ENGR3500 – Plant Layout and Material Handling

Question 1: The estimated output of a machine is 75 units per hour based on an engineered standard at 100% productivity. The machine is expected to be in operation 80% of the time with maintenance downtime and tooling changeovers accounting for 20% of the time. Due to employee turnover and training, the productivity of the workforce is 90% against the engineered standards. For planning purposes, what will be the output of this machine each hour?

Question 2: Using the data from Question 1, The company requires an output of 860 units per hour in order to meet their estimated sales. Approximately how many machines will be required?

Question 3: What are the dimensions of Material Handling? Discuss with examples.

Question 4: What are the important categories of material handling equipment? Give examples.

Question 5: A manufacturing process is illustrated by the above diagram. One unit of B requires 2 units of A. One unit of D requires 1 unit of B and 3 units of C. The scrap rates at A, B, C, and D are 5%, 4%, 6%, and 3% respectively. The maximum production rates at A, B, C, and D, in units per hour, are 300, 200, 400, and 100 respectively. What is the capacity at process C in equivalent good units per hour?

Question 6: Discuss advantages and limitations of open office space layout versus the conventional office space layout.

Question 7: What is Cube Utilization? How does it help in optimizing plant layout?

Question 8: A charcoal grill manufacturing company makes 2,400 grills per day. The eight hour daily shift uses 50 min. of down time and operates at 80% performance rating. If the size of the grill carton is 30” x 30” x 24”, at what rate (feet per minute) should the packaging conveyor move to achieve the daily production targets?

Question 9: Create a schedule for a company working in two shifts with 48 people so that there are no more than 8 people at any one time in the locker rooms and lunch and dinner breaks.

Question 10: What are the six activity codes used in a Muther Grid? What do they stand for? Give examples.

Question 11: What is ergonomics? What are the four types of human factors? Why are they important? Give examples.

Question 12: What are auxiliary or support services? What are the advantages and limitations of a common receiving and shipping department?

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