Problem
Questions
1. Thermostats are subjected to rigorous testing before they are
shipped to air conditioning technicians around the world. Results from the last
five samples are shown in the table. Draw and R Chart and an xbar chart. Based on the charts, is the process under
control? (20 Points)

Observations 

Sample 
1 
2 
3 
4 
5 
1 
73.5 
70.8 
72.2 
73.6 
71.0 
2 
71.3 
71.0 
73.1 
72.7 
72.2 
3 
70.0 
72.6 
71.9 
72.4 
73.3 
4 
71.1 
70.6 
70.3 
74.2 
73.6 
5 
70.8 
70.7 
70.7 
73.5 
71.1 
Answer 1:
2. A professor records the number of students who complain
each week throughout the semester. If the class size is forty students, what
are 3sigma control limits for this class? Construct a control pchart and
interpret the data. Is the process in
control? (20 points)
Week number 
Complaints 
1 
5 
2 
2 
3 
7 
4 
1 
5 
3 
6 
2 
7 
8 
8 
1 
9 
3 
10 
5 
11 
4 
12 
6 
13 
3 
14 
1 
15 
4 
Answer 2:
3. A department store chain is designing a layout for a new store. The
store manager wants to provide as much convenience as possible for her
customers. Based on historical data, the number of trips between departments
per hour is given in the following closeness matrix. A block plan showing a
preliminary layout is also shown.
Closeness Factors (Trips per hour)
1/O 2/S 3/H 4/T 5/A 6/E
1. Office Supplies (O) — 40 100 50 20 10
2. Sporting Goods (S) — 100 80 60 80
3. Hardware (H) — 70 100 50
4. Toys (T) — 70 90
5. Automotive (A) — 60
6. Electronics (E) —


3. HARDWARE 

4. TOYS 
5. 
6.ELECTRONICS 
Customer
travel between departments is restricted to the aisles shown in the block plan
as dotted lines.
CALCULATIONS
TABLE:
Dept. Pair 
Closeness Factor (w) 
Original Distance (d_{O}) 
w´ 
Revision #1 Distance (d_{1}) 
w´ 
1 – 2 

1 – 3 

1 – 4 

1 – 5 

1 – 6 

2 – 3 

2 – 4 

2 – 5 

2 – 6 

3 – 4 

3 – 5 

3 – 6 

4 – 5 

4 – 6 

5 – 6 

TOTAL 

Complete the calculations and fill in the table
above. Based on the table above answer
the following questions.
a) What is the total expected weighteddistance
score between Office Supplies and Hardware? (4 points)
b) What is the total weighteddistance score
between Hardware and Toys? (4 points)
c) What is the total weighteddistance score for
the entire store? (4 points)
d) A suggestion has been made to switch Hardware
and Automotive. What would the total weighteddistance score for the entire
store if these two departments were switched? (4 points)
e) Based on your calculations, would you
recommend that Hardware and Automotive be switched? (4 points)
Answer 3:
4. Balance the assembly line for the tasks contained in the table. The
desired output is 240 units per day. Available production time per day is 480
minutes.
Work Element 
Time (Sec.) 
Immediate Predecessor(s) 
A 
40 
— 
B 
45 
— 
C 
55 
A 
D 
55 
B 
E 
65 
B 
F 
40 
C,D 
G 
25 
D,E 
a)
What is the desired Cycle time in seconds? (4 points)
b) What is the theoretical minimum
number of stations? (4 points)
c)
Use trial and error to work out a solution in the table below. Your efficiency should be at least 90%. (10
Points)
Station 
Candidates 
Choice 
WorkElement Time (Sec) 
Cumulative Time (Sec) 
Idle Time 
d)
Calculate the efficiency of your solution. (2 points)
Answer 4:
5. A manufacturer’s research
and development center must expand by building a new facility. The search has
been narrowed to five locations, all of which are acceptable to management. The
assessment of these sites is being made on the basis of the five subjective
location factors that follow. Management has agreed to use a fivepoint scale
(Excellent = 5, and Poor = 1) to quantify and compare their subjective opinions
about the relative goodness of the sites. The weight reflects the importance of
each factor in the decision.
Locations 

Factor 
Weight 
A 
B 
C 
D 
E 
Labor climate 
0.30 
4 
2 
1 
4 
2 
Proximity to markets 
0.30 
5 
3 
3 
4 
4 
Quality of life 
0.15 
1 
3 
2 
1 
5 
Proximity to suppliers 
0.15 
2 
5 
3 
4 
3 
Taxes 
0.10 
4 
4 
4 
1 
3 
Calculate the weighted score for each alternative. Which location
would you recommend?(15 points)
Answer 5:
6. Complete the following MPS Record (15 points)
Lot Size 
130 

Lead Time 
1 

Quantity on Hand 
45 
1 
2 
3 
4 
5 
6 
7 
8 
9 
10 
Forecast 
25 
25 
25 
25 
50 
50 
50 
50 
40 
20 

Customer Orders (booked) 
30 
20 
5 
8 
2 

Projected OnHand Inventory 

MPS Quantity 

MPS start 

Available to Promise Inventory 
7. Use the bill of materials and inventory records to determine the
quantity of purchased items necessary to assemble 20 end items if the
manufacturer uses lotforlot ordering. There are no end items currently on
hand, and none of the components have any scheduled receipts. (20 points)
Component 
Onhand 
Component 
Onhand 
A 
5 
D 
15 
B 
75 
E 
3 
C 
10 
F 
20 
Answer 7:
8.
Use the table below to answer
the following questions.
a)
Use the information in the Table above, what is the throughput time for
the process, assuming that the Call Center is always busy and has customers
waiting to be processed? (5 points)
b)
Use the information in Table above, what is the process bottleneck? (5
points)
c) Use the information in Table above, what
is the 8hour capacity for the process? (5 points)
d) Use the information in Table above, where
would you expect customer wait times to occur? (5 points)
Answer 8: