Test Bank | Ch9 Layout Strategies – 10th Global Ed

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Operations Management, 10e, Global Edition (Heizer/Render)

Chapter 9 Layout Strategies

1) McDonald's "Made for You" kitchen system represents a strategic layout decision even though an obvious benefit of the system is a dramatic reduction in the inventory of food prepared in advance.

Diff: 1

Topic: Global company profile

Objective: no LO

2) The objective of layout strategy is to develop an effective and efficient layout that will meet the firm's competitive requirements.

Diff: 1

Topic: The strategic importance of layout decisions

Objective: no LO

3) The work cell layout, a special arrangement of machinery and equipment to focus on the production of a single product or group of related products, is for manufacturing applications and has no relevance to services.

Diff: 2

Topic: Types of layout

Objective: LO9-6

4) The layout approach that addresses trade-offs between space and material handling is called the fixed position layout.

Diff: 2

Topic: Types of layout

Objective: LO9-4

5) Utilization of the total "cube" is the dominant consideration in office layout.

Diff: 2

Topic: Office layout

Objective: LO9-1

6) One guideline for a retail layout is to locate high-draw items around the periphery of the store.

Diff: 2

Topic: Retail layout

Objective: LO9-2

7) Category management is the use of computer software to evaluate the profitability of merchandising plans.

Diff: 2

Topic: Retail layout

Objective: LO9-2

8) Servicescape refers to the physical surrounding in which the service is delivered.

Diff: 2

Topic: Retail layout

Objective: LO9-2

9) One guideline for determining the arrangement and space allocation of a retail store is to place high-impulse and high-margin items such as housewares and beauty aids in prominent locations.

Diff: 2

Topic: Retail layout

Objective: LO9-2

10) Cross-docking processes items as they are received, rather than placing them in storage; this helps explain why "warehouses" are now called "distribution centers."

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

11) The dominant problem associated with the fixed-position layout is that workers are fixed in position, and cannot be reassigned.

Diff: 2

Topic: Fixed-position layout

Objective: LO9-4

12) A process-oriented layout is the traditional way to support a product differentiation strategy.

Diff: 1

Topic: Process-oriented layout

Objective: LO9-5

13) Job lots are groups or batches of parts processed together.

Diff: 1

Topic: Process-oriented layout

Objective: LO9-5

14) Process-oriented layouts typically have low levels of work-in-process inventory.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

15) CRAFT is software for balancing assembly lines.

Diff: 2

Topic: Process-oriented layout

AACSB: Use of IT

Objective: LO9-5

16) The most common tactic to arrange departments in a process-oriented layout is to minimize material handling costs.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

17) The work cell improves process layouts by reducing floor space and by reducing direct labor cost.

Diff: 2

Topic: Work cells

Objective: LO9-6

18) The balancing of work cells uses the same procedures as the balancing of an assembly line.

Diff: 2

Topic: Work cells

Objective: LO9-6

19) A focused work center is well suited to the production of a large family of products requiring similar processing, even if their demands are not very stable.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

20) A fabrication line and an assembly line are both types of repetitive and product-focused layout, but only the fabrication line utilizes workstations.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

21) The biggest advantage of a product layout is its flexibility to handle a varied product mix.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

22) The minimum number of workstations depends upon the set of task times and the precedence chart, but not the number of units scheduled.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

23) A product requires 24 separate tasks, and the sum of those task times is 14 minutes; if the cycle time is 2 minutes, then at least 12 workstations will be needed.

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

24) If the schedule calls for the production of 120 units per day and 480 minutes of production time are available per day, the maximum cycle time would be 4 minutes.

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

25) Product-oriented layouts tend to have high levels of work-in-process inventories.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

26) One drawback of a product-oriented layout is that work stoppage at any one point ties up the whole operation.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

27) Cycle time is the maximum time that the product is allowed at each work station.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

28) Heuristics are problem-solving procedures that mathematically optimize the solution.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

29) Which of the following is not one of McDonald's "seven major innovations"?

A) the Happy Meal

B) drive-through windows

C) breakfast menus

D) play areas

E) "Made by You" kitchen system

Diff: 2

Topic: Global company profile

Objective: no LO

30) The objective of layout strategy is to

A) minimize cost

B) develop an efficient and effective system that meets competitive requirements

C) maximize flexibility

D) minimize space used

E) minimize material handling costs

Diff: 2

Topic: The strategic importance of layout decisions

Objective: no LO

31) The main goal of retail layout is

A) minimizing material handling cost

B) maximizing high-margin sales

C) minimizing storage costs

D) minimizing space required

E) none of the above

Diff: 2

Topic: Types of layout

Objective: LO9-2

32) Which layout's main objective is to equalize the task time for each station?

A) work cell

B) fixed position

C) process oriented

D) job shop

E) product oriented

Diff: 2

Topic: Types of layout

Objective: LO9-7

33) A hospital's layout most closely resembles which of the following?

A) product oriented

B) work cell

C) job shop

D) project

E) none of the above

Diff: 2

Topic: Types of layout

Objective: LO9-5

34) Deloitte & Touche solved the empty desk problem by

A) eliminating permanent desks

B) implementing a "hoteling" program

C) creating open offices

D) none of the above

Diff: 2

Topic: Types of layout

Objective: LO9-1

35) The layout strategy that deals with low-volume, high-variety production is

A) fixed-position layout

B) retail layout

C) warehouse layout

D) office layout

E) none of the above

Diff: 2

Topic: Types of layout

Objective: LO9-5

36) "A special arrangement of machinery and equipment to focus on production of a single product or group of related products" describes what layout type?

A) fixed-position layout

B) intermittent production

C) focused factory

D) work cell

E) warehouse layout

Diff: 2

Topic: Types of layout

Objective: LO9-6

37) A good layout requires determining

A) material handling requirements

B) capacity and space requirements

C) environment and aesthetics

D) cost of moving between various work areas

E) all of the above

Diff: 2

Topic: Types of layout

Objective: no LO

38) Retail layouts thrive on the notion that

A) handling costs should be minimized

B) storage costs should be minimized

C) average customer visit duration should be maximized

D) space used should be minimized

E) maximizing customer exposure rate maximizes sales and profit

Diff: 2

Topic: Retail layout

Objective: LO9-2

39) Slotting fees

A) are charged by retailers to stock a product

B) can amount to over $25,000

C) are not a part of Wal-Mart's business practices

D) can reduce the ability of small businesses to introduce new products

E) all of the above

Diff: 2

Topic: Retail layout

Objective: LO9-2

40) Which of the following is not a retail layout practice?

A) high-draw items along periphery

B) distribute power items throughout store

C) end-aisle locations are used to maximize product exposure

D) high-margin and impulse items in prominent locations

E) All of the above are retail layout practices.

Diff: 2

Topic: Retail layout

Objective: LO9-2

41) How are retail layouts judged?

A) sales ($) per sq. ft. (or linear foot in certain situations)

B) total storage cost

C) average customer trip duration

D) minimizing total space required

E) Any of the above are effective measures.

Diff: 2

Topic: Retail layout

Objective: LO9-2

42) The fixed-position layout would be most appropriate in which of the following settings?

A) a fast-food restaurant

B) a doctor's office

C) a casual dining restaurant

D) a cruise ship assembly facility

E) none of the above

Diff: 2

Topic: Fixed-position layout

Objective: LO9-4

43) For which of the following operations would a fixed-position layout be most appropriate?

A) assembling automobiles

B) producing TV sets

C) constructing a highway tunnel or bridge

D) refining of crude oil

E) running an insurance agency

Diff: 3

Topic: Fixed-position layout

Objective: LO9-4

44) Because the fixed-position layout problem is so difficult to solve on-site, operations managers

A) virtually never employ this layout strategy

B) utilize this approach only for construction projects such as bridges and office towers

C) increase the size of the site

D) often complete as much of the project as possible off-site

E) utilize this layout only for defense contractors

Diff: 2

Topic: Fixed-position layout

Objective: LO9-4

45) One factor impacting the fixed-position layout strategy is

A) minimizing difficulties caused by material flow varying with each product

B) requiring frequent contact close to one another

C) the provision of low-cost storage with low-cost material handling

D) the movement of material to the limited storage areas around the site

E) balancing product flow from one work station to the next

Diff: 2

Topic: Fixed-position layout

Objective: LO9-4

46) The type of layout which features departments or other functional groupings in which similar activities are performed is

A) process-oriented

B) product-oriented

C) fixed-position

D) mass production

E) unit production

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

47) One of the major advantages of process-oriented layouts is

A) high equipment utilization

B) large work-in-process inventories

C) flexibility in equipment and labor assignment

D) smooth and continuous flow of work

E) none of the above

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

48) The main issue in designing process layouts concerns the relative positioning of

A) safety devices

B) departments

C) raw materials

D) entrances, loading docks, etc.

E) supervisors to their employees

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

49) Which of the following is not an information requirement for solving a load-distance problem?

A) a list of departments or work centers

B) a projection of work flows between the work centers

C) the distance between locations

D) a list of product cycle times

E) the cost per unit of distance to move loads

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

50) The major problem addressed by the process-oriented layout strategy is

A) the movement of material to the limited storage areas around the site

B) requiring frequent contact close to one another

C) the provision of low-cost storage with low-cost material handling

D) minimizing difficulties caused by material flow varying with each product

E) balancing product flow from one work station to the next

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

51) The most common tactic followed in process-layout planning is to arrange departments or work centers so they

A) minimize the cost of skilled labor

B) maximize the machine utilization

C) allocate the available space equally to all the departments

D) minimize the costs of material handling

E) none of the above

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

52) Which type of layout is specifically designed to encourage employees to interact?

A) warehouse

B) job shop

C) open office

D) retail

E) repetitive/continuous

Diff: 1

Topic: Types of layout

AACSB: Communication

Objective: LO9-1

53) Which of the following is true for process layouts, but false for product-oriented layouts?

A) low in-process inventories

B) flexibility in equipment and labor assignments

C) low variety of products

D) high volume of output

E) often solved by assembly line balancing

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

54) A big advantage of a process-oriented layout is

A) its flexibility in equipment and labor assignments

B) its low cost

C) the simplified scheduling problem presented by this layout strategy

D) the ability to employ low-skilled labor

E) its high equipment utilization

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

55) One disadvantage of process-oriented layouts arises from

A) the use of special purpose equipment

B) machine maintenance, which tends to seriously degrade the capacity of the entire system

C) the use of specialized material handling equipment

D) the need for stable demand

E) the use of the general purpose machines and equipment

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

56) The typical goal used when developing a process-oriented layout strategy is to

A) minimize the distance between adjacent departments

B) minimize the material handling costs

C) maximize the number of different tasks which can be performed by an individual machine

D) minimize the level of operator skill necessary

E) maximize job specialization

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

57) Which of the following is true of a focused factory?

A) It may be focused in ways other than by product or layout.

B) It may be focused only by processing requirements.

C) It is much like a product facility within an otherwise process facility.

D) All of the above are true.

E) None of the above is true.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

58) In the Office Relationship Chart, which rating reflects the highest importance for two departments' closeness to each other?

A) A

B) E

C) I

D) O

E) X

Diff: 2

Topic: Office layout

Objective: LO9-1

59) Which of the statements below best describes office layout?

A) groups workers, their equipment, and spaces/offices to provide for movement of information

B) addresses the layout requirements of large, bulky projects such as ships and buildings

C) seeks the best personnel and machine utilization in repetitive or continuous production

D) allocates shelf space and responds to customer behavior

E) deals with low-volume, high-variety production

Diff: 2

Topic: Office layout

Objective: LO9-1

60) Which of the following constitutes a major trend influencing office layouts?

A) downsizing

B) globalization

C) environmental issues

D) off-site employees

E) health issues

Diff: 2

Topic: Office layout

Objective: LO9-1

61) Which of the following does not support the retail layout objective of maximizing customer exposure to products?

A) locate high-draw items around the periphery of the store

B) use prominent locations for high-impulse and high-margin items

C) maximize exposure to expensive items

D) use end-aisle locations

E) convey the store's mission with the careful positioning of the lead-off department

Diff: 2

Topic: Retail layout

Objective: LO9-2

62) Ambient conditions, spatial layout and functionality, and signs, symbols, and artifacts are all

A) indicators of imbalance on an assembly line

B) indicators that cross-docking has been successful

C) elements of customization in a warehouse layout

D) elements of servicescapes

E) elements of successful office layouts

Diff: 2

Topic: Retail layout

Objective: LO9-2

63) Balancing low-cost storage with low-cost material handling is important in a(n)

A) fixed-position layout

B) process-oriented layout

C) office layout

D) repetitive and product-oriented layout

E) warehouse layout

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

64) Which of the following requires an information system that provides inbound product identification, its destination, and routing of the product to the designated outbound vehicle?

A) phantom-docking

B) random stocking

C) ASRS

D) customizing

E) cross-docking

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

65) The major problem addressed by the warehouse layout strategy is

A) minimizing difficulties caused by material flow varying with each product

B) requiring frequent contact close to one another

C) addressing trade-offs between space and material handling

D) balancing product flow from one work station to the next

E) none of the above

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

66) The concept of customizing in a warehouse layout

A) is possible, but causes serious loss of oversight of the quality function

B) cannot be considered seriously in today's high efficiency factories

C) is theoretically sound, but several years away in practice

D) is a new trend in value-added activities in warehouses

E) none of the above

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

67) ASRS stands for

A) automated storage and retrieval system

B) automated storage and recovery system

C) automated scan and recognize system

D) automated scan and retail system

E) none of the above

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

68) Which of the following is true of random stocking?

A) It is a derivation of FCFS.

B) Its results always minimize handling costs.

C) Products have their own permanent storage spot.

D) Each pick can be of only one product.

E) None of the above is true.

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

69) Cross-docking is

A) seldomly placing an item in storage, it is sent straight from incoming to outbound

B) using docks for either incoming or outbound shipments

C) using a single dock to unload and then load the same truck

D) all of the above

E) none of the above

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

70) Which one of the following is not common to repetitive and product-oriented layouts?

A) a high rate of output

B) specialization of labor

C) ability to adjust to changes in demand

D) low unit costs

E) All are common to product-oriented layouts.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

71) Which of the following is not an advantage of work cells?

A) reduced direct labor cost

B) decreased use of equipment and machinery

C) heightened sense of employee participation

D) reduced raw material and finished goods inventory

E) reduced investment in machinery and equipment

Diff: 2

Topic: Work cells

Objective: LO9-6

72) Balancing a work cell is done

A) before the work cell equipment is sequenced

B) as part of the process of building an efficient work cell

C) before takt time is calculated

D) so that each assembly line workstation has exactly the same amount of work

E) to minimize the total movement in a process layout

Diff: 2

Topic: Work cells

Objective: LO9-6

73) Takt time is

A) the total work time available divided by units required by the consumer

B) the units required divided by workers required

C) a fictional time increment similar to a therblig

D) the same thing as cycle time in a process layout

E) an important consideration in balancing an assembly line

Diff: 2

Topic: Work cells

Objective: LO9-6

74) A process layout problem consists of 4 departments, each of which can be assigned to one of four rooms. The number of different solutions to this problem is __________, although all of them may not have different material handling costs.

