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Data required for developing good layouts
• Product Analysis
Types of products and specifications
Detail of components
Production volume
• Process Analysis
Material flow (patern, diagram, data)
Types of layout
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Input Data and Activities • What data are critical to the facility plan?
• Categorizes the information as:
P – Product (what?)
Q – Quantity (how much?)
R – Routing (where?)
S – Support (with what?)
T – Timing (when?)
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Input Data and Activities
• Tompkins, White, et. al., categorize it as:
Product Design – what is to be produced?
Process Design – how is it to be produced?
Schedule Design – when and how much?
Product
Schedule Process
Facility
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Product Analysis
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Specification a.Dimension, Weight, Material &
Drawing
b.Quality of product
c.Specific requirement
Volume Production quantity & variation
Part’s
Breakdown
a.Flow process.
b.Assembly process.
c.Processing time.
d.Machine, jig, tool and other.
Product Design
• Based on – Function
– Aesthetics
– Costs
– Materials
– Manufacturing Methods
• Key point – The product design MUST be finalized before
designing the facility. Otherwise a flexible facility is needed.
Driven by market
demand
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Tools Used in Product Design
• Product/Part Drawings
2-D, 3-D visualization
• Exploded Assembly Diagrams
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Tools Used in Process Design
A partial list (dependent on product and service):
• Process Flowcharts and Process Maps
• Make vs. Buy
• Parts Lists
• Bill of Materials
• Route Sheets
• Assembly Charts
• Operations Process Charts
• Precedence Diagrams
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Process Flowcharts
Reserve Storage
Quality Assurance
Back to Vendor
UPS
Parcel Post
Next-Day UPS
Mono-gramming
Embroid-ering
Hemming
Gift Boxing
Receiving Active Bins
Picking Packing Shipping
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Process Maps
Place order
Drink
Eat salad or soup
Eat dinner
Receives check
Gives payment to waiter
Collect change, leave tip
Fill in tip amount
Give order to waiter
Prepare dinner order
Prepare soup or salad order
Give order to waiter
Is order complete?
Give soup or salad order to chef
Give dinner order to chef
Get drinks for customer
Deliver salad or soup order to customer
Deliver dinner to customer
Deliver check to customer
Receive payment for meal
Cash or Credit?
Bring change to customer
Run credit card through
Return credit slip to customer
Collect tip
Y
N
Credit
Cash
Customer Waiter Salad Chef Dinner Chef
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Make vs. Buy?
Can item be
purchased?
MAKE
Can we
make the
item?
BUY
Is it cheaper
for us to
make?
BUY
Is the capital
available?
MAKE
Yes
No
Yes Yes
No
No No
BUY
Yes
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Parts List
• A listing of component parts.
Company: TW Inc. Prepared By: JSU
Product: Air Flow Regulator Date: 6/30/2003
Part No. Name Drwg. No. Qty/unit Material Size Make/Buy
1050 Pipe plug 4006 1 Steel 0.5" x 1.00" Buy
2200 Body 1003 1 Aluminum 2.75" x 2.5" x 1.5" Make
3250 Seat Ring 1005 1 Stainless Steel 2.97" x 0.87" Make
3251 O-Ring - 1 Rubber 0.75" diam. Buy
3252 Plunger 1007 1 Brass 0.812" x 0.715" Make
3253 Spring - 1 Steel 1.4" x 0.225" Buy
3254 Plunger Housing 1009 1 Aluminum 1.6" x 0.225" Make
3255 O-Ring - 1 Rubber 0.925" diam. Buy
4150 Plunger Retainer 1011 1 Aluminum 0.42" x 1.2" Make
4250 Lock Nut 4007 1 Aluminum 0.21" x 1.00" Buy
PARTS LIST
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Bill of Materials • Many different types of “structured parts lists”
Company: TW Inc. Prepared By: JSU
Product: Air Flow Regulator Date: 6/30/2003
Level Part No. Name Drwg. No. Qty/unit Make/Buy
0 0021 Air Flow Regulator 0999 1 Make
1 1050 Pipe plug 4006 1 Buy
1 6023 Main assembly - 1 Make
2 4250 Lock Nut 4007 1 Buy
2 6022 Body Assembly - 1 Make
3 2200 Body 1003 1 Make
3 6021 Plunger Assembly - 1 Make
4 3250 Seat ring 1005 1 Make
4 3251 O-Ring - 1 Buy
4 3252 Plunger 1007 1 Make
4 3253 Spring - 1 Buy
4 3254 Plunger Housing 1009 1 Make
4 3255 O-ring - 1 Buy
4 4150 Plunger retainer 1011 1 Make
BILL OF MATERIALS
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Bill of Materials
12 Computer Device
11 Keyboard Assembly (Purchased)
10 Color Video Display Device
8 Video Panel (Purchased)
7 Circuit Board
9 Main CPU Unit
6 Power Supply Kit (Purchased)
5 PC Board Assembly
3 Main PC Board (Purchased)
4 Disk Drive Unit
2 Floppy Drive
1 Hard Drive
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Route Sheet
Oper.
