Copyright ©2014 Pearson Education, Inc.
B, C
B, C
B, C
D, E, F G
E, G
E, G
I
CHAPTER 9 LAY O U T ST R A T E G I E S 133
134 CHAPTER 9 LA Y O U T ST R A T E G I E S
CHAPTER 9 LAY O U T ST R A T E G I E S 135
136 CHAPTER 9 LA Y O U T ST R A T E G I E S
138 CHAPTER 9 LA Y O U T ST R A T E G I E S
Cottrell Bicycle Co.
Shortest Operation Time
Cycle Time = 147.6 Seconds
Station
Task
Time
Time Left
Ready Tasks
1
J3
3
144.60
K3, F7
F7
21
123.60
K3, C1
K3
60
63.60
C1, K4, K9, J1, J2
J2
22
41.60
C1, K4, K9, J1, F3,
F4
K4
24
17.60
C1, K9, J1, F3, F4
2
K9
27
120.60
C1, J1, F3, F4, G4
F3
32
88.60
C1, J1, F4, G4, E3
J1
66
22.60
C1, F4, G4, E3, G5
3
G5
29
118.60
C1, F4, G4, E3, E2
E2
18
100.60
C1, F4, G4, E3
C1
78
22.60
F4, G4, E3, B5
4
G4
79
68.60
F4, E3, B5, F9
5
F4
92
55.60
E3, B5, F9, D6
D6
53
2.60
E3, B5, F9, D9
6
D9
37
110.60
E3, B5, F9
B5
108
2.60
E3, F9, A1, A2
7
A1
52
95.60
E3, F9, A2
A2
72
23.60
E3, F9
8
E3
109
38.60
F9, D8
9
D8
78
69.60
F9
10
F9
126
21.60
D7
11
D7
72
75.60
B3
B3
72
3.60
B7
12
B7
18
129.60
A3
A3
114
15.60
Time allocated (cyc sta) = 1771.20; Min (theoretical) # of stations = 10
Time needed (sum task) = 1462.00; Efficiency = 82.54%;
Idle time (alloc-needed) = 309.20 seconds per cycle
Entrance 1
Exam II 3
Lab, EKG 5
O.R. 6
Exam I 2
X-ray 4
Casts 8
R.R. 7
Entrance 1
Exam II 3
Lab, EKG 5
O.R. 6
Exam I 2
X-ray 4
Casts 8
R.R. 7
Lab, EKG 5
O.R. 6
R.R. 7
Casts 8
Improved layout:
Entrance 1
Exam I 2
Lab, EKG 5
O.R. 6
Exam II 3
X-ray 4
R.R. 7
Casts 8
Patient movement = 4,800 feet
Improved layout:
Entrance 1
Exam I 2
Lab, EKG 5
O.R. 6
Exam II 3
X-ray 4
Casts 8
R.R. 7
Patient movement = 4,700 feet
More improved layout (with Exam rooms swapped):
Patient movement = 6,700 feet
CHAPTER 9 LAY O U T ST R A T E G I E S 139
C
4
A, B
D
1
E
2
F
4
1
A, D
2
B, G
3
C, F
D
1
E
2
F
4
1
A, D
2
B, G
3
C, F
400minutes
140 CHAPTER 9 LA Y O U T ST R A T E G I E S
==
25,200 seconds
Cycle time 18 seconds / unit
1,400 units
=
==
Minimum number of stations cycle time
97 5.4, or 6 workstations
18
ti
97 seconds
Efficiency 0.951
6 stations 17 seconds
==
1
240
2
120*
5
180
1
240
2
120*
5
180
3. Assuming the addition of a second clerk (anywhere you
choose), what is the maximum number of applications the process
can handle?
35 seconds. So without adding any personnel, as was done above,
it is possible to process up to 90 renewals per hour.
Creative rearranging and combining of tasks can produce
4. How would you suggest modifying the process in order to
accommodate 120 applications per hour?
This question requires trial-and-error creation of proposed
Solution C
Job
Time
(sec)
Station
Process
Time (sec)
Maximum
Output
(per hr)
Cost/Hour
1 + 2 + 3 + 4
145
5
29
124.1
$60.00
5
20
1
20
180
16.00 + 10.00
6
30
1
30
120*
18.00
Cost per renewal = $104.00 120 = $0.867 $104.00
* Indicates a bottleneck step.
Copyright ©2014 Pearson Education, Inc.
9 minutes.)
1. A hospital considers many variables in layout design. These
include:
a) Nursing efficiency: How far does a nurse have to travel, in walk-
ing time and distance, to patients, suppliers, break rooms, etc.?
b) Security: How to protect patients, especially babies, from
2. The traditional “racetrack,” or linear hallway, layout is less in
favor today than layouts that consider the efficiency of a limited and
expensive resource, such as nurses. The circular pod design makes it
much easier for nurses to see and reach each room. This not only
3. Using Figure 9.21’s linear layout, if Nurse Smith makes
6 round trips to each of the 12 patient rooms, 20 to medical supply,
5 to break room, and 12 to linen supply, his total distance traveled is:
Total distance = 6 trips × 2 (for round trip) × (20 + 30 + 40 + 50 +
60 + 70 + 20 + 30 + 40 + 50 + 60 + 70)
+ 20 trips medical supply 2 50
Solution D
Job
Time
(sec)
Station
Process
Time (sec)
Maximum
Output
(per hr)
Cost/Hour
1 + 4
55
2
27.5
130
24.00
2
30
1
30
120*
12.00
3
60
2
30
120*
24.00
5
20
1
20
180
16.00 + 10.00
6
0
1
30
120*
18.00
Cost per renewal = $104.00 120 = $0.867 $104.00
* Indicates a bottleneck step.