A) 1

B) 4

C) 16

D) 24

E) unknown

Diff: 2

Topic: Process-oriented layout

AACSB: Analytic Skills

Objective: LO9-5

75) Solving a load-distance problem for a process-oriented layout requires that

A) the difficulty of movement be the same for all possible paths

B) pickup and setdown costs vary from department to department

C) the cost to move a load be the same for all possible paths

D) takt time be less than 1

E) CRAFT software examine all possible department configurations

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

76) Which of the following layouts generally has the best machine utilization?

A) fixed-position layout

B) repetitive and product-oriented layout

C) process-oriented layout

D) office layout

E) warehouse layout

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

77) Which of the following is not one of the requirements of cellular production?

A) test (poka-yoke) at each station in the cell

B) adequate volume for high equipment utilization

C) a high level of training, flexibility, and empowerment of employees

D) being self-contained, with its own equipment and resources

E) identification of families of products, often through the use of group technology codes

Diff: 2

Topic: Work cells

Objective: LO9-6

78) The assumption of stability of demand is important for justifying which of the following layout types?

A) fixed-position layout

B) product-oriented layout

C) process-oriented layout

D) all of the above

E) none of the above

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

79) Which layout type assumes an adequate volume for high equipment utilization?

A) product-oriented layout

B) process-oriented layout

C) fixed-position layout

D) retail layout

E) warehouse layout

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

80) A product-oriented layout would be most appropriate for which one of the following businesses?

A) fast food

B) steel-making

C) insurance sales

D) clothing alterations

E) a grocery store

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

81) The assumptions necessary for a successful product layout include all of the following except

A) adequate volume for high equipment utilization

B) standardized product

C) volatile product demand

D) All of the above are appropriate assumptions.

E) None of the above is an appropriate assumption.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

82) Which of these layouts is most suitable for processing sugar from sugar beets or sugar cane?

A) process-oriented layout

B) fixed-position layout

C) focused factory

D) product-oriented layout

E) work cell layout

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

83) Which of the following is true regarding fabrication lines?

A) They are the same thing as assembly lines.

B) They are the same thing as focused factories.

C) They are a special type of process-oriented layout.

D) Balancing their assembly line is more technological than worker oriented.

E) None of the above is true.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

84) The central problem in product-oriented layout planning is

A) minimizing material handling within workstations

B) minimizing labor movement between workstations

C) equalizing the space allocated to the different workstations

D) maximizing equipment utilization

E) minimizing the imbalance in the work loads among workstations

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

85) A disadvantage of product-oriented layout is that

A) there is a lack of flexibility in handling a variety of products or production rates

B) high volume is required because of the large investment needed to set up the process

C) work stoppage at any one point halts the whole operation

D) All of the above are disadvantages of product-oriented layouts.

E) None of the above is a disadvantage of product-oriented layouts.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

86) The main advantage of a product-oriented layout is typically

A) low raw material cost

B) employability of highly skilled labor

C) high flexibility

D) low capital cost

E) low variable cost per unit

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

87) In a product-oriented layout, the process of deciding how to assign tasks to workstations is referred to as

A) station balancing

B) process balancing

C) task allocation

D) line balancing

E) work allocation

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

88) In assembly line balancing, the theoretical minimum number of workstations is

A) the ratio of the sum of all task times to cycle time

B) always (when a fraction) rounded upward to the next larger integer value

C) not always possible to reach when tasks are actually assigned to stations

D) all of the above

E) none of the above

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

89) In assembly line balancing, cycle time (the ratio of available production time to scheduled production) is the

A) minimum time that a product is allowed at each workstation

B) maximum time that a product is allowed at each workstation

C) optimum time that a product is allowed at each workstation

D) desired cycle time that a product is allowed at each workstation

E) all of the above

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

90) A production line is to be designed to make 500 El-More dolls per day. Each doll requires 11 activities totaling 16 minutes of work. The factory operates 750 minutes per day. The required cycle time for this assembly line is

A) one-half minute

B) one and one-half minutes

C) two minutes

D) 5,500 minutes

E) cannot be determined from the information given

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

91) A production line is to be designed for a job with four tasks. The task times are 2.4 minutes, 1.4 minutes, 0.9 minutes, and 1.7 minutes. The maximum cycle time is __________ and the minimum cycle time is __________ minutes.

A) 1.8; 1.4

B) 1.6; 0.9

C) 6.4; 2.4

D) 2.4; 0.9

E) none of these

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

92) Cycle time is computed as

A) desired output divided by the daily operating time

B) daily operating time divided by the product of desired output and the sum of job times

C) the product of desired output and the sum of job times divided by daily operating time

D) daily operating time divided by the scheduled output

E) 1.00 minus station time

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

93) Daily capacity of a product layout is determined by

A) operating time divided by cycle time

B) cycle time divided by operating time

C) operating time divided by total task time

D) total task time divided by cycle time

E) cycle time divided by total task time

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

94) Four hundred and eighty minutes of production time are available per day. Scheduled production is 120 units per day. What is the required cycle time?

A) 4 minutes

B) 5 minutes

C) 6 minutes

D) 7 minutes

E) 8 minutes

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

95) A production line is to be designed for a product whose completion requires 21 minutes of work. The factory works 400 minutes per day. Can an assembly line with five workstations make 100 units per day?