No.
Operation
Description
Machine
Type
Tooling Setup
(hr.)
Oper.
Time
(hr.)
Mtls.
Parts
0104 Shape, drill,
cut off
Auto sc.
Machine
.5 in dia coller, cir.
Form tool, .45”
diam center drill
5 0.0057 Alum
1”x12’
0204 Machine Slot
and thread
Chucker 0.045” slot saw,
turret slot
2.25 0.0067
0304 Drill 8 holes Auto dr.
unit
0.078” diam twist
drill
1.25 0.0038
0404 Debur and
Blow out
Drill press Deburring tool with
pilot
0.5 0.0031
SA 1 Enclose
subassembly
Dennison
hydraulic
press
None 0.25 0.0100
Company: ARC Inc.
Produce: Air Flow Regulator
Part: Plunger Housing
Part No. 3254
Prepared by: JSU
Part No. 6/6/03
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Routing sheet MASTER ROUTING LIST MASTER ROUTING LIST
--PART NUMBER-- ---------DESCRIPTION---------- DATE ALT CODE BUYER/PLANNER --PART NUMBER-- ---------DESCRIPTION---------- DATE ALT CODE BUYER/PLANNER
DRAWING REVISIONDRAWING REVISION
H6709 HANDLE,DENSPLY PROBE 6/25/92 B 239 H6709 HANDLE,DENSPLY PROBE 6/25/92 B 239
G G
--------STANDARD-------- --------STANDARD--------
TIME MOVETIME MOVE
OPER WORK OPER SETUP CREW MACH --TOOLING REF-- --SETUP- -LABOR- -MACHINE-- I/O OPER WORK OPER SETUP CREW MACH --TOOLING REF-- --SETUP- -LABOR- -MACHINE-- I/O
BASIS TIME -----EFFECTIVE----BASIS TIME -----EFFECTIVE----
& ALT CENTER CODE CODE FACTOR GROUP NUMBER HOURS HOURS HOURS & ALT CENTER CODE CODE FACTOR GROUP NUMBER HOURS HOURS HOURS
CDE/-QTY- -DAYS- FROM TOCDE/-QTY- -DAYS- FROM TO
10 01226 1.0 01226 T9330 12.000 336.880 336.880 4 10 01226 1.0 01226 T9330 12.000 336.880 336.880 4
1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99
PARTIAL AHEAD QTYPARTIAL AHEAD QTY
----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------
MAKE @ AUTO 804843P MAKE @ AUTO 804843P
C 804843P B C 804843P B
A A02247 A A A02247 A
15 02053 1.0 02053 T9712 1.500 41.670 83.330 4 15 02053 1.0 02053 T9712 1.500 41.670 83.330 4
1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99
PARTIAL AHEAD QTYPARTIAL AHEAD QTY
----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------
DRILL & TAP 804843P1 DRILL & TAP 804843P1
B 804843P1 A B 804843P1 A
20 02053 1.0 02053 T9713 1.500 8.330 16.670 4 20 02053 1.0 02053 T9713 1.500 8.330 16.670 4
1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99
PARTIAL AHEAD QTYPARTIAL AHEAD QTY
----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------
KNURL OD KNURL OD
30 03029 1.0 .000 33.330 33.330 4 30 03029 1.0 .000 33.330 33.330 4
1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99
PARTIAL AHEAD QTYPARTIAL AHEAD QTY
----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------
SCOTCHBRITE/BELT SCOTCHBRITE/BELT
40 03105 1.0 03105 .000 3.000 3.000 4 40 03105 1.0 03105 .000 3.000 3.000 4
1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99
PARTIAL AHEAD QTYPARTIAL AHEAD QTY
----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------
PASSIVATE PASSIVATE
50 03005 1.0 .000 54.170 54.170 4 50 03005 1.0 .000 54.170 54.170 4
1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99
PARTIAL AHEAD QTYPARTIAL AHEAD QTY
----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------
BUFF BUFF
60 03007 1.0 03007 .000 50.000 50.000 4 60 03007 1.0 03007 .000 50.000 50.000 4
1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99
PARTIAL AHEAD QTYPARTIAL AHEAD QTY
----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------
GLASSBEAD KNURL/ SHIP GLASSBEAD KNURL/ SHIP
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Analog model of the assembly process.
