB CDEF
c.
30 30 20
A BCD EF
d.
30 25 25
A BC DEF
Answer: c
30 30 20
A BCD EF
Task Time Rank

A 30 1
B 15 2
C 10 3
D 5 6
E 10 4
F 10 5
90 | P a g e
Station 1 Station 2 Station 3

A (30 – 30 = 0) B (30 – 15 = 15) E (30 – 10 = 20)
C (15 – 10 = 5) F (20 – 10 = 10)
D (5 – 5 = 0)
ST1 = 30 mins ST2 = 30 mins ST3 = 20 mins
49. Refer to problem no. 47, calculate the new efficiency of the manufacturing process.
a. 89% b. 83%
c. 81% d. 93%
Answer: a. 89%
lead time (30 + 15 + 10 + 5 + 10 + 10)

a. 3 b. 2
c. 4 d. 1
Answer: a. 3
lead time (30 + 15 + 10 + 5 + 10 + 10)

cycle time 30
51. Pepper & Mys Bakeshop has set a production quota of 600 party cakes per 40-hour workweek. Use
the following information to compute for the cycle time.
Work Predecessor Performance Time (min)

Element
A - 1
B A 2
C B 2
D A, E 4
E - 3
F C, D 4
a. 3 b. 16
c. 4 d. 13
Answer: c. 4
1 2 2
A B C
F 4
E D
3 4
91 | P a g e

Cycle time= = = 4 minutes
desired units of output (600 party cakes)
52. Refer to problem no. 51, compute the theoretical minimum number of workstations.
a. 5 b. 3
c. 2 d. 4
Answer: d. 4
lead time (1 + 2 + 2 + 4 + 3 + 4)
N= = = 4 workstations
cycle time 4
53. Refer to problem no. 51, balance the line using incremental utilization method
a.
3 3.25 3.25 3.25
AB CDEF CDEF CDEF
b.
2.5 2.5 5.5 5.5
ABC ABC DEF DEF
c.
3 3.25 3.25 3.25
3.25
d.
3.0 3.0 3.25 3.25 3.25
AB AB CEDF CEDF CEDF
Answer: c
3.25
3 3.25 3.25 3.25
92 | P a g e
Based on Incremental Utilization Method (IUM)
WS Task Task Time # of WS’s Incremental Utilization

1 A 1 1/ 4 = 0.25 = 1 25%
1 A, B 1+2=3 3/ 4 = 0.75 = 1 75%
1 A, B, C 3+2=5 5/ 4 = 1.25 = 2 62.5%
2 C 2 2/ 4 = 0.50 = 1 50%
2 C,E 2+3=5 5/ 4 = 1.25 = 2 62.5%
2 C, E, D 5+4=9 9/ 4 = 2.25 = 3 75%
2 C, E, D, F 9 + 4 = 13 13/ 4 = 3.25 = 4 81%
54. Refer to problem no. 51, calculate the efficiency of the assembly line.
a. 95% b. 90%
c. 80% d. 83%
Answer: c. 80%
lead time (1 + 2 + 2 + 4 + 3 + 4)
Efficiency = = = 80%
55. The Hanzel Pizza is revamping its order processing and pizza-making procedures. In order to deliver
fresh pizza fast, six elements must be completed.
Work Element Precedence Time

(min)
A Receive order - 2
B Shape dough A 1
C Prepare toppings A 2
D Assemble pizza B, C 3
E Bake pizza D 3
F Deliver pizza E 3
If the demand is 120 pizzas per night (5:00 p.m. to 1:00 a.m.), compute the cycle time for the process.
a. 4 b. 3
c. 14 d. 13
Answer: a. 4
2 1 3 3 3
A B D E F
C
2

desired units of output (120 pizzas)
93 | P a g e
56. Refer to problem no. 55, compute the lead time for the process.
a. 4 b. 3
c. 14 d. 13
Answer: c. 14
Lead time= (2 + 1 + 2 + 3 + 3 + 3) = 14 minutes
57. Refer to problem no. 55, Calculate the theoretical minimum number of workstations.
a. 2 b. 3
c. 4 d. 5
Answer: c. 4
lead time (2 + 1 + 2 + 3 + 3 + 3)
cycle time 4
58. Refer to problem no. 55, balance the line using the most number of followers method.
a.
3 5 3 3
AB CD E F
b.
3 2 3 3 3
AB C D E F
c.
4 1 3 3 3
AC B D E F
d.
4 4 3 3
AC BD E F
94 | P a g e
Answer: d
4 4 3 3
AC BD E F
Task Time Number of Followers

A 2 5
B 1 3
C 2 3
D 3 2
E 3 1
F 3 0
Station 1 Station 2 Station 3 Station 4

A (4 – 2 = 2) B (4 – 1 = 3) E (4 – 3 = 1) F (4 – 3 = 1)
C (2 – 2 = 0) D (3 – 3 = 0)
ST1 = 4 mins ST2 = 4 mins ST3 = 3 mins ST4 = 3 mins
59. Refer to problem no. 55, compute the efficiency of the line.
a. 88% b. 91%
c. 89% d. 93%
Answer: a. 88%
lead time (2 + 1 + 2 + 3 + 3 + 3)
60. Refer to problem no. 55, suppose demand increases to 160 pizzas per night. What is the new cycle
time?
a. 4 b. 3
c. 14 d. 13
Answer: b. 3
1
B
2 3 3 3
A D E F
C
2

desired units of output (160 pizzas)
95 | P a g e
61. Refer to problem no. 60, balance the line based on the longest task time method.
a.
3 5 3 3
AB CD E F
b.
3 2 3 3 3
AB C D E F
c.
4 1 3 3 3
AC B D E F
d.
4 4 3 3
AC BD E F
Answer: b
3 2 3 3 3
AB C D E F
Task Time Rank

A 2 4
B 1 6
C 2 5
D 3 1
E 3 2
F 3 3
Station 1 Station 2 Station 3 Station 4 Station 5

A (3 – 2 = 1) C (3 – 2 = 1) D (3 – 3 = 0) E (3 – 3 = 0) F (3 – 3 = 0)
B (1 – 1 = 0)
ST1 = 3 mins ST2 = 2 mins ST3 = 3 Mins ST4 = 3 mins ST5 = 3 mins
62. Refer to problem no. 60, calculate the new theoretical minimum number of workstations.
a. 2 b. 3
c. 4 d. 5
96 | P a g e
Answer: d. 5
lead time (2 + 1 + 2 + 3 + 3 + 3)
cycle time 3
63. Neren’s Eye Care, Inc., is a full-service optical supplier that sells eyeglasses, contact lenses,
protective eye apparel to opticians. Bogs’ job is to assemble custom-ordered lenses into eyeglasses
for customers. Sales have been good lately, and Bogs has been assembling 100 glasses a day. The
manager of Neren’s asked Bogs to write down the precedence requirements and approximate
assembly times for each step in the assembly process. The data are shown here.

(min)
A Inspect right and left lens for scratches and - 1.0
proper match
B Pop lens into frame A 1.0
C Position right side piece and attach to frame B 0.4
D Position left side piece and attach to frame B 0.4
E Package C, D 2.0
Assuming an 8-hour workday, how long does it take Bogs to assemble one pair of glasses?
a. 2 b. 2.4
c. 4 d. 4.8
Answer: d. 4.8
0.4
C
1 1
A B E
2
D
0.4

Cycle time = = = 4.8 minutes
desired units of output (100 eyeglasses)
Lead time = (1 + 1 + 0.4 + 0.4 + 2) = 4.8 minutes
64. Refer to problem no. 63, Neren’s anticipates a surge in demand with the opening of its own retail
outlets. If the assembly process is set up as an assembly line, what is the maximum number of
eyeglasses that can be assembled in one day, regardless of the number of workers hired?
a. 200 b. 240
c. 100 d. 480
Answer: b. 240
(4.8 minutes x 100 eyeglasses)

Maximum eyeglasses/day = = 240 eyeglasses
2 minutes
97 | P a g e
1 1.8 2
A BCD E
With maximum time in a workstation of 2 minutes it can produce 240 eyeglasses with 3 workers
65. Refer to problem no. 64, what is the efficiency of the line?
a. 80% b. 91%
c. 100% d. 95%
Answer: a. 80%
lead time (1 + 1 + 0.4 + 0.4 + 2)

Efficiency = = = 80%
66. Prof. Jone has assigned 15 cases in his Seminar class to be completed in a 15 week semester. The
students, of course, are moaning and groaning that the caseload cannot possibly be completed in the
time allotted. Prof. Jone sympathetically suggests that the students work in groups and learn to
organize their work efficiently. Knowing when a situation is hopeless, the students make a list of the
tasks that have to be completed in preparing a case. These tasks are listed here, along with
precedence requirements and estimated time in days. Assuming students will work 5 days a week on
this assignment, how many students should be assigned to each group?
Element Description Precedence Time (days)

A Read case - 1
b Gather data a 4
c Search literature a 3
d Load in data b 1
e Run computer analysis d 4
f Write/type case c, e 4
a. 3 b. 4
c. 5 d. 6
Answer: b. 4
4 1 4
B D E
1
C F
3 4
total working hours (15 weeks x 5 days)