A) yes, with exactly 100 minutes to spare

B) no, but four workstations would be sufficient

C) no, it will fall short even with a perfectly balanced line

D) yes, but the line's efficiency is very low

E) cannot be determined from the information given

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

96) Four hundred and eighty minutes of production time are available per day. The schedule calls for the production of 80 units per day. Each unit of the product requires 30 minutes of work. What is the theoretical minimum number of workstations?

A) 2

B) 3

C) 4

D) 5

E) 6

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

97) Which of the following is not a heuristic rule for assigning tasks to workstations in a product layout?

A) longest tasks first

B) in order of most number of following tasks

C) median tasks first

D) shortest tasks first

E) in accordance with positional weight

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

98) If a layout problem is solved by use of "heuristics," this means that

A) there was no other way to solve the problem

B) no computer software was available

C) the problem has only a few alternatives to evaluate

D) no optimum solution exists

E) a "satisfactory" solution is acceptable

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

99) Which of the following is a common heuristic for assembly line balancing?

A) debits near the windows, credits near the door

B) manufacturers locate near materials, retailers locate near customers

C) earliest due date first

D) ranked positional weight

E) none of the above

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

100) An assembly line consists of 21 tasks grouped into 5 workstations. The sum of the 21 task times is 85 minutes. Cycle time for the line is 20 minutes. The efficiency of this line is

A) 4.2 percent

B) 17 percent

C) 85 percent

D) 100 percent

E) none of the above

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

101) An assembly line consists of 158 tasks grouped into 32 workstations. The sum of all task times is 105 minutes. Cycle time for the line is 4 minutes. The efficiency of this line is approximately

A) 8 percent

B) 21 percent

C) 82 percent

D) 100 percent

E) none of the above

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

102) McDonald's "Made for You" kitchen system represents a __________ use of layout decisions.

Diff: 1

Topic: Global company profile

Objective: LO9-5

103) __________ layouts deal with low-volume, high-variety production with like machines and equipment grouped together

Diff: 1

Topic: Process-oriented layout

Objective: LO9-5

104) A(n) __________ is a special product-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

105) A(n) __________ groups workers, their equipment, and spaces/offices to provide for comfort, safety, and movement of information.

Diff: 2

Topic: Office layout

Objective: LO9-1

106) The __________ is a non-numeric method for determining which departments are located near one another, and which departments are kept farther apart.

Diff: 2

Topic: Office layout

Objective: LO9-1

107) A(n) __________ addresses flow, allocates space, and responds to customer behavior.

Diff: 2

Topic: Retail layout

Objective: LO9-2

108) __________ are fees manufacturers pay to get their products displayed.

Diff: 2

Topic: Retail layout

Objective: LO9-2

109) __________ refers to the physical surroundings in which a service takes place, and how they affect customers and employees.

Diff: 2

Topic: Retail layout

Objective: LO9-2

110) __________ avoids placing materials or supplies in storage by processing them as they are received for shipment.

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

111) The project remains in one place and workers and equipment come to that one work area in a __________ layout.

Diff: 2

Topic: Retail layout

Objective: LO9-2

112) __________ is the use of computer software to evaluate the profitability of merchandising plans in a retail layout.

Diff: 2

Topic: Retail layout

AACSB: Use of IT

Objective: LO9-2

113) __________ is that element of balancing a work cell that superficially resembles cycle time.

Diff: 2

Topic: Work cells

Objective: LO9-6

114) A(n) __________ line is a machine-paced product-oriented facility for building components.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

115) __________ is the maximum time that the product is available at each workstation.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

116) Identify McDonald's "seven major innovations

Diff: 2

Topic: Global company profile

Objective: no LO

117) In what specific areas does the layout decision establish a firm's competitive priorities?

Diff: 2

Topic: The strategic importance of layout decisions

Objective: no LO

118) To develop a good facility layout, what must be determined?

Diff: 2

Topic: Types of layout

Objective: no LO

119) Identify the seven fundamental layout strategies. Describe the use of each one very briefly.

3. Warehouse layout: Addresses trade-offs between space and material handling.

4. Fixed-position layout: Addresses the layout requirements of large, bulky projects such as ships and buildings

5. Process-oriented layout: Deals with low-volume, high-variety production.

6. Work cell layout: Arranges machinery and equipment to focus on the production of a single product or a group of related products

7. Product-oriented layout: Seeks the best personnel and machine utilization in repetitive or continuous production.

Diff: 2

Topic: Types of layout

Objective: LO9-1, LO9-2, LO9-3, LO9-4, LO9-5, LO9-6, LO9-7

120) What techniques can be used to overcome the inherent problems of fixed-position layouts?

Diff: 2

Topic: Fixed-position layout

Objective: LO9-4

121) "Having a focused work center is like having a factory within a factory." Discuss. Include in your discussion what conditions make focused work centers appropriate.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

122) Why do work cells increase the use of equipment and machinery?

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

123) What are the advantages of focused factories?

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

124) Explain how a load-distance model helps solve problems in process layout.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

125) Identify the four requirements for cellular production.

