Deck 3: Process Planning

Question 1

Which of the following is a major difference between continuous processes and flow shops?

A)Inputs are fixed for continuous shops and the flow of work is continuous for flow shops
B)In flow shops,there is a discrete product or service instead of products not naturally divisible
C)Degree of automation is higher for flow shops
D)Continuous shops tend to be very small while flow shops tend to be very large
E)Both A and C

Answer 1

In flow shops,there is a discrete product or service instead of products not naturally divisible

Question 2

The product-process matrix developed by Hayes and Wheelwright (1979)explains how transformation systems vary from project-on the top left corner-to continuous processes-on the bottom right corner.Its vertical axis illustrates:

A)Output quantity
B)Variety of outputs
C)Quality
D)Breadth of outputs
E)None of the above

Answer 2

Variety of outputs

Question 3

Experienced staff needed to run job shops tends to increase its direct labor costs.

Answer 3

True

Question 4

Which form of transportation system utilizes group technology?

A)Flow shop
B)Job shop
C)Cellular production
D)Project operations
E)None of the above

Question 5

In the Service Matrix,to which quadrant does recreation belong?

A)Service shop
B)Professional service
C)Mass service
D)Service factory
E)Project shop

Question 6

Of the following,which form of transformation system has the lowest output variety but the highest batch size?

A)Job shop
B)Cellular
C)Project
D)Flow shop

Question 7

Which of the following is not a major element of a service guarantee?

A)Must be unconditional
B)Must be easy to communicate and for the customer to understand
C)Must include preventive measures for "fail safing"
D)Must be meaningful to the customer
E)All of the above are major elements

Question 8

A gap in the service process that is considered the misperception by the service provider of what the customer truly needs.

A)Gap 1
B)Gap 3
C)Gap 4
D)Gap 10
E)Gap 12

Question 9

Which of the following has the lowest fixed costs?

A)Job shop
B)Flow shop
C)Continuous transformation process
D)Cellular production

Question 10

The cost-volume-distance (CVD)model is suitable for layouts in which moving materials or people between departments is a major consideration.

Question 11

Why do continuous processes typically run 24 hours a day,seven days a week?

A)There is a need to spread their huge fixed cost over as large a volume as possible
B)Price is often the single most important factor in competing with their products
C)Facilities are a maze of pipes,conveyors,tanks,valves,vats,and bins
D)Both A and B
E)A and C but not B

Question 12

Layout analysis is usually performed for the following purpose(s):

A)Maximize operational efficiency
B)Reduce safety or health hazards
C)Minimize interference or noise between areas
D)All of the above
E)None of the above

Question 13

A general characteristic of a job shop is that it requires a small variety of inputs,and minimal variations in the time it takes for a complete "job".

Question 14

A __ is commonly used to produce highly standardized outputs in extremely large volume.

A)Job shop
B)Flow shop
C)Continuous transformation process
D)Cellular production
E)None of the above

Question 15

Which of the following is not a well-known problem in flow shops?

A)Boredom
B)Workers may be dehumanized by manufacturing lines
C)Absenteeism
D)All of the above are well-known problems in flow shops
E)None of the above

Question 16

Paced lines use some sort of conveyor to move output along the production line at a variable rate,so that operators do their work as they need.

Question 17

A/An ___ item is produced in batches of some size that is set by the customer,and then delivered upon its completion.

A)Make-to-order
B)Make-to-stock
C)Order-to-make
D)Stock-to-order
E)Finish-to-order

Question 18

Which of the following is false for job shops?

A)Unique jobs must be produced
B)Output batch size is moderately large,to make it cost effective
C)The flow of work through facilities tends to be intermittent
D)Groupings of staff and equipment are done according to function
E)None of the above

Question 19

Which of the following is not a basic form of transformation systems?

A)Job shop
B)Flow shop
C)Continuous transformation process
D)All of the above are basic forms of transformation systems

Question 20

Balancing a production line includes the following tasks,except:

A)Finding a cycle time in which each workstation can complete its tasks
B)Take into account precedence relationships among tasks
C)Identify the task with the longest operation time
D)Calculate the number of workstations that completes the job in the minimum amount of time
E)None of the above

Question 21

A logical,nominal,or virtual cell refers to a situation where the equipment is physically adjoining and reserved for production of only one part family.

Question 22

As the costs of fixed equipment investments rise with the volume produced,companies move from project to job,flow,and then cell transformation systems.

Question 23

Name some differences between flow shop and continuous process.

Question 24

Of large scale and finite duration,_____ _____ tend to be non-repetitive,with multiple and often simultaneous,highly interdependent tasks.

Question 25

Explain how the flow shop and the continuous process are similar.

Question 26

According to the service matrix developed by Schmenner,services with low contact intensity and customization attain profitability through high prices rather than high volumes.

Question 27

What are the three elements of servicescapes most emphasized by Bitner?

Question 28

What are some common disadvantages that result from both continuous process and flow shops?

Question 29

Give one example of where the continuous transformation process is used.Explain why.

Question 30

In the product-process matrix,when the size of a batch increases significantly,with a corresponding decrease in output variety,then the flow shop is appropriate.

Question 31

Continuous processes are characterized by low to moderate output variety and one to few in batch size.

Question 32

In cellular production the cellular form allows for a level of customization usually found in job shops.

Question 33

What is the difference in a make-to-stock item and a make-to-order item?

Question 34

What characteristics divide service systems,and what is the name of the four quadrants they are divided into?

Question 35

In cellular production,parts with similar processing requirements are called part families.What are some of the classifications for separating these parts?

Question 36

In process planning there are both short and long tasks involved in stations.Describe how both tasks differ when being assigned to different stations.

Question 37

What is the difference between "make-to-stock" and "make-to-order"?

Question 38

Explain how balancing a production line uses cycle time for success.

Question 39

The concept of _____ ______ (Chase and Stewart,1994)is used by organizations to help guarantee their service,by anticipating where a service failure might occur and installing preventive measures.

Question 40

What are the four major elements of a service guarantee?

Question 41

In what ways can a flow shop minimize costs (be specific)?

Question 42

What important advice did Chase and Tansik write about customer delivery systems,and why is it useful information?

Question 43

When would it be better for a firm to use flow shops rather than continuous process?

Question 44

Explain how it can be difficult to efficiently manage a job shop.

Question 45

What kinds of companies benefit from continuous process and explain why it is so valuable for their company.

Question 46

What two basis do shops use to formally plan their layouts to group the equipment and why?

Question 47

In the service industry why is it important to know exactly what characteristics of the service need to be emphasized? Give an example.

Question 48

Explain how pace can become an issue in a flow shop.

Question 49

What are some of the disadvantages of using a job shop? Explain.

Question 50

In designing a process system,what are three key things that may indicate that the project form is appropriate?

Question 51

What are some of the advantages of cellular production? Explain.

Question 52

Why is it difficult to layout the operations of a job shop? Explain.

Question 53

How does cellular form within production reduce machine setup times?

Question 54

What are some of the advantages of using a job shop? Explain.

Question 55

What are some of the disadvantages of cellular production? Explain.