Cycle time = = = 5 days
98 | P a g e
lead time (1 + 4 + 3 + 1 + 4 + 4)
N= = = 3.4 ≈ 4 workstations or students
cycle time 5
67. The precedence diagram and task times (in minutes) for assembling Reyson’s Stamp Pad are shown
here. Set up an assembly line to produce 125 stamp pads in a 40-hour week. What is the cycle time?
8 5
A B F 4 J 9
C D E H 7 K 3
6 10 2
G I
a. 10 5 b. 19.2
c. 61 d. 2
Answer: b. 19.2

desired units of output (125 stamp pads)
a.
19 19 11 12
ABC DFG EHI JK
b.
19 19 18 5
ACB DGF EHJ IK
c.
19 17 13 12
ABC DEG FHI JK
99 | P a g e
d.
19 16 14 12
ACB DFE GHI JK
Answer: b.
19 19 18 5
ACB DGF EHJ IK
Task Time Number of Followers Rank
A 8 7 1
B 5 6 3
C 6 6 2
D 10 5 4
E 2 4 7
F 4 4 6
G 5 4 5
H 7 3 8
I 2 1 10
J 9 1 9
K 3 0 11
Station 1 Station 2 Station 3 Station 4

A (19.2 – 8 = 11.2) D (19.2 – 10 = 9.2) E (19.2 – 2 = 17.2) I (19.2 – 2 = 17.2)
C (11.2 – 6 = 5.2) G (9.2 – 5 = 4.2) H (17.2 – 7 = 10.2) K (17.2 – 3 = 14.2)
B (5.2 – 5 = 0.2) F (4.2 – 4 = 0.2) J (10.2 – 9 = 1.2)
ST1 = 19.0 ST2 = 19.0 ST3 = 18 ST4 = 5
69. The work elements, precedence requirements, and time requirements to assemble a picture frame
are shown here. What is the cycle time capable of producing 1,600 frames per 40-hour week?

(min)
A Attach left frame side to top of frame - 0.35
B Attach right frame side to bottom of frame - 0.35
C Attach left and right frame subassemblies A, B 0.70
D Cut 8-inch x 10-inch glass - 0.50
E Cut 8-inch x 10-inch cardboard - 0.50
F Place glass into frame C, D 0.20
G Place cardboard into frame E, F 0.20
H Secure cardboard and glass F, G 0.50
I Apply descriptive label to glass D 0.10
a. 1.5 b. 0.70
c. 0.10 d. 3.4
Answer: a. 1.5
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.10
I
.35 .50
A D
.20
C F H .50
.70
B E
.35 .50
G
.20

desired units of output (1600 frames)
70. Refer to problem no. 69, balance the assembly line based on the computed cycle time using
incremental utilization method
a.
1.4 1.2 .80
ABC DEG FIH
b.
1.30 1.40 0.70
DABI CEF GH
c.
1.40 1.40 0.60
ABC DEFG HI
d.
1.45 1.45 0.50
DEAI BCFG H
Answer: c
101 | P a g e
1.40 1.40 0.60
ABC DEFG HI
Based on Incremental Utilization Method (IUM)
WS Task Task Time # of WS’s Incremental Util

1 A 0.35 0.35/ 1.50 = 0.23 = 1 23%
1 A, B 0.35 + 0.35 = 0.70 0.70/ 1.50 = 0.47 = 1 47%
1 A, B, C 0.70 + 0.70 = 1.40 1.40/ 1.50 = 0.93 = 1 93%
1 A, B, C, D 1.40 + 0.50 = 1.90 1.90/ 1.50 = 1.27 = 2 63%
2 D 0.50 0.50/ 1.50 = 0.33 = 1 33%
2 D, E 0.50 + 0.50 = 1.00 1.00/ 1.50 = 0.67 = 1 67%
2 D, E, F 1.00 + 0.20 = 1.20 1.20/ 1.50 = 0.80 = 1 80%
2 D, E, F, G 1.20 + 0.20 = 1.40 1.40/ 1.50 = 0.93 = 1 93%
2 D, E, F, G, H 1.40 + 0.50 = 1.90 1.90/ 1.50 = 1.27 = 2 63%
3 H 0.50 0.50/ 1.50 = 0.33 = 1 33%
3 H, I 0.50 + 0.10 = 0.60 0.60/ 1.50 = 0.40 = 1 40%
Effective CT = 1.40
a. 1,600 b. 1,715
c. 1,750 d. 1,656
Answer: b. 1,715
Maximum Output per Week = 2,400 mins per week = 1,715 units/ week
------------------------------
1.40
72. Refer to problem no. 69, balance the assembly line based on the computed cycle time using most
number of followers method.
a.
1.4 1.2 .80
ABC DEG FIH
b.
1.30 1.40 0.70
DABI CEF GH
102 | P a g e
c.
1.40 1.40 0.60
ABC DEFG HI
d.
1.45 1.45 0.50
DEAI BCFG H
Answer: b
Based on the Most Number of Task Followers:
Task Time No. of Task Followers Rank