Diff: 2

Topic: Process-oriented layout

Objective: LO9-5

126) A facilities manager at a company headquarters once said, "I'd like to use Muther's office relationship chart or the load-distance model to solve our layout problems, but neither tool can optimize. I want the best layout possible." Discuss.

Diff: 2

Topic: Office layout

AACSB: Reflective Thinking

Objective: LO9-1

127) What design guidelines help retail layouts to maximize customer exposure to products?

1. locating the high-draw items around the periphery of the store

2. using prominent locations for high-impulse and high-margin items

3. distributing what are known in the trade as "power items" to both sides of an aisle, and dispersing them to increase the viewing of other items

4. using end aisle locations because they have a very high exposure rate

5. conveying the mission of the store by careful selection in the positioning of the lead-off department

Diff: 2

Topic: Retail layout

Objective: LO9-2

128) Consider the five ideas for determining the overall arrangement of most retail stores. How are these ideas implemented (a) in a supermarket, and (b) in a fine department store? (Please consider the entire store--not just the areas where merchandise is displayed.)

Diff: 3

Topic: Retail layout

AACSB: Reflective Thinking

Objective: LO9-2

129) Briefly explain what "slotting" is. Why is slotting considered a "controversial" practice? What ethical issues might arise with regard to slotting?

Diff: 3

Topic: Retail layout

AACSB: Ethical Reasoning

Objective: LO9-2

130) What is a servicescape? How is it related to the retail layout problem? What are the three elements of servicescape for dealing with these human issues?

Diff: 2

Topic: Retail layout

Objective: LO9-2

131) What is cross-docking? Why is it appropriate for some forms of warehouse layout?

Diff: 2

Topic: Warehousing and storage layouts

Objective: LO9-3

132) What are the two basic types of product layouts? Explain how they are alike, and how they are different.

Diff: 3

Topic: Repetitive and product-oriented layout

Objective: LO9-7

133) Explain what the purpose of assembly line balancing is. Describe briefly how it is done. Explain how assembly line balancing supports the needs of product layout.

Diff: 3

Topic: Repetitive and product-oriented layout

Objective: LO9-7

134) Define the following terms that occur in assembly line balancing: cycle time, minimum number of workstations, and efficiency.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

135) What is the role of heuristics in solving layout problems? Provide a brief example, drawing from manufacturing situations, retailing situations, or other service situations.

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

136) Assembly line balancing has just been used to solve a product layout problem. Two solutions look especially attractive to the plant managers. Both solutions make the same output per day, and both have the same number of workstations. The managers were going to break the tie by looking at line efficiency, but discovered that both lines had the same efficiency as well. Should they have been surprised at this? Explain.

Diff: 3

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

137) What are the advantages and disadvantages of product layouts?

• The low variable cost per unit usually associated with high-volume, standardized products

• Low material handling costs

• Reduced work-in-process inventories

• Easier training and supervision

• Rapid throughput

The disadvantages are:

• The high volume required because of the large investment needed to establish the process

• That work stoppage at any point halts the whole operation

• A lack of flexibility when handling a variety of products or production rates

Diff: 2

Topic: Repetitive and product-oriented layout

Objective: LO9-7

138) Develop a solution for the following line balancing problem, allowing a cycle time of 5 minutes.

a. Draw the precedence diagram for the set of tasks.

b. Calculate the theoretical minimum number of workstations.

c. Balance this line using the longest task time heuristic.

d. What tasks are assigned to which stations?

e. Does the solution have the minimum number of stations? Explain.

f. How much idle time is there, summed over all workstations?

g. What is the efficiency of this line?

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

139) An assembly line has been designed to make battery-powered beverage mixers. Task details are shown in the table below:

a. What is the assigned cycle time (in minutes)?

b. What is the maximum output rate of this line in mixers per hour?

c. What is the total idle time per cycle?

d. What is the assembly line's efficiency?

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

140) Departments A, B, C, and D need to be assigned to four rooms 1, 2, 3, and 4. These rooms are arranged in a row, in that order, with 20 meters between each. The departmental work flows are contained in the table below.

a. What is the material handling total of assigning A-1, B-2, C-3, D-4?

b. What is the material handling total of assigning A-1, B-3, C-4, D-2?

(b) The material handling total of A-1, B-3, C-4, D-2 is 5400, which is also the optimal solution. Details: 1-2 (A-D): 20x20+20x10=600; 1-3 (A-B): 40x30+40x5=1400; 1-4 (A-C): 60x5+60x0=300; 2-3 (B-D): 20x20+20x5=500; 2-4 (C-D):40x40+40x0=1600; and 3-4 (B-C): 20x40+20x10=1000. These six elements sum to 5400.

Diff: 2

Topic: Process-oriented layout

AACSB: Analytic Skills

Objective: LO9-5

141) The flow and distance data in the table below were input into a layout software program, and solved by "pairwise comparison." That solution called for assignments A-4, B-1, C-3, and D-2, with a total movement of 2430. Verify that result. Is that solution optimal? Can you offer an improved solution? What is the total movement of your alternate solution?

Diff: 2

Topic: Process-oriented layout

AACSB: Analytic Skills

Objective: LO9-5

142) Cyclone Appliances has developed a new European-style convection oven that will be made on an assembly line. The schedule requires 80 ovens in an 8-hour day. The assembly includes seven tasks. The table below indicates the performance time and the sequence requirements for each task.

a. What is the cycle time for this assembly operation?

b. What is the theoretical minimum number of workstations?

c. Draw the precedence diagram.

