University of Toronto

Department of Mechanical and Industrial Engineering

MIE468: Facility Planning
(Winter 2014)
Homework #2 Solutions
Problem 1
All Ik values are rounded up.
=

100,000

=
= 103,093
0.97
(1 )

100,000

=
= 113,041
(1 )(1 )(1 ) 0.97 0.96 0.95

100,000

=
= 107,389
(1 )(1 ) 0.97 0.96

200,000

=
= 206,186
0.97
(1 )

200,000

=
= 226,081
(1 )(1 )(1 ) 0.97 0.95 0.96

200,000

=
= 217,038
(1 )(1 ) 0.97 0.95

Setup times are identical for machines A, B and C for a particular product. The setup time for
product X on each machine is 20 mins; the setup time for product Y on each machine is 40 mins.
Assuming a single setup is needed to produce the annual requirement of a product on a machine,
the number of machines required is determined as follows:
=

. ,
. ,
+
+
+

(. )()(. ) (. )()(. ) ()()

. ,
. ,
+
+
+

(. )()(. ) (. )()(. ) ()()

. ,
. ,
+
+
+

(. )()(. ) (. )()(. ) ()()

= .

= .
= .

If setups occur more frequently, then additional machines might be required due to the lost
production cost by setups.

University of Toronto
Department of Mechanical and Industrial Engineering
MIE468: Facility Planning
(Winter 2014)
Problem 2
I=

750
O
=
= 937.5 938
(1 d) 0.80

()

=
=
= .

Alternatively, you could say that the loss of one hour per shift is reduction in the reliability:

()

=
=
= .
()

Problem 3
1

Part

1
2
3
4
5
6
7
8
9

2
1

1
1
1

Machine
3
4
1
1
1
1
1
1
1

5
1
1

1
1

1
1
1

Part

2. DCA
a. Tabulate Sums

Sum

1
2
3
4
5
6
7
8
9

2
1

1
1
1

1
4

Machine
3
4
1
1
1
1
1
1
1
4

1
4

5
1
1

1
1
4

1
1
1

1
4

sum
3
2
3
2
2
2
3
2
3

University of Toronto
Department of Mechanical and Industrial Engineering
MIE468: Facility Planning
(Winter 2014)

Part

b. Sort Sums

Sum

9
7
3
1
8
6
5
4
2

1
1

6
1
1

1
1

6
1

1
1

1
1

Machine
5
4
1
1
1
1
1

1
4

1
1
4

3
1
1
1

1
4

1
1
1

1
1
4

Part

c. Sort Columns
9
7
3
1
8
6
5
4
2

Machine
4
5
1
1
1
1
1

1
1

1
1
1

Part

d. Sort Rows
9
3
6
5
4
7
1
8
2

6
1
1
1
1

1
1
1
1
1

Machine
4
5
1
1
1
1

1
1
1
1

Group machines (6, 1, 4) and machines (5, 3, 2)

2. SCA
Iteration 1
Machine pair
{1,2}
{1,3}
{1,4}

SC
0
0
3/5

Combine?

1
1
1
1

1
1

sum
3
3
3
3
2
2
2
2
2

University of Toronto
Department of Mechanical and Industrial Engineering
MIE468: Facility Planning
(Winter 2014)
{1,5}
{1,6}
{2,3}
{2,4}
{2,5}
{2,6}
{3,4}
{3,5}
{3,6}
{4,5}
{4,6}
{5,6}

0
3/5
1/2
0
1/2
0
0
1
0
0
3/5
0

Iteration 2
Machine pair
{1,2}
{1,(3,5)}
{1,4}
{1,6}
{2,(3,5)}
{2,4}
{2,6}
{(3,5),4}
{(3,5),6}
{4,6}

SC
0
0
3/5
3/5
1/2
0
0
0
0
3/5

Iteration 3
Machine pair SC
{(1,4,6),2}
0
{(1,4,6),(3,5)} 0
{2,(3,5)}
1/2

Yes

=> Combine (3,5)

Combine?

Yes
Yes

Yes

=> Combine (1,4,6)

Combine?

Yes

=> Combine (2,3,5)

Group machines (1,4,6) and machines (2,3,5)

3

2
1.0
0.8

0.5
0.33

Problem 4

No standard solution.

Problem 5

Part-Machine Relationship

1
2
3
4
5

1
0
0
0
0

2
0
1
0
1
0

3
0
1
0
1
1

4
1
0
1
0
0

5
0
1
0
0
0

6
1
0
1
0
0

7
0
0
0
0
1

Calculating the matrix

1
2
3
4
5

1
0
6
1
5
5

2
6
0
5
1
3

3
1
5
0
4
4

4
5
1
4
0
2

5
5
3
4
2
0

1
2
3
4
5

1
0
6
1
5
5

2
6
0
5
1
3

3
1
5
0
4
4

4
5
1
4
0
2

5
5
3
4
2
0

1
0
0
0
0
0

2
0
0
0
0
0

3
1
0
1
0
0

4
0
1
0
1
1

5
0
0
0
0
0

dij

Distance Matrix
dij

Variables:

family, j
Part, i
1
2
3
4
5

number of families

2
Objective

4.000001

First part family (P1, P3) corresponds to machines 1,4 and 6

Second part family (P2, P4, P5) corresponds to machines 2,3,5,7

each part at most selected once

1
1
1
1
1