A 0.35 4 2
B 0.35 4 3
D 0.70 4 1
C 0.50 3 4
E 0.50 2 5
F 0.20 2 6
G 0.20 1 7
H 0.50 0 8
I 0.10 0 9

D (1.50 – 0.50 = 1.00) C (1.50 – 0.70 = 0.80) G (1.5 – 0.20 = 1.30)
A (1.00 – 0.35 = 0.65) E (0.80 – 0.50 = 0.30) H (1.3 – 0.50 = 0.80)
B (0.65 – 0.35 = 0.30) F (0.30 – 0.20 = 0.10)
I (0.30 – 0.10 = 0.20)
ST = 1.5 – 0.20 = 1.30 ST = 1.5 – 0.10 = 1.40 ST = 1.5 – 0.80 = 0.70
Effective CT = 1.40
1.30 1.40 0.70
DABI CEF GH
a. 1,600 b. 1,715
c. 1,750 d. 1,656
Answer: b. 1,715
------------------------------
1.40
103 | P a g e
74. Refer to problem no. 69, balance the assembly line based on the computed cycle time using longest
task time method.
a.
1.4 1.2 .80
ABC DEG FIH
b.
1.30 1.40 0.70
DABI CEF GH
c.
1.40 1.40 0.60
ABC DEFG HI
d.
1.45 1.45 0.50
DEAI BCFG H
Answer: d
Based on the Longest Task Time
Task Task Time (min) Rank

A 0.35 5
B 0.35 6
C 0.70 1
D 0.50 2
E 0.50 3
F 0.20 7
G 0.20 8
H 0.50 4
I 0.10 9

D (1.50 – 0.50 = 1.00) B (1.50 – 0.35 = 1.15) H (1.5 – 0.50 = 1.00)
E (1.00 – 0.50 = 0.50) C (1.15 – 0.70 = 0.45)
A (0.50 – 0.35 = 0.15) F (0.45 – 0.20 = 0.25)
I (0.15 – 0.10 = 0.05) G (0.25 – 0.20 = 0.05)
ST = 1.5 – 0.05 = 1.45 ST = 1.5 – 0.05 = 1.45 ST = 1.5 – 1.00 = 0.50
Effective CT = 1.45
104 | P a g e
1.45 1.45 0.50
DEAI BCFG H
a. 1,600 b. 1,715
c. 1,750 d. 1,656
Answer: d. 1,656
------------------------------
1.45
76. Refer to problem no. 69, calculate the maximum number of frames that can be assembles each week.
a. 2,557 b. 2,452
c. 3,567 d. 3,429
Answer: d. 3,429
5 days 8 hours 60 minutes 1 frame
Number of frames(in a week) = x x x = 3428.57 ≈ 3429
week day hour 0.70min
77. Refer to problem no. 76, rebalance the line for maximum production. Assuming one worker per
workstation. How many workers would be required?
a. 5 b. 4
c. 6 d. 3
Answer: a. 5

desired units of output (3428 frames)
Lead time = (0.35 + 0.35 + 0.70 + 0.50 + 0.50 + 0.20 + 0.20 + 0.50 + 0.10) = 3.4 minutes
lead time 3.4

N= = = 4.86 ≈ 5 workers
cycle time 0.7
78. Refer to problem no. 76, assume the company can sell as many frames as can be produced. If
workers are paid P60.00 an hour. What is the total cost per frame?
a. 1.67 b. 1.47
c. 6.17 d. 7.14
Answer: d. 7.14
3428 frame 1 week 1 day 1 hour

Cost per worker = x x x = P1.42833 / worker
week 5 day 8 hour P60.00
105 | P a g e
Total cost = P1.42833 x 5 workers = P7.14 / frame
79. The Racela Finance Corporation has set a processing quota of 80 insurance claims per 8-hour day.
The claims process consists of five elements, which are detailed in the following table. Racela has
decided to use an assembly line arrangement to process the forms and would like to make sure they
have set up the line in the most efficient fashion. Calculate the cycle time required to meet the
processing quota.
Element Precedence Performance Time (min)

A - 4
B A 5
C B 2
D A 1
E C, D 3
a. 5 b. 6
c. 15 d. 16
Answer: b. 6
4 5 2
A B C
3
D
1

desired units of output (80 insurance claims)
80. Refer to problem no. 79, determine how many claims can actually be processed on your line.
a. 60/ day b. 70/ day

c. 80/ day d. 90/ day
Answer: c. 80/ day
8 hour 60 minutes _1 claim

No. of claims = x x = 80 / day
day hour 6 minute
106 | P a g e
81. A firm must produce 40 units/day during an 8-hour workday. Tasks, times, and predecessor activities
are given below.
Task Time (Minutes) Predecessor(s)

A 2 -
B 2 A
C 8 -
D 6 C
E 3 B
F 10 D, E
G 4 F
H 3 G
Total 38 minutes
Determine the cycle time to produce the 40 units per day.
a. 10 b. 38
c. 12 d. 20
Answer: c. 12
Cycle Time = 8 hrs x 60 mins/hr = 480 = 12 minutes

40 units 40
82. Thomas Santos, manager of a metropolitan branch office of the state department of motor vehicles,
attempted to perform an analysis of the driver’s license renewal operations. He identified the steps
and associated times required to perform each step as follows:
Job Average Time to perform (seconds)