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

143) An electronics manufacturer makes remote control devices for interactive-cable-TV systems. The following assembly tasks must be performed on each device.

a. Draw the precedence diagram for this problem.

b. What is the sum of the task times?

c. What cycle time will allow the production of 200 units over a ten-hour day?

d. What is the theoretical number of workstations needed?

e. Balance this assembly line using the heuristic most following tasks and the heuristic longest operation time.

f. How do these two solutions differ? Which do you prefer; why?

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

144) A company is designing a product layout for a new product. It plans to use this production line eight hours a day in order to meet a schedule of 400 units per day. The tasks necessary to produce this product are detailed in the table below.

a. Draw the network described in the table.

b. Without regard to a production schedule, what is the minimum possible cycle time (in seconds) for this situation; what is the maximum?

c. What is the required cycle time (in seconds) in order to meet the schedule?

d. What is the theoretical minimum number of workstations needed to meet the schedule?

e. Balance this line using longest processing time.

f. What is the efficiency of the balance obtained in part e?

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

145) You have been asked to balance a flow shop assembly operation to achieve an output rate of 80 units per eight-hour day. Task times and precedence relationships are shown in the table below.

a. Draw the precedence diagram.

b. Determine the desired cycle time.

c. Determine the theoretical minimum number of stations needed.

d. Balance this line using most following tasks.

e. What is the efficiency of the line obtained in part d?

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

146) A firm operates a flow shop building kitchen cabinetry for recreational vehicles. The major activities of this process are listed below.

a. Draw the appropriate network for this project.

b. What would the cycle time be if the goal is to produce 20 units per month (the plant operates

160 hours per month)?

c. What is the theoretical minimum number of workstations needed?

d. Balance with the most following tasks heuristic. What tasks are assigned to which stations?

e. What is the efficiency of the line obtained in part d?

(b) The cycle time is 160/20=8 hours; (c) This line requires at least 30/8=3.75 or 4 stations; (d) A and C are in Station 1; B is in Station 2; D is in Station 3; E and F occupy Station 4; and G and H are in Station 5. (e) Efficiency is 30/40=.75 or 75 percent.

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

147) There are three work centers (A, B, and C) behind the financial aid counter at a nearby university. They can each fit into any of three office spaces (1, 2, and 3) off the corridor behind the desk. There is no student contact in these areas, only workers. The distance 1-2 is 20 feet, 2-3 is 30 feet, and 1-3 is 50 feet. The matrix of work (trips per day) at the three centers is in the following table. Remember that each trip must be a round-trip (from 1 to 2 and back, for example).

a. How many possible assignments are there? List them.

b. Calculate the total distance traveled in each of these assignments.

c. Which assignment minimizes distance traveled?

Diff: 3

Topic: Process-oriented layout

AACSB: Analytic Skills

Objective: LO9-5

148) Hemo-tech, Inc., a biomedical technology and research laboratory, produces a standard blood filtering device on an assembly line basis. Six basic tasks are performed along an assembly line. The time to perform each task and the tasks that must immediately precede each task are in the table below. Twenty pumps per 450-minute day must be produced by the assembly line.

a. Draw the network diagram of the precedence relationships.

b. Identify the absolute minimum and maximum cycle times.

c. How many workstations are required to meet the schedule?

d. What is the cycle time required to meet demand?

e. Balance this line using most following tasks heuristic.

f. What is the efficiency of the line obtained in part e?

g. Can the efficiency of this solution be improved? Explain.

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

149) A firm is planning to set up an assembly line to assemble 40 units per hour, and 57 minutes per hour are productive. The time to perform each task and the tasks which precede each task are:

a. Draw a network diagram of precedence relationships.

b. Compute the required cycle time per unit in minutes.

c. Compute the theoretical minimum number of workstations required to produce 40 units per hour.

d. Balance this line using longest processing time.

e. What is the efficiency of the line obtained in part d?

Diff: 3

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

150) An insurance claims processing center has six work centers, any of which can be placed into any of six physical departmental locations. Call the centers 1, 2, 3, 4, 5, and 6, and the departments A, B, C, D, E, and F. The current set of assignments is A-3, B-1, C-6, D-2, E-4, and F-5.

The (symmetric) matrix of departmental distances, in meters is

The matrix of work flow (estimated trips per day) is among centers

The firm estimates that each trip costs approximately $4.

a. What is the cost of the current assignment?

b. Use trial-and-error to find one improved assignment.

c. What is that assignment, and what is its cost?

Diff: 3

Topic: Process-oriented layout

AACSB: Analytic Skills

Objective: LO9-5

151) An assembly line with 11 tasks is to be balanced. The longest task is 2.4 minutes, the shortest task is 0.4 minutes, and the sum of the task times is 18 minutes. The line will operate for 600 minutes per day.

a. Determine the minimum and maximum cycle times.

b. What range of output is theoretically possible for the line?

c. What is the minimum number of stations needed if the maximum output rate is to be sought?

d. What cycle time will provide an output rate of 200 units per day?