• Circles denote components
• Links denote
operations/subassemblies
• Squares represent inspections
operation
• Begin with the original product and
to trace the product disassembly
back to its basic components.
Assembly Chart 2200
3254
3253
3252
3251
3250
3255
4150
4250
A-1
Pack
SA-1
A-2
A-3
I-1 1050
A-4
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Found by superimposing
the route sheets and the
assembly chart, a chart
results that gives an
overview of the flow within
the facility.
Operations Process Chart www.aeunike.lecture.ub.ac.id
Operator-Machine Charts • Tool for showing activity of
both operator and machine along a time line
• Also called “multiple activity chart”
Example: 1 minute to load
1 minute to unload
6 minute run cycle
0.5 minute to inspect and pack
0.5 minute to travel to another machine
Time Operator M1
0.5 U1 UNLOAD
1 U1 UNLOAD
1.5 L1 LOAD
2 L1 LOAD
2.5 I&P RUN
3 RUN
3.5 RUN
4 RUN
4.5 RUN
5 RUN
5.5 IDLE RUN
6 RUN
6.5 RUN
7 RUN
7.5 RUN
8 RUN
Cycle Time 8 min
Oper Idle 5.5 min
Mach. Idle 0 min
Prod. Rate 0.125 pc/min
ONE MACHINE
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Operator Machine Charts
Time Operator M1 M2 Time Operator M1 M2 M2
0.5 U1 UNLOAD RUN 0.5 U1 UNLOAD RUN RUN
1 U1 UNLOAD RUN 1 U1 UNLOAD RUN RUN
1.5 L1 LOAD RUN 1.5 L1 LOAD RUN RUN
2 L1 LOAD RUN 2 L1 LOAD RUN RUN
2.5 I&P RUN RUN 2.5 I&P 1 RUN IDLE RUN
3 T-2 RUN RUN 3 T-2 RUN IDLE RUN
3.5 U2 RUN UNLOAD 3.5 U2 RUN UNLOAD RUN
4 U2 RUN UNLOAD 4 U2 RUN UNLOAD RUN
4.5 L2 RUN LOAD 4.5 L2 RUN LOAD RUN
5 L2 RUN LOAD 5 L2 RUN LOAD RUN
5.5 I&P RUN RUN 5.5 I&P 2 RUN RUN IDLE
6 T-1 RUN RUN 6 T-3 RUN RUN IDLE
6.5 RUN RUN 6.5 U3 RUN RUN UNLOAD
7 RUN RUN 7 U3 RUN RUN UNLOAD
7.5 IDLE RUN RUN 7.5 L3 RUN RUN LOAD
8 RUN RUN 8 L3 RUN RUN LOAD
8.5 I&P 3 IDLE RUN RUN
Cycle Time 8 min 9 T-3 IDLE RUN RUN
Oper. Idle 2 min
Mach Idle 0 min Cycle Time 9 min
Prod Rate 0.25 pc/min Oper. Idle 0 min
Mach Idle 1 min
Prod Rate 0.333333 pc/min
TWO MACHINES THREE MACHINES
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Manufacturing Process: Simple Description
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Inventory
Suppliers$ $$
Material
Manufacturing Manufacturing
Manufacturing Inventory
Quality Assurance
Distribution
CACAT
RECYCLE
RECYCLE
CACAT
CACAT
RECYCLECACAT
WIP Stotage WIP Stotage WIP Stotage
Data requirement for layout decisions
• Frequency of flow of material / some other measure of interaction between departments
• Shape and size of departments
• Floor space available
• Location restrictions for departments, if any
• Adjacency requirements between pairs of departments, if any
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Five types of layout
• Product layout
• Process layout
• Fixed-position layout
• Group-technology layout
• Hybrid layout
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Types of Departments/Layouts Volume
High
Medium
Low
Low Medium High Variety
Product
Department
Fixed Materials
Location
Department
Process
Department
Product
Family
Department
Product
Layout
Fixed Location
Layout
Group Technology
Layout
Process
Layout
Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id
Product Layouts
L
L
L L
L M
M
M
D D
D
D G
G
G
G A
A
Product C Department
Product A Department
P
P
P