A. Review renewal application for correctness 15
B. Process and record payment 30
C. Check file violations and restrictions 60
D. Conduct eye test 40
E. Photograph applicant 20
F. Issue temporary license 30
Santos found that each step was assigned to a different person. Santos also found that jobs A, B, C,
and D were handled by general clerks who were each paid P270.00 per hour. Job E was by a
photographer paid P360.00 per hour. Job F, the issuing of temporary licenses, was required by state
policy to be handled by a uniformed motor vehicle officer. Officers were paid P405.00 per hour, but
they could be assigned to any job except photography.
A review of the jobs indicated that job A, reviewing the application for correctness, had to be
performed before any other step could be taken. Similarly, job F, issuing the temporary license, could
not be performed until all the other steps were completed. The checking of file violations and
restrictions could be performed while the applicant is having his eye test. The branch offices were
charged P450.00 per hour for each camera to perform photography.
Determine the maximum number of applications per hour that can be handled by the present
configuration of the process?
a. 60 b. 90
c. 120 d. 180
Answer: a. 60
107 | P a g e
60
15 C
30 20 30
A B E F
40
CT = 60 seconds
Max. no. of application per hour = 3,600 = 60 applications per hour

60
83. Refer to problem no. 82, how many applications can be processed per hour if a second clerk is added
to check for violations?
a. 60 b. 90
c. 120 d. 180
Answer: b. 90
30
15 C
30 20 30
A B E F
40
CT = 40 seconds
Max. no. of applications per hour = 3,600 = 90 applications per hour
40
84. In addition to problem no. 83, assuming one more clerk is added to job D, what is the maximum
number of applications the process can handle?
a. 60 b. 90
c. 120 d. 180
Answer: c. 120
108 | P a g e
30
15 C
30 20 30
A B E F
20
CT = 30 seconds
Max. no. of applications per hour = 3,600 = 120 applications per hour
30
85. Refer to problem no. 82, what is the required cycle time of the process to accommodate 180
applications per hour?
a. 15 b. 20
c. 40 d. 60
Answer: b. 20
Max. no. of applications per hour = 180 application per hour
CT = 3,600 = 20 seconds
180
15
15 C
15 20 15
A B E F
20
86. Refer to problem no. 82, compute for the costs per application per hour involved in the current
process.
a. 30.60 b. 18.90
c. 23.40 d. 38.25
Answer: d. 38.25
109 | P a g e
Job No. of Worker & Labor Cost

Current
A 1 x 270 = 270.00
B 1 x 270 = 270.00
C 1 x 270 = 270.00
D 1 x 270 = 270.00
E 1 x 360 = 360.00
F 1 x 405 = 405.00
-------------
1845.00
camera +450.00
-------------
2295/ 60 applications
P38.25 per application
87. Refer to problem no. 84, for the costs per application per hour involved in the alternative process.
a. 30.60 b. 18.90
c. 23.62 d. 38.25
Answer: c. 23.62
Job No. of Worker & Labor Cost

Alternative
A 1 x 270 = 270.00
B 1 x 270 = 270.00
C 2 x 270 = 540.00
D 2 x 270 = 540.00
E 1 x 360 = 360.00
F 1 x 405 = 405.00
-------------
2385.00
camera +450.00
-------------
2835/ 120 applications
P23.62 per application
88. Given:
From/To A B C D E F
A 15 50 125
B 20 75
C 50 120 120
D
E 50 100
F 110 100
110 | P a g e
a.
A B C
D E F
b.
C B E
F A D
c.
B A F
E C D
d.
D B E
C F A
Answer: c.
35 235
B A F
125 220
100
E C D
220
Zero non-adjacent loads
111 | P a g e
Layout:
B A F
E C D
89. Given:

1 50 100 20
2 30 50 10
3 20 100
4 50
5
6
a.
1 2 6
4 3 5
b.
5 2 1
4 3 6
c.
2 6 5
3 4 1
112 | P a g e
d.
6 3 4
1 5 2
Answer: b.
10 50
5 2 1
50 100
50 30 20
4 3 6
20 100
Layout:
5 2 1
4 3 6
90. Given:

1. Administration 3 6 5 6 10
2. Social services 8 1 1
3. Institutions 3 9
4. Accounting 2
5. Education 1
6. Internal audit
a.
4 1 2
113 | P a g e
6 5 3
b.
3 6 4
2 5 1
c.
1 5 4
3 6 2
d.
6 3 2
5 1 4
Answer: d.
Diagram: 1
8 Non-adjacent loads
6 3 2 5-2 1
9 5-4 2
Total = 3
10 3
6 1
5 1 4
6 5
114 | P a g e
Layout:
6 3 2
5 1 4
91. Given:
Loads/day
From/To A B C D E
A 30 60 20
B 30 30
C 80
D 40
E
a.
C A
D E
b.
C B
D A
c.
B D
E A
115 | P a g e
d.
A E
C B
Answer: c.
Diagram:
30
C B D
30
80 40
80 60
E A
20
Layout:
B D
E A
92. Matthew Design Company has been asked to design the layout for a newly constructed office
building of one of its clients. The closeness matrix showing the daily trips between its six department
offices is given below.
Trips between Departments

Department
1 2 3 4 5 6
1 25 90 165
2 105
3 125 125
4 25
5 105
6
116 | P a g e
a.
3 1 5
6 4 2
b.
2 5 3
4 1 6
c.
5 1 4
3 6 2
d.
1 6 2
3 5 4
Answer: b.
Diagram: 105 125

2 5 3
25 90
25 105
125
4 1 6
165
117 | P a g e
Layout:
2 5 3
4 1 6
93. Given:
Flow between Departments (Number of Moves)
Departments 1 2 3 4 5 6 7 8
1. Shipping and receiving 175 150 80 20 75
2. Plastic molding stamping 90 100 125 120
3. Metal forming 350
4. Sewing department 25 25
5. Small toy assembly 180 187
6. Large toy assembly 374 103
7. Painting 7
8. Mechanism assembly
a.
5 1
2 6 4
3 7 8
118 | P a g e
b.
1 7
5 2 6
3 8 4
c.
4 5
6 1 3
2 8 7
d.
6 4
7 8 2
5 1 3
119 | P a g e
Answer: d.
25
6 4
Diagram:
25
125
374 100
103
7 120
7 8 2
187 175
2 350
180 75 90
5 1 3
80 150
Layout:
6 4
7 8 2
5 1 3
94. Given:
From/To Stores Turning Milling Press Plate Assembly Warehouse

Stores 6 12 9 1 4
Turning 3 4
Milling 7 2
Press 3 1 1
Plate 1 3 4 3
Assembly 1 7
Warehouse
120 | P a g e
a.
Press Warehouse
Warehouse Plate Milling
Stores Turning
b.
Turning Stores
Milling Press Warehouse
Plate Assembly
c.
Assembly Warehouse
Turning Plate Press
Assembly Stores
d.
Milling Assembly
Plate Warehouse Turning
Stores Press
121 | P a g e
Answer: c.
Diagram:
7
Assembly Warehous
e
1
2 4 1
8 3
Milling Plate Press
1 5 Non-adjacent load
3 1
9 5 Assembly-Stores 5
Total = 5
Turning Stores
6
Layout:
Assembly Warehouse
Milling Plate Press
Turning Stores
95. Based on the relationship chart below, what is it recommended layout?
122 | P a g e
a.
4 6
1 5
2 3
b.
6 4
1 5
3 2
c.
2 3 6
1 5
d.
6 3 2
5 1
Answer:
c.
2 3 6
1 5
2 3 6
1 5
4
123 | P a g e
96. Based on the relationship chart below, what is its recommended layout?
a.
5 3 1
2 4
6 7
b. 1 3
4 2
5 6 7
c.
3 1
6 2 4
7 5
d.
1 3
6 2 4
5 7
124 | P a g e
Answer: d.
1 3
6 2 4
5 7
1 3
6 2 4
5 7
97. Given:
Legend: CV Values Legend CV Values

A 10,000 E 1,000
I 100 O 10
U 0 X -1,000
Activity Area (sq. m)

1. W ood cutting 1,280
A
2. Receiving 560 E
I X
3. Framing 1,280 U U
E U
I
U U
4. Upholstery 1,120 X U
U I
E U U
5. Fabric storage 960 I I
A I U
E U
6. Fabric cutting 960 U
A U
7. Sewing 640 U U
U U
O
8. Shipping 800
E
9. Offices 800
O
10. General Storage 480
Distance between departments: Adjacent = 1, Partial Adjacent = 0.5, Non-Adjacent = 0
Using CORELAP, what is Total Closeness Rating (TCR) Value of Department 1?
a. 10,000 b. 11,000
c. 12,000 d. 14,000
Answer: c. 12,000
TCR – Department 1 = 10,000(1) + 1,000(1) + 100(0) + 10(0) + 0(6) + absolute - 1000 (1) = 12,000
125 | P a g e
98. In reference to problem no. 97, what activity is the first to be placed on the grid?
a. 7 b. 2
c. 5 d. 6
Answer: d. 6
TCR – Department 6 = 10,000(2) + 1,000(1) + 100(1) + 10(0) + 0(5) + absolute - 1000 (0) = 21,100
99. In reference to problem no. 98, what is your final layout?
a.
10 5 6
1 3 7
2 8 4 9
b.
10 1 7
3 5 6
4 8 9 2
c.
10 1 4
8 9 2
7 3 5 6
126 | P a g e
d.
10 5 6
8 4 7
2 1 3 9
Answer:
a.
10 5 6
8 4 7
1
2 3 9
DEPARTMENT 1 2 3 4 5 6 7 8 9 10 A E I O U X TCR ORDER

