Deck 3: Product and Process Design and Mapping

Question 1

The process which is most capital-intensive and often requires very specialized technology is ________.

Answer 1

continuous-flow

Question 2

Use the information below to answer the following question(s).
A small automotive parts manufacturer is evaluating opening a new manufacturing plant for assembly of its battery chargers line.The location being considered has a monthly fixed cost of $42,000 and a variable cost of $3 per charger.Chargers sell for $ 7 each.
The other option (in addition to the option of opening a new manufacturing plant)being considered is subcontracting the work to an external vendor.This option has a monthly fixed cost of $6,000 and a variable cost of $5 per charger.Chargers continue to sell for $7 each.What is the break-even point for the subcontracting option in units per month?

A)6,000
B)3,000
C)10,000
D)7,500

Answer 2

B

Question 3

Discuss the product-process matrix.What happens when a product is assigned to be made with the wrong process? Explain.

Answer 3

The product-process matrix matches the characteristics of the product with the "right" process to make it.Product characteristics that are important include the production volume and product variety.
At one end of the spectrum in the matrix includes very standardized products with high volume production.These products are ideally made using a continuous flow process or an assembly line type of process.Each of these processes usually involves advanced technology requiring machines and equipment which are very expensive (capital intensive with high fixed costs).Hence the high volume production justifies such high fixed cost investments.If such processes are used to make products with low production volumes,it will lead to inefficiencies due to dis-economies of scale.
The other end of the spectrum includes products which have high variety and are customizable and usually made in low volumes.Such products are usually made using a job-shop type process which uses many general purpose (inexpensive)tools and is labor intensive.If job-shop type processes are attempted to be used for high volume standardized products,the costs would be very high due to the process being labor intensive and it would also be impossible to achieve high volume production.

Question 4

What is takt time?

A)Time between placement and receipt of an order
B)The latest time an activity can be completed in a project
C)Cycle time for a product
D)The time spent by a customer waiting in queue

Question 5

The process which requires high worker skill levels and worker training requirements is

A)assembly line.
B)job shop.
C)batch.
D)continuous.

Question 6

Comparing various process options and their relationship to volume and variety can be accomplished using

A)breakeven analysis.
B)product-process matrix.
C)net present value.
D)payoff matrix analysis.

Question 7

The benefits of flexible manufacturing systems (FMS)include

A)moderate production volumes.
B)higher flexibility as compared to an assembly line.
C)quick changeover from part to part.
D)All of the above

Question 8

Continuous-flow processes are capital-intensive usually requiring very specialized technologies.

Question 9

The process which is used to produce a variety of products in low volumes is ________.

Question 10

A job shop is used for producing highly standardized products in large volumes.

Question 11

In a process map,a rectangle indicates

A)a decision.
B)work performed.
C)materials leaving the process.
D)data input.

Question 12

An advantage of a production line process is

A)the ability to produce highly customized products.
B)the high degree of flexibility of the process.
C)the low per unit cost of items produced on the line.
D)the range of output typically produced on such a process.

Question 13

Cellular manufacturing systems (choose two)

A)are usually U-shaped production lines.
B)allow parts to move in a variety of different directions.
C)support low-volume production more efficiently than in a job shop.
D)support mass assembly of products.

Question 14

In which type of process are you likely to see,at most,only minor variations in the type of product or service being produced?

A)Assembly line
B)Job shop
C)Batch
D)Project

Question 15

In a process map,a diamond symbol indicates

A)a decision.
B)work performed.
C)materials leaving the process.
D)data input.

Question 16

The type of processing system which is used for highly standardized products is

A)continuous flow.
B)job shop.
C)batch.
D)project.

Question 17

The process which is the least labor intensive is

A)assembly line.
B)job shop.
C)batch.
D)continuous.

Question 18

Use the information below to answer the following question(s).
A small automotive parts manufacturer is evaluating opening a new manufacturing plant for assembly of its battery chargers line.The location being considered has a monthly fixed cost of $42,000 and a variable cost of $3 per charger.Chargers sell for $ 7 each.
What is the break-even point in units per month?

