Question 1

Common reasons for redesign of layouts include:

Accepted Answer

A)  I and II 
B)  II and IV 
C)  I and III 
D)  II, III, and IV 
E)  I, II, III, and IV 
A)  I and II 
B)  II and IV 
C)  I and III 
D)  II, III, and IV 
E)  I, II, III, and IV

Question 2

In cellular manufacturing, machines and equipment are grouped by type (e.g., all grinders are grouped into a cell).

Accepted Answer

A) True 
 B)False

Question 3

Avoiding bottlenecks is the primary goal of product design.

Accepted Answer

A) True 
 B)False

Question 4

As compared to rigid automation, the benefits of flexible manufacturing systems include:

Accepted Answer

A)  reduced labor requirements. 
B)  higher efficiency. 
C)  larger batch sizes. 
D)  significantly lower fixed costs. 
E)  significantly lower variable costs. 
A)  reduced labor requirements. 
B)  higher efficiency. 
C)  larger batch sizes. 
D)  significantly lower fixed costs. 
E)  significantly lower variable costs.

Question 5

Which of the following is not a significant concern for process selection?

Accepted Answer

A)  variety in products/services 
B)  flexibility of equipment 
C)  volume of output 
D)  pricing strategy 
E)  flexibility of personnel 
A)  variety in products/services 
B)  flexibility of equipment 
C)  volume of output 
D)  pricing strategy 
E)  flexibility of personnel

Question 6

Continuous production systems are typically very rigid and costly to change.

Accepted Answer

A) True 
 B)False

Question 7

A company needs to rebalance a product layout for producing new plastic license plates. They plan to use the assembly line six hours in order to meet projected demand of 2,160 license plates each day. The following table describes the tasks involved in the production of this product:  
For output to equal projected demand, what is the theoretical minimum number of workstations needed?

Accepted Answer

A)  2 
B)  2.8 
C)  3 
D)  4 
E)  5 
A)  2 
B)  2.8 
C)  3 
D)  4 
E)  5

Question 8

A production line is to be designed for a job with three tasks. The task times are .3 minutes, 1.4 minutes, and .7 minutes. For a single production line with no parallel activities, the minimum cycle time in minutes is:

Accepted Answer

A)  .3. 
B)  .7. 
C)  1.4. 
D)  2.4. 
E)  .8. 
A)  .3. 
B)  .7. 
C)  1.4. 
D)  2.4. 
E)  .8.

Question 9

The substitution of machinery that has sensing and control devices for human labor is best described by the term:

Accepted Answer

A)  automation. 
B)  feedback control. 
C)  computer-aided manufacturing. 
D)  computer-integrated manufacturing. 
E)  flexible manufacturing system. 
A)  automation. 
B)  feedback control. 
C)  computer-aided manufacturing. 
D)  computer-integrated manufacturing. 
E)  flexible manufacturing system.

Question 10

An idle percentage of zero means a line is perfectly balanced.

Accepted Answer

A) True 
 B)False

Question 11

A process layout is more susceptible to shutdowns caused by equipment breakdowns than a product layout.

Accepted Answer

A) True 
 B)False

Question 12

A production line is to be designed for a job with three tasks. The task times are .4 minutes, 1.2 minutes, and .5 minutes. The maximum cycle time in minutes is:

Accepted Answer

A)  .4. 
B)  .5. 
C)  1.2. 
D)  2.1. 
E)  .7. 
A)  .4. 
B)  .5. 
C)  1.2. 
D)  2.1. 
E)  .7.

Question 13

Job shops tend to be __________ while continuous processes tend to be __________.

Accepted Answer

A)  in services; in manufacturing 
B)  short-term and capital intensive; long-term and labor intensive 
C)  small scale and flexible; large-scale and inflexible 
D)  standardized; customized 
E)  low cost-per-unit; high cost-per-unit 
A)  in services; in manufacturing 
B)  short-term and capital intensive; long-term and labor intensive 
C)  small scale and flexible; large-scale and inflexible 
D)  standardized; customized 
E)  low cost-per-unit; high cost-per-unit

Question 14

Morale problems can be a reason for redesign of a facility layout.

Accepted Answer

A) True 
 B)False

Question 15

A possible disadvantage of a product layout is an inflexible system.

Accepted Answer

A) True 
 B)False

Question 16

continuous

Accepted Answer

A)  Continuous 
B)  repetitive 
C)  project 
D)  batch 
E)  job shop 
A)  Continuous 
B)  repetitive 
C)  project 
D)  batch 
E)  job shop

Question 17

Mismatches between operational capabilities and market demand can have a negative impact on an organization.

Accepted Answer

A) True 
 B)False

Question 18

QRS Corp. is designing a product layout for a new product. They plan to use this production line 10 hours a day in order to meet forecasted demand of 900 units per day. The following table describes the tasks necessary to produce this product:  
Without considering forecasted demand, what is the minimum possible cycle time for this production line?

Accepted Answer

A)  10 seconds 
B)  20 seconds 
C)  34 seconds 
D)  38 seconds 
E)  152 seconds 
A)  10 seconds 
B)  20 seconds 
C)  34 seconds 
D)  38 seconds 
E)  152 seconds

Question 19

A company needs to locate three departments (X, Y, and Z) in the three areas (I, II, and III) of a new facility. They want to minimize interdepartmental transportation costs, which are expected to be $.50 per load per meter moved. An analyst has prepared the following distances and flow matrices:  
What is the total flow (loads per week) between department Y and department Z?

Accepted Answer

A)  140 
B)  160 
C)  200 
D)  250 
E)  300 
A)  140 
B)  160 
C)  200 
D)  250 
E)  300

Question 20

Heuristic rules are used primarily in which of these types of layouts?

Accepted Answer

A)  I 
B)  II 
C)  I and III 
D)  I and II 
E)  II and III 
A)  I 
B)  II 
C)  I and III 
D)  I and II 
E)  II and III

Exam 8: Process Selection and Facility Layout

Common reasons for redesign of layouts include:

In cellular manufacturing, machines and equipment are grouped by type (e.g., all grinders are grouped into a cell).

Avoiding bottlenecks is the primary goal of product design.

As compared to rigid automation, the benefits of flexible manufacturing systems include:

Which of the following is not a significant concern for process selection?

Continuous production systems are typically very rigid and costly to change.

A production line is to be designed for a job with three tasks. The task times are .3 minutes, 1.4 minutes, and .7 minutes. For a single production line with no parallel activities, the minimum cycle time in minutes is:

The substitution of machinery that has sensing and control devices for human labor is best described by the term:

An idle percentage of zero means a line is perfectly balanced.

A process layout is more susceptible to shutdowns caused by equipment breakdowns than a product layout.

A production line is to be designed for a job with three tasks. The task times are .4 minutes, 1.2 minutes, and .5 minutes. The maximum cycle time in minutes is:

Job shops tend to be __________ while continuous processes tend to be __________.

Morale problems can be a reason for redesign of a facility layout.

A possible disadvantage of a product layout is an inflexible system.

continuous

Mismatches between operational capabilities and market demand can have a negative impact on an organization.

Heuristic rules are used primarily in which of these types of layouts?

Introduction to Operations Management

Competitiveness

Forecasting

Product and Service Design

RELIABILITY – Static

Strategic Capacity Planning for Products and Services

Decision Theory– Static

Work Design and Measurement

learning curve– Static

Location Planning and Analysis

The Transportation Model– Static

Management of Quality

Quality Control

Acceptance Sampling– Static

Aggregate Planning and Master Scheduling

MRP and ERP

Inventory Management

JIT and Lean Operations

Maintenance– Static

Supply Chain Management

Scheduling

Project Management

Management of Waiting Lines

Linear Programming

Filters

Job shops tend to be while continuous processes tend to be .