1 A E U X U U U U U 1 1 0 0 6 1 12,000 5
2 A I U E E X I U I 1 2 3 0 2 1 13,300 3
3 E I I U U U U U U 0 1 2 0 6 0 1,200 8
4 U U I E I I I U U 0 1 4 0 4 0 1,400 6
5 X E U E A E U U U 1 3 0 0 4 1 14,000 2
6 U E U I A A A U U U 2 1 1 0 5 0 21,100 1
7 U X U I E A U U O O 1 1 1 2 3 1 12,120 4
8 U I U I U U U O O E 0 1 2 1 5 0 1,210 7
9 U U U U U U O O O 0 0 0 3 6 0 300 10
10 U I U U U U O E O 0 1 1 2 5 0 1,120 9
127 | P a g e
5000 10000 5000 500 6000 10500 5000

10000 6 10000 wp5 1000 5 6 10000
5000 10000 5000 500 6000 10500 5000
5-6 = A = 10,000 5-5-7 = E = 1,000

6-7 = A = 10,000
500 1050 550 50 0 0 0 0

1000 5 6 150 50 5 6 0
500 1150 7 150 100 4 7 0
50 100 50 50 100 50 0
4-5 = E = 1,000
4-6 = I = 100 8-5 = U = 0
4-7 = I = 100 8-6 = U =0
8-4 = I = 100
8-7 = U = 0
0 0 0
500 1000 5 6 0 0 0 0 0
1000 8 4 7 10 0 10 5 6 0
500 1000 505 10 5 0 8 4 7 0
0 50 100 50 0
8-10 = E = 1,000
5-10 =U=0 3-10 = U =0 3-8 = U = 0
6-10 =U=0 3-5 = U = 0 3-4 =I =100
4-10 =U = 0 3-6 = U = 0 3-7 = U = 0
7-10 = O = 10
10 5 0 0 50 500 1500 1500 500

0 10 5 6 5 150 10 5 6 500
0 8 4 7 10 5,150 8 4 7 -500
0 1 3 10 5 10050 1 3 9 -500
0 0 0 0 5000 10050 5100 50 0
9-10 = O =10 2-10 = I =100

9-5 = U = 0 2-8 = I = 100
9-6 = U = 0 2-1 = A = 10,000
9-8 = O = 10 2-3 = I = 100
9-4 = U = 0 2-9 = U = 0
9-7 = O = 10 2-7 = X = -1000
9-1 = U = 0 2-6 = E = 1,000
9-3 = U = 0 2-5 = E = 1,000
FINAL
10 5 6
8 4 7
2 1 3 9
128 | P a g e
100. Given:
Parts-Machines Matrix
Parts
1 2 3 4 5 6 7 8
A x x x
B x x
C x x
D x x x x
E x
Machines F x x
G x x
H x x x
I x x
J x x
K x
L x x x
Using Digital Clustering Algorithm (DCA), prepare the final cell formation with additional machines, if
needed.
a. 5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
B X X
J X X
L X X X
G X X
K X
C X X
F X X
I X X
E X
b. 5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
B X X
J X X
L1 X X
G X X
K X
L2 X
C X X
F X X
I X X
E X
129 | P a g e
c. 5 6 1 4 7 3 2 8
D X X X X
A X X X
H X X X
B X X
J X X
C X X
F X X
I X X
E X X X
L X X
G X X
K X
d. 5 6 1 4 7 3 2 8
D X X X X
A X X X
H X X X
B X X
J X X
C X X
F X X
I X X
E1 X
E2 x x
L X X
G X X
K X
Answer:
b. 5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
B X X
J X X
L1 X X
G X X
K X
L2 X
C X X
F X X
I X X
E X
130 | P a g e
Solutions:
 Present machine layout and parts movement
PRESENT LAYOUT
PARTS MACHINES OUTPUT/ASSEMBLY
1 A
B
2
C
3 5
D
4 E
F
5
G
6 6
H
7 3
I
1
8 J
4
K
7
L
2
8
 Sum of Xs per column and row in order
5 2 3 6 8 7 1 4
D X X X X
A X X X
H X X X
L X X X
B X X
C X X
F X X
G X X
I X X
J X X
E X
K X
131 | P a g e
 Matrix with sorted columns
5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
L X X X
B X X
C X X
F X X
G X X
I X X
J X X
E X
K X
 Matrix with sorted rows
5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
B X X
J X X
L X X X
G X X
K X
C X X
F X X
I X X
E X
 Final cell formation with additional machines, if needed
5 6 1 4 2 8 7 3
D X X X X
A X X X
H X X X
B X X
J X X
L1 X X
G X X
K X
L2 X
C X X
F X X
I X X
E X
132 | P a g e
 Proposed cellular layout
PROPOSED LAYOUT
PARTS MACHINES OUTPUT/ASSEMBLY
5 D 5
6 A
1 H 6
B
4 1
J 4
2 L
G 2
8 K 8
7 L2
3 C
I 7
E 3
133 | P a g e
REFERENCES
[1] Clark, J. E., ―Facility Planning, Principles, Technology, Guidelines‖. Pearson Prentice Hall, 2008
[2] Francis, R.L., McGinnis, L.F., Jr., and White, J.A. ―Facility Layout and Location – An Analytical
Approach, Second Edition‖. Prentice Hall, Inc., 1992
[3] Garcia-Diaz, A., and Smith, J.M. ―Facilities Planning and Design‖. Pearson Prentice Hall, 2008
[4] James, R. W. and Alcorn, P.A. ―A Guide to Facilities Planning‖. Pearson Prentice Hall, 1991
[5] Russel, R.S. and Taylor, B.W., III ―Operations Management, Third Edition‖, Prentice Hall, Inc.,
2000
[6] Schonberger, R.J., and Knod, E.M., Jr., ―Operations Management – Customer-Focused
Principles, Sixth Edition‖. Times Mirror Education Group, 1997
[7] Tompkins J. A. et al., ―Facilities Planning, Latest Edition‖. J. Wiley, 2003
134 | P a g e

