Deck 4: Process Design and Analysis

Question 1

A product made on an assembly line generally will have a lower unit cost than a product produced in a job shop.

Answer 1

True

Question 2

The workflow for a process layout tends to follow an organized standard route.

Answer 2

False

Question 3

Process choice normally involves numerous decisions regarding the relationships among workers,technology,raw materials,and job assignments.

Answer 3

True

Question 4

Constructing a new building on a university campus is an example of a project.

Question 5

Customers are normally much more involved in the service delivery process than with manufactured goods.

Question 6

A job shop is appropriate for products that are delivered in high volume.

Question 7

A job shop normally produces a customized product using general purpose equipment.

Question 8

A service factory generally has lower levels of customer involvement than a service shop.

Question 9

A process layout groups together machines,equipment,or people with similar functions.

Question 10

An assembly line is an example of a product layout.

Question 11

Manufacturing processes can be described on a continuum where the volume for each type of product varies from low to high,whereas the reliability of customized goods varies conversely from high to low.

Question 12

A continuous process has high volume and low flexibility,and works with discrete items.

Question 13

Line processes generally produce high-volume goods using general purpose equipment.

Question 14

A product can seldom be produced using more than one process.

Question 15

A car assembly operation is an example of a job shop.

Question 16

Services are easily inventoried to buffer fluctuations in demand.

Question 17

A hospital is an example of a service factory.

Question 18

A product layout generally has lower inventory levels than a process layout.

Question 19

The service process matrix differs along two dimensions: the degree of labor intensity and the degree of customer involvement.

Question 20

Service-oriented businesses typically experience a trade-off between the degree of sales opportunity and production efficiency.

Question 21

Which of the following is a service provider that has low customer contact in combination with high labor intensity?

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

Question 22

Process choice involves decisions about all of the following except

A)Workers
B)Technology
C)Raw materials
D)Job assignments
E)Product marketing

Question 23

A bottleneck will determine the amount of output of a process.

Question 24

Outsourcing generally gives an organization more control over the production process.

Question 25

Which of the following statements about the job shop production process is not true?

A)Customization tends to be high.
B)Volume is fairly low.
C)Unit cost is low compared to other processes.
D)Equipment tends to be general purpose.
E)Workers' skills tend to be broad.

Question 26

The three basic layout types discussed in the chapter are process,product,and ____.

A)Continuous
B)Fixed position
C)Regional
D)Service factory
E)Project

Question 27

A fixed-position layout is appropriate for very large items,like a cruise ship.

Question 28

Flow between work centers can be illustrated using from-to charts.

Question 29

Gantt Charts,flowcharting,and bottlenecks are visual techniques to help analyze a process.

Question 30

Reengineering emphasizes the role of the process in producing goods.

Question 31

Which of the following would be classified as a project?

A)Producing custom eye glasses for walk-up customers
B)A new product development team
C)Making millions of ballpoint pens
D)Baking an oven full of bread loaves
E)Producing unleaded gasoline

Question 32

Service-oriented businesses typically experience a trade-off between which of the following?

A)Cost and flexibility
B)Sales opportunity and production efficiency
C)Cost and production efficiency
D)Customer contact and labor intensity
E)Flexibility and cost

Question 33

Customers are generally an integral part of the process when delivering services.

Question 34

Which of the following is suitable for low-volume customized product creation?

A)Job shop
B)Batch
C)Line flow
D)Continuous flow
E)None of these options

Question 35

Which of the following does not describe a continuous process?

A)Very capital intensive
B)Very low unit cost
C)Very standardized
D)Very customized products
E)Very inflexible

Question 36

Throughput is the number of units that can be produced per unit of time.

Question 37

A break-even analysis can help to determine how many stations to use in an assembly line.

Question 38

Which of the following has the lowest unit cost for a discrete process?

A)Project
B)Job shop
C)Batch
D)Line flow
E)Continuous flow

Question 39

Which of the following is not a "service factory"?

A)Hospital
B)Movie theater
C)Airline
D)Hotel
E)Fast food restaurant

Question 40

Assembly line balancing is the technique of assigning work to individual stations so that the variability across all stations in an assembly line is maximized.

Question 41

If an assembly process consists of 5 steps in series (activity A,activity B,activity C,activity D,and activity E),what activity is the bottleneck if activity A takes 20 seconds,B takes 10 seconds,C takes 30 seconds,D takes 15 seconds,and E takes 5 seconds per unit?

A)Activity A
B)Activity B
C)Activity C
D)Activity D
E)Activity E

Question 42

When selecting a process to improve,which of the following should be given priority?

A)A process that lowers costs
B)A process that improves productivity
C)A process that matters most to customers
D)A process that improves quality
E)A process that simplifies assembly

Question 43

Which of the following is not an advantage of a product layout?

A)Processing rates are faster than a process layout.
B)Lower inventory requirements than a process layout.
C)Less material handling than a process layout.
D)More flexible than a process layout.
E)More efficient than a process layout.

Question 44

The output of a process is the inverse of what term?

A)Bottleneck
B)Cycle time
C)Output
D)Break-even
E)Utilization

Question 45

What volume is required to break even if a product has fixed costs of $25,000,variable costs of $25 per unit,and the sales price is $40 per unit?