Product B Department
A
Sh
ipp
ing
De
pa
rtme
nt
Re
ceiv
ing
De
pa
rtme
nt
Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id
The Process Layout
L
L
L
L
L
L
L
L
L
L M
M
M
M
D
D
D
D
D
D
D
D
G
G
G
G
G
G
A A A Receiving and Shipping Assembly
Painting Department
Lathe Department Milling
Department Drilling Department
Grinding Department
P
P
Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id
Flow of Materials in Process Layouts
L
L
L
L
L
L
L
L
L
L M
M
M
M
D
D
D
D
D
D
D
D
G
G
G
G
G
G
A A A Receiving and Shipping Assembly
Painting Department
Lathe Department Milling
Department Drilling Department
Grinding Department
P
P
Source: Russell & Taylor, 2007 www.aeunike.lecture.ub.ac.id
Product Family (Cellular) Layout
L
L
L
L
L
L
L
L
L M
M
M
M
D D
D D
D
D
D
G
G
G G
G
G
A A
Receiving and Shipping
Special Department
Rotational Parts Cell
P
P
Rectangular Parts Cell
Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id
A Manufacturing Cell
Key: S = Saw L = Lathe HM = Horizontal milling machine VM = Vertical milling machine G = Grinder
Paths of three workers moving within cell Material movement
In Out Worker 1
Worker 2
Worker 3
Dir
ect
ion
of
pa
rt m
ov
em
en
t w
ith
in c
ell
S
L
HM
VM
G
VM
L
Final inspection
Finished part
Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id
Project (Fixed-Position) Layout
L
L
L
L
M
D D D
G
G G
G
A
A
Receiving and Shipping
P
Sto
rag
e
Sto
rag
e
Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id
Hybrid Layouts
• Combination of the layouts discussed. • A combination of group layout in manufacturing cells,
product layout in assembly area, and process layout in the general machining and finishing section is used.
TM
TM TM
TM TM DM
BM
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General Characteristics
Characteristic Product Process Product
Family Project
Throughput Time Low High Low Medium
Work in process Low High Low Medium
Skill Level Choice High Med-High Mixed
Product Flexibility Low High Med-High High
Demand Flexibility Medium High Medium Medium
Mach Utilization High Med-Low Medium-High Medium
Worker Utilization High High High Medium
Reliability Can be
low
High High Medium
Unit production
cost
Low High Low High
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Exercise – What Type of Layout?
• Ford Louisville Assembly Plant ___________
• Suburban Hospital ___________
• Louisville International Airport ___________
• KFC Restaurant ___________
• Boeing Aircraft ___________
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Flexible Manufacturing Systems Automated machining operations, tool changers
Automated material handling, computer control
Designed around size of parts processed & average processing time for parts
Can process wide variety of items quickly
Very few large systems exist
• Progressive layout – all parts same route
• Closed loop – larger variety, alternative routes
• Ladder layout – two machines work on same part
• Open field layout – most complex
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Flow process chart
FLOW PROCESS CHART
Subject Charted TB03100 Face Panel Chart No. 112XAG
Drawing No. Part No. Chart of Method Present
Chart Begins Receiving Charted By N.L.
Chart Ends Steel Dept. Date Feb. 5/90 Sheet 1 of 1
Dist.