2014 - Solved Problems in Facility Planning

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SOLVED PROBLEMS IN

FACILITY PLANNING & DESIGN

FORMULAS IN FACILITY PLANNING & DESIGN

Factor Analysis Technique

di = (xi – x)2 + (yi – y)2

FACILITY DESIGN – SCHEDULE DESIGN

Pk = % of scrap produced in operation k

Yield with Reworking

Yield = (I) (%G) + (I) (1 – %G) (%R)

I = planned number of units of product started in the production process

F= _____Total Time Required to Perform the Operation_______

Product Layout – Line Balancing

Line Balancing Based on Incremental Utilization Method

Line Balancing Based on the Largest Number of Following Tasks

Line Balancing Based on the Longest Task Time

 Adds tasks to a workstation one at a time in the order of task precedence.

Process Layout – Block Diagramming

 Develop the load summary chart

Process Layout – Systematic Layout Planning

 Determine the total flow

Measuring Effectiveness of the Relationship Diagram

Min Z =   Lij x Dij

Process Layout - Manual CORELAP Algorithm

 Computerized Relationship Layout Planning (CORELAP) is a construction algorithm to create an

Procedure to Select Departments

Procedure to Place Departments

o The placement of a department is determined by evaluating all possible locations around

Cellular Layout – Direct Clustering Algorithm

 Form the Parts-Machines Matrix.

Facility Planning & Design Acronyms:

ALDEP - Automated Layout Design Program

PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE

NAME: _____________________________________ DATE: ____________________

1. _______ 21. _________ 41. _________ 61. _________ 81. _________

2. _______ 22. _________ 42. _________ 62. _________ 82. _________

3. _______ 23. _________ 43. _________ 63. _________ 83. _________

4. _______ 24. _________ 44. _________ 64. _________ 84. _________

5. _______ 25. _________ 45. _________ 65. _________ 85. _________

6. _______ 26. _________ 46. _________ 66. _________ 86. _________

7. _______ 27. _________ 47. _________ 67. _________ 87. _________

8. _______ 28. _________ 48. _________ 68. _________ 88. _________

9. _______ 29. _________ 49. _________ 69. _________ 89. _________

SCORE: __________ /100 X 100 = __________%

PASSING RATE: 75%

PROBLEMS IN FACILITY PLANNING & DESIGN - QUALITATIVE

a. Roughed-Out Layout Method b. Production-Center Method

a. Progressive Layout b. Open-Field Layout

3. Which of the following is a walking industrial vehicle?

a. Tractor Trailer b. Straddle Carrier

4. How many lavatories do you need if a business organization has 41 to 60 employees?

5. Drawing on the use of adjacency in the graph-based procedure, the _________________ is

a. Total Closeness Rating b. Weighted Placement Value

a. An effective production facility b. An efficient operations management

a. Planning Principle b. System Principle

8. Cellular layout is a type of layout which –

a. Groups machines into department according to their function.

9. What is the preferred area requirement of the President’s Office?

a. 80 – 110 sq. ft. b. 100 – 150 sq. ft.

a. Facility Planning b. Facility Location

11. Which of the following is not a characteristic of product layouts?

a. Standardized product b. Sequential arrangements of machines

a. ALDEP - Automated Layout Design Program

F= _Total Time Required to Perform the Operation___

NAME: _________________ DATE:

1. ___ 21. _ 41. _ 61. _ 81. _____

2. ___ 22. _ 42. _ 62. _ 82. _____

3. ___ 23. _ 43. _ 63. _ 83. _____

4. ___ 24. _ 44. _ 64. _ 84. _____

5. ___ 25. _ 45. _ 65. _ 85. _____

6. ___ 26. _ 46. _ 66. _ 86. _____

7. ___ 27. _ 47. _ 67. _ 87. _____

8. ___ 28. _ 48. _ 68. _ 88. _____

9. ___ 29. _ 49. _ 69. _ 89. _____

SCORE: /100 X 100 = %