A)10,500
B)11,000
C)9,000
D)12,700

Question 19

The tool used to compare various process options and their relationship to volume and variety is known as ________.

Question 20

Which option should be chosen if the expected demand is 5,000 units per month?

A)New manufacturing plant
B)Subcontracting
C)Either of the two options
D)None of the two options

Question 21

In Muther's grid the Symbol "X" represents

A)Absolutely necessary.
B)Important.
C)Unimportant.
D)Undesirable.

Question 22

U-shaped production lines that are more efficient for low-volume production as compared to a job shop are known as flexible manufacturing systems.

Question 23

If a line is balanced with 80-percent efficiency,the "balance delay"

A)would be 20 percent.
B)would be 80 percent.
C)would be 100 percent.
D)depends on the next operation.

Question 24

Use the information below to answer the following question(s).
A production line operates for 450 minutes per day.Desired production volume is 80 units per day.Total task time to make the product is 56 minutes.
What is the minimum number of workstations required?

A)5
B)8
C)10
D)12

Question 25

Use the information below to answer the following question(s).
A production line operates for 450 minutes per day.Desired production volume is 80 units per day.Total task time to make the product is 56 minutes.
What is the efficiency of the production line?

A)99.56%
B)11.11%
C)66.67%
D)33.33%

Question 26

In a process map,a rectangle indicates that ________.

Question 27

Use the information below to answer the following question(s).
A production line operates for 450 minutes per day.Desired production volume is 80 units per day.Total task time to make the product is 56 minutes.
What is the balance delay?

A)88.88%
B)0.44%
C)66.67%
D)33.33%

Question 28

In Muther's grid the Symbol "X" represents Important.

Question 29

The cycle time in a production line is determined by

A)amount of time available divided by total task time.
B)production volume divided by amount of time available.
C)amount of time available divided by production volume.
D)production volume multiplied by amount of time available.

Question 30

Fixed position layouts

A)support mass assembly of products.
B)are layouts in which products remain fixed and machines or equipment are moved to products.
C)are usually U-shaped production lines.
D)are layouts in which equipment and machines remain fixed and products are moved to machines.

Question 31

The model used in designing functional layouts where movement is minimized is called the

A)product-process matrix.
B)load-distance model.
C)center of gravity model.
D)line balancing method.

Question 32

A schematic picture of a process using symbols is called a ________.

Question 33

Use the information below to answer the following question(s).
A production line operates for 450 minutes per day.Desired production volume is 80 units per day.Total task time to make the product is 56 minutes.
What is the optimal cycle time?

A)3.6 minutes
B)7.25 minutes
C)5.625 minutes
D)3.875 minutes

Question 34

The process of allocating tasks to process workstations in an efficient manner is called

A)idle time analysis.
B)cycle time optimization.
C)kanban allocation.
D)line balancing.

Question 35

In Muther's grid the Symbol "I" represents

A)Absolutely necessary.
B)Important.
C)Unimportant.
D)Undesirable.

Question 36

The minimum possible cycle time in a production line is determined by the

A)longest task time.
B)shortest task time.
C)average task time.
D)total task time.

Question 37

A production manager wants to design an assembly line that will turn out 800 widgets per day.There will be eight working hours in each day.What is the optimum cycle time?

A)36 seconds
B)60 seconds
C)6 seconds
D)3.6 seconds

Question 38

In a fixed position layout,the workstation stays fixed and product moves from workstation to workstation.

Question 39

In a process map,the diamond symbol indicates that work is actually performed.

Question 40

In a process map,the diamond symbol indicates that ________.

Question 41

Goods that use similar technologies that can coexist in a family of products are known as

A)complementary products.
B)substitute products.
C)similar products.
D)technological products.

Question 42

A process of designing products that are enhancements to existing products is called

A)discontinuous design.
B)process design.
C)continuous design.
D)reverse design.

Question 43

The difference between basic research and applied research is that applied research

A)is generally not profit motivated.
B)often has a profit motive.
C)often leads to long product life cycles.
D)requires technological push.

Question 44

The first phase of the product life cycle is

A)development.
B)introduction.
C)growth.
D)decline.