142 CHAPTER 9 LA Y O U T ST R A T E G I E S
+ 5 trips break room 2 40
+ 12 trips linen room 2 30
ADDITIONAL CASE STUDY*
MICROFIX INC.
134 CHAPTER 9 LA Y O U T ST R A T E G I E S
CHAPTER 9 LAY O U T ST R A T E G I E S 135
136 CHAPTER 9 LA Y O U T ST R A T E G I E S
138 CHAPTER 9 LA Y O U T ST R A T E G I E S
Cottrell Bicycle Co.
Shortest Operation Time
Cycle Time = 147.6 Seconds
Station
Task
Time
Time Left
Ready Tasks
1
J3
3
144.60
K3, F7
F7
21
123.60
K3, C1
K3
60
63.60
C1, K4, K9, J1, J2
J2
22
41.60
C1, K4, K9, J1, F3,
F4
K4
24
17.60
C1, K9, J1, F3, F4
2
K9
27
120.60
C1, J1, F3, F4, G4
F3
32
88.60
C1, J1, F4, G4, E3
J1
66
22.60
C1, F4, G4, E3, G5
3
G5
29
118.60
C1, F4, G4, E3, E2
E2
18
100.60
C1, F4, G4, E3
C1
78
22.60
F4, G4, E3, B5
4
G4
79
68.60
F4, E3, B5, F9
5
F4
92
55.60
E3, B5, F9, D6
D6
53
2.60
E3, B5, F9, D9
6
D9
37
110.60
E3, B5, F9
B5
108
2.60
E3, F9, A1, A2
7
A1
52
95.60
E3, F9, A2
A2
72
23.60
E3, F9
8
E3
109
38.60
F9, D8
9
D8
78
69.60
F9
10
F9
126
21.60
D7
11
D7
72
75.60
B3
B3
72
3.60
B7
12
B7
18
129.60
A3
A3
114
15.60
Time allocated (cyc sta) = 1771.20; Min (theoretical) # of stations = 10
Time needed (sum task) = 1462.00; Efficiency = 82.54%;
Idle time (alloc-needed) = 309.20 seconds per cycle
Lab, EKG 5
O.R. 6
R.R. 7
Casts 8
Improved layout:
Entrance 1
Exam I 2
Lab, EKG 5
O.R. 6
Exam II 3
X-ray 4
R.R. 7
Casts 8
Patient movement = 4,800 feet
Improved layout:
Entrance 1
Exam I 2
Lab, EKG 5
O.R. 6
Exam II 3
X-ray 4
Casts 8
R.R. 7
Patient movement = 4,700 feet
More improved layout (with Exam rooms swapped):
Patient movement = 6,700 feet
CHAPTER 9 LAY O U T ST R A T E G I E S 139
C
4
A, B
400minutes
140 CHAPTER 9 LA Y O U T ST R A T E G I E S
==
25,200 seconds
Cycle time 18 seconds / unit
1,400 units
=
==
Minimum number of stations cycle time
97 5.4, or 6 workstations
18
ti
97 seconds
Efficiency 0.951
6 stations 17 seconds
==
3. Assuming the addition of a second clerk (anywhere you
choose), what is the maximum number of applications the process
can handle?
35 seconds. So without adding any personnel, as was done above,
it is possible to process up to 90 renewals per hour.
Creative rearranging and combining of tasks can produce
4. How would you suggest modifying the process in order to
accommodate 120 applications per hour?
This question requires trial-and-error creation of proposed
Solution C
Job
Time
(sec)
Station
Process
Time (sec)
Maximum
Output
(per hr)
Cost/Hour
1 + 2 + 3 + 4
145
5
29
124.1
$60.00
5
20
1
20
180
16.00 + 10.00
6
30
1
30
120*
18.00
Cost per renewal = $104.00 120 = $0.867 $104.00
* Indicates a bottleneck step.
Copyright ©2014 Pearson Education, Inc.
9 minutes.)
1. A hospital considers many variables in layout design. These
include:
a) Nursing efficiency: How far does a nurse have to travel, in walk-
ing time and distance, to patients, suppliers, break rooms, etc.?
b) Security: How to protect patients, especially babies, from
2. The traditional “racetrack,” or linear hallway, layout is less in
favor today than layouts that consider the efficiency of a limited and
expensive resource, such as nurses. The circular pod design makes it
much easier for nurses to see and reach each room. This not only
3. Using Figure 9.21’s linear layout, if Nurse Smith makes
6 round trips to each of the 12 patient rooms, 20 to medical supply,
5 to break room, and 12 to linen supply, his total distance traveled is:
Total distance = 6 trips × 2 (for round trip) × (20 + 30 + 40 + 50 +
60 + 70 + 20 + 30 + 40 + 50 + 60 + 70)
+ 20 trips medical supply 2 50
Solution D
Job
Time
(sec)
Station
Process
Time (sec)
Maximum
Output
(per hr)
Cost/Hour
1 + 4
55
2
27.5
130
24.00
2
30
1
30
120*
12.00
3
60
2
30
120*
24.00
5
20
1
20
180
16.00 + 10.00
6
0
1
30
120*
18.00
Cost per renewal = $104.00 120 = $0.867 $104.00
* Indicates a bottleneck step.
142 CHAPTER 9 LA Y O U T ST R A T E G I E S
+ 5 trips break room 2 40
+ 12 trips linen room 2 30
ADDITIONAL CASE STUDY*
MICROFIX INC.