(ft)
Time Chart
Symbol
Oper
ID
Dept
ID
M/C
ID
# of
pieces
How
moved
Process Description
.02 1 A1 S&R 100 Truck Received material 0.022 wcs (51" x 102")
220 .02 1 H2 MF1 100 Forklift To crane bay area
2 WIP1 100 Stored temporarily
20 .02 2 H2 MF1 100 Conveyor To hydra shear
.01 1 M1 MF1 HS1 100 Cut to length (front panel)
50 .02 3 H3 MF2 13G
142
95 Forklift To machine #13G (100 ton press) or Komatsu
(machine 142) or to HYMAC 101 (7" & over neck)
.01 2 M2 MF2 101 95 Necking operation (punch hole)
160 .03 4 H3 MF2 95 Forklift To machine # 136
.03 3 M2 MF2 136 95 Punch holes
240 .01 5 H1 MF3 95 Forklift To machine #155 or machine #104 or machine #111
.05 4 M2 MF3 155 95 Braking operation
260 .01 6 H1 WIP2 94 AGV To marshalling area
3 S&R 94 Temporary storage
150 .01 7 H3 WIP3 94 AGV To steel dept.
Summary
Event Total Time Distance
Operations 4
Inspections — — —
Transportations 8 (min.) 1100 ft.
Storages 3
Delays
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Flow diagram
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MESIN FRAIS MESIN BUBUT
MESIN BORMESIN BOR
MEJA
PE
NE
RIM
AA
NP
EN
YIM
PA
NA
N
AL
AT
ME
JA
PE
RA
KIT
AN
Peluncur
Bahan
Peluncur
Bahan
PEMANGGANG
PA
INT
ING
PE
NG
EM
AS
AN
Peluncur
Bahan
Peluncur
Bahan
Peluncur
Bahan
Peluncur
Bahan
Peluncur
Bahan
Peluncur
Bahan
Peluncur
Bahan
1
1
2
2
1
3
MEJA
3
3
2
5
4
6
3
65
7
6
8
4
9
5
11
7
12
8
13
6
14
9
15
7
10
16 1
7
11
18
8
18
12
20
13
PE
NG
IRIM
AN
FINISHINGASSEMBLING
GU
DA
NG
DIAGRAM ALIR (FLOW DIAGRAM)
Qualitative flow data
• Relationship chart – A absolutely necessary – E especially important – I important – O ordinary – U unimportant – X undesirable
• Percentages of A, E, I, O, U and X ratings – A 2-5% – E 3-10% – I 5-15% – O 10-25% – U 25-60% – X depends
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Qualitative flow data
• Color coding relationships
– A Red
– E Orange or Yellow
– I Green
– O Blue
– U Uncolored
– X Brown
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Sample relationship chart
1. Form
2. Trim
3. Treat
4. Assembly
5. Pack and Ship
A/1
E/2
X/3
O/2
U
I/2
U
E/2
U
U
Code Reason
1 Bulky material
2 Ease of supervision
3 Safety
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Quantitative flow data
• From-to frequency of trips matrix
Dept1
Dept2
Dept3
Dept4
Dept5
Det 6
Dept 1 - 12 3 3
Dept 2 21 -
Dept 3 4 5 - 8 8 8
Dept 4 - 4 4
Dept 5 1 2 2 15 - 19
Dept 6 4 9 7 19 -
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Quantitative flow data
• Frequency of trips between departments matrix
Dept1
Dept2
Dept3
Dept4
Dept5
Dept6
Dept 1 - 33 7 3 1 4
Dept 2 33 - 5 2 9
Dept 3 7 5 - 8 10 8
Dept 4 3 8 - 19 11
Dept 5 1 2 10 19 - 38
Dept 6 4 9 8 11 38 -
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Distance Measures
• Euclidean
• Squared Euclidean
• Rectilinear
• Tchebychev
• Aisle distance
• Adjacency
• Shortest Path
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Euclidean, Squared Euclidean, Rectilinear and Tchebychev
Facility i
Facility j
(xj,yj)
(xi,yi)
|yi-yj|
|xi-xj|
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Aisle Distance, Adjacency and Shortest Path
Facility i
Facility j
d
a
Facility k
b
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HW for Gravity Method
• Two high-speed copiers are to be located in the fifth floor of an office complex that houses four departments of the Social Security Administration. Coordinates of the centroid of each department as well as the average number of trips made per day between each department and the copiers’ yet-to-be-determined location are known and given in Table below. Assume that travel originates and ends at the centroid of each department. Determine the optimal location-the x and y coordinates-for the copiers.
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Dept. No. x Coordinate y Coordinate Average No. of Daily Trips to Copiers
1 10 2 6
2 10 10 10
3 8 6 8
4 12 5 4