A)15,625 units
B)1,667 units
C)1,000 units
D)625 units
E)385 units

Question 46

Which of the following is not a process analysis and redesign technique?

A)Reengineering
B)Flowcharting
C)Simulation
D)From-to charts
E)Parallel processing

Question 47

When a machine shop decides to have another organization perform the heat-treating operation on its products instead of doing its own heat treating,what does this illustrate?

A)Reengineering
B)Self-sourcing
C)Outsourcing
D)Job shop
E)Continuous process

Question 48

List three advantages of a process layout.

Question 49

What are the three basic layout types?

Question 50

Producing 12-inch,13-inch,and 14-inch wheel hubs on the same machine center is an example of a/an ____.

A)Fixed-position layout
B)Group technology
C)Assembly line
D)Batch process
E)Project

Question 51

If an assembly process consists of 5 steps in series (activity A,activity B,activity C,activity D,and activity E),what is the utilization of the bottleneck activity if A takes 20 seconds,B takes 10 seconds,C takes 30 seconds,D takes 15 seconds,and E takes 5 seconds per unit?

A)100%
B)66%
C)50%
D)33%
E)12%

Question 52

A self-service filling station is an example of

A)Reengineering
B)Self-sourcing
C)Outsourcing
D)Job shop
E)Continuous process

Question 53

Which of the following is not an advantage of a process layout?

A)Uses general purpose equipment
B)Less capital intensive than other layouts
C)Highly flexible
D)High risk of layout redesign for products with uncertain life cycles
E)High capacity utilization

Question 54

When a bottleneck is improved by adding another processing station in line with the original station,it is an example of

A)Cycle time
B)Reengineering
C)Parallel processing
D)Series processing
E)Flowcharting

Question 55

If 60 seconds are available,and the cycle time is 15 seconds,how many units per minute can be produced?

A)0
B)4
C)15
D)60
E)900

Question 56

The time it takes to complete a particular step or action is

A)Bottleneck
B)Cycle time
C)Output
D)Break-even
E)Utilization

Question 57

Identify the five classifications of the product-process matrix.

Question 58

Briefly describe a job shop with relation to flexibility,unit cost,customer involvement,volume,and capital investment.

Question 59

Comparing the number of products that must be produced to justify a given process is an example of

A)Break-even analysis
B)Reengineering
C)Bottleneck analysis
D)Cycle time computation
E)Line balancing

Question 60

Identify the four classifications of the service process matrix and provide an example of each.

Question 61

Draw and identify three common flowcharting symbols.

Question 62

Describe outsourcing and give two reasons why its use has increased.

Question 63

In a paced assembly process,if station A takes 2 minutes per unit,station B takes 1 minute per unit,and station C takes 3 minutes per unit,compute the utilization for each station and identify the bottleneck.

Question 64

What is the output in terms of products per hour for a three-step process with an 8-minute cycle time for step 1,a 9-minute cycle time for step 2,and a 10-minute cycle time for step 3?

Question 65

Refer to the following break-even chart and describe what machines should be selected for various numbers of products.
B.Machine 2 has the lowest cost if the number of products is between B and C.Machine 3 has the lowest cost if the number of products is between C and D.

Question 66

Cindy's Ceramics produces a standard 4-inch diameter vase with custom decorations related to the season of the year.Her ceramic firing oven can fire four vases at a time.Each firing cycle takes 90 minutes.What is the average cycle time?

Question 67

Describe the use of group technology.

Question 68

The staff member at the airport money exchange booth has three main duties: exchanging money,making money orders,and wiring money.For the current layout,the staff member must travel 3 feet to exchange money.Money is exchanged about 20 times an hour and is a primary part of the job,so it is given a weight of 4.Making money orders require walking 10 feet and is done about 2 times per hour.Making money orders is given a weight of 2.Wiring money is done about 4 times an hour,has a weight of 3 and requires traveling 14 feet.What is the load distance score?

Question 69

Ted's T-shirts makes custom shirts on equipment that costs $350.The material costs $8 per shirt and sells for $15 per shirt.What volume is required to make $1750 a week?

Question 70

Ted's T-shirts makes custom shirts on equipment that costs $350.The material costs $8 per shirt and sells for $15 per shirt.If he makes 20 shirts,what is the total revenue?

Question 71

Ted's T-shirts makes custom shirts on equipment that costs $350.The material costs $8 per shirt and sells for $15 per shirt.If he makes 20 shirts,what is the total variable cost?

Question 72

Benny's Bookmarks sells hand-stitched bookmarks at country fairs.His business is doing well.He is investigating buying a stitching machine to allow him to make the bookmarks more efficiently.The current manual method costs $1 per bookmark to stitch.A new machine costs $1000,and it will cost $0.50 to make a bookmark.How many bookmarks must be produced to break even?

Question 73

Ted's T-shirts makes custom shirts on equipment that costs $350.The material costs $8 per shirt and sells for $15 per shirt.At the break-even point,what is the total revenue?

Question 74

Ted's T-shirts makes custom shirts on equipment that costs $350.The material costs $8 per shirt and sells for $15 per shirt.How many shirts must be sold to break even?

Question 75

List three advantages of a product layout.