Question 45

ATVs and snowmobiles are examples of complementary products.

Question 46

In Muther's grid the Symbol "U" represents ________.

Question 47

The process of designing products that are complete changes from existing products is called continuous design.

Question 48

The process of allocating tasks to process workstations in an efficient manner is called ________.

Question 49

A process of applying imagination to invent new products and services is called ________.

Question 50

A manufacturer of detergent enhances their product offering by introducing new scents of their product.This is an example of which kind of R&D?

A)Technological push
B)New product innovation
C)Market pull
D)Discontinuous design

Question 51

A manufacturer of video game consoles introduces a new product in the market with new eye tracking sensor technology.This is an example of which kind of R&D?

A)Technological push
B)Muther's technology
C)Market pull
D)Continuous design

Question 52

Applied research is practical exploration that often has a profit motive.

Question 53

The last phase of the product life cycle is

A)introduction.
B)development.
C)decline.
D)growth.

Question 54

Goods that use similar technologies that can coexist in a family of products are known as substitute products.

Question 55

Layouts in which the product is stationary and equipment or machines are brought to the product is known as a ________.

Question 56

The required cycle time necessary to meet forecasted needs for a product.is known as ________.

Question 57

U-shaped production lines that are more efficient for low-volume production as compared to a job shop are known as ________.

Question 58

A process that represents a trade-off between mass assembly operations and job shops in terms of flexibility and production volumes is known as ________.

Question 59

Traditional products such as dining room furniture have very short product life cycles.

Question 60

The model used in designing functional layouts where movement is minimized is called the ________.

Question 61

The fact that a product is more likely to fail either very early in its life or late in its useful life is called the

A)bathtub-shaped hazard function of reliability.
B)system reliability function.
C)component reliability function.
D)series reliability function.

Question 62

A system has 4 components in series,each having a reliability of 0.8.What is the reliability of the system?

A)0.8
B)3.2
C)0.2
D)0.4096

Question 63

Research and Development (R&D),which involves continuous development that takes existing products and enhances them to reinvigorate the product life cycle,is called ________.

Question 64

A manufacturer of light bulbs tests their products in a very rigorous manner to achieve 5000 hours of life,which is much higher than the industry standard.This is an example of

A)Design for Reuse.
B)Design for Reliability.
C)Design for Manufacture.
D)Design for Maintainability.

Question 65

A method for translating customer requirements into functional design is known as ________.

Question 66

Concurrent engineering involves performing the different tasks of design

A)sequentially.
B)interchangeably.
C)technologically.
D)simultaneously.

Question 67

In concurrent engineering,the different tasks of design are performed ________.

Question 68

The propensity for a part to not fail over a given time is called ________.

Question 69

Quality Function Deployment (QFD)is also known as house of quality.

Question 70

A system of design that facilitates the making of products is known as

A)Design for Reuse.
B)Design for Reliability.
C)Design for Manufacture.
D)Design for Maintainability.

Question 71

High-tech products such as smartphones have very ________ product life cycles.

Question 72

ATVs and snowmobiles are examples of ________.

Question 73

A graphical representation of the life phases that a product experiences is known as ________.

Question 74

Concurrent engineering involves performing the different tasks of design sequentially.

Question 75

Apple makes their iPhone phone models such that consumers cannot replace the battery in the phones when required.This is an example of poor

A)Design for Reuse.
B)Design for Reliability.
C)Design for Manufacture.
D)Design for Maintainability.

Question 76

The process of designing products that are enhancements to existing products is known as ________.

Question 77

Goods that use similar technologies that can coexist in a family of products are known as ________.

Question 78

Quality Function Deployment is

A)a method for translating customer requirements into functional design.
B)also known as voice of the customer.
C)also called house of quality.
D)All of the above

Question 79

List and discuss the steps in the Product Design Process.

Question 80

A computer manufacturer designs their product such that it is easy for consumers to upgrade product components like the memory in the future at a reasonable cost.This is an example of

A)Design for Reuse.
B)Design for Reliability.
C)Design for Manufacture.
D)Design for Maintainability.