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

152) A facility is trying to set up an assembly line, and has identified the various tasks, and their relationship to each other, as shown in the following table. They wish to produce 600 units per day, working two 8-hour shifts.

a. Draw a network diagram of precedence relationships.

b. Compute the required cycle time per unit in seconds.

c. Compute the minimum number of workstations required to produce 600 units per day.

d. Balance this line using longest processing time.

e. What is the efficiency of the line obtained in part d?

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

153) A work cell is required to make 200 computerized diagnostic assemblies (for installation into hybrid automobiles) each day. The cell currently works an eight hour shift, of which seven hours is available for productive work. What is takt time for this cell?

Diff: 2

Topic: Work cells

AACSB: Analytic Skills

Objective: LO9-6

154) A work cell is scheduled to build 120 digital light processor (DLP) assemblies each week. These assemblies are later installed into home theater projection systems. The work cell has 7.5 hours of productive work each day, six days per week. What is takt time for this cell?

Diff: 2

Topic: Work cells

AACSB: Analytic Skills

Objective: LO9-6

155) A work cell is required to make 80 computerized diagnostic assemblies (for installation into hybrid automobiles) each day. The cell currently works an eight hour shift, of which seven hours is available for productive work. These assemblies require five operations, with times of 1.0, 0.8, 2.4, 2.5, and 1.4 minutes each. What is takt time for this cell? How many workers will be needed?

Diff: 2

Topic: Work cells

AACSB: Analytic Skills

Objective: LO9-6

156) A work cell is required to make 140 computerized diagnostic assemblies (for installation into hybrid automobiles) each day. The cell currently works an eight hour shift, of which seven hours is available for productive work. These assemblies require five operations. Standard times for these operations are: Operation A, 3.0 minutes, B, 1.8 minutes, C, 2.4 minutes, D, 2.5 minutes, and E, 1.4 minutes. What is takt time for this cell? How many workers will be needed to achieve this schedule? Use the grid below to construct a work balance chart for this cell.

Diff: 2

Topic: Work cells

AACSB: Analytic Skills

Objective: LO9-6

157) An airport is trying to balance where to place three airlines. The distance between terminals and the number of trips that travelers make between airlines per day are listed. Find the assignment that minimizes the distance travelers must walk.

A(1)-B(2)-C(3)=110(4000)+195(6000)+180(5000)=2510K

A(1)-B(3)-C(2)=110(5000)+195(6000)+180(4000)=2440K

A(2)-B(1)-C(3)=110(4000)+195(5000)+180(6000)=2495K

A(2)-B(3)-C(1)=110(6000)+195(5000)+180(4000)=2355K

A(3)-B(2)-C(1)=110(6000)+195(4000)+180(5000)=2340K

A(3)-B(1)-C(2)=110(5000)+195(4000)+180(6000)=2410K

Airline A should be assigned terminal 3, Airline B terminal 2 and Airline C terminal 1 to minimize the distance travelers must go.

Diff: 2

Topic: Process-oriented layout

AACSB: Analytic Skills

Objective: LO9-5

158) Brandon's computer shop has hired a consultant to help apply operation management techniques to increase profits. Currently the shop sells most of its computers to a high-end customized online retailer and sales are steady at 250 per month. A single work cell produces the computers. To produce the computer three operations are required. First the parts must be assembled, next software must be installed, and finally the computer must be safely packed and labeled for shipping. These operations take 2 hours, 5 hours, and 1 hour respectively. If there are 6 available work hours each day and the shop operates 20 days per month find:

A: The takt time

B: The number of workers Brandon should hire

Total operation time = 2+5+1=8hours. Workers required = Operation time/Takt Time = 8/.48 = 16.67 = 17 workers required.

Diff: 2

Topic: Work cells

AACSB: Analytic Skills

Objective: LO9-6

159) A manufacturing work cell has a takt time of 7 minutes and is staffed by 10 workers. If the work cell delivers 68 units each day find

A. The total operation time

B. The amount of time worked during the day for all 10 workers combined

C. If the plant is open for only 8 hours per day, can the staff meet demand?

Time worked = Takt time * Units Delivered * # workers = 7minutes*(68)*10 =4760 minutes = 79.33 hours

10 workers * 8hours/day = 80 hours per day are available. From B only 79.33 are required, so the workers can meet demand.

Diff: 2

Topic: Work cells

AACSB: Analytic Skills

Objective: LO9-6

160) A company is trying to balance production between 3 workstations on an assembly line. Currently there are 5 tasks that need to be performed. These tasks, ABCDE, have required times of 2 minutes, 4 minutes, 1 minutes, 3 minutes, and 10 minutes respectively. The assembly line needs to produce 40 units per day to meet demand and can work for up to 8 hours each day.

A. What is the required cycle time?

B. What is the theoretical minimum # of workstations?

C. Assign the tasks according to shortest task time.

D. Is there a better way to divide the work than in Part C?

Minimum # of workstations = Sum of task times / Cycle time = (2+4+1+3+10)/12 = 1.667 stations = 2 stations

Workstation A would be assigned Task C for a total of 1 minute, Task A for a total of 3 minutes, Task D for a total of 6 minutes, Task B for a total of 10 minutes. Task E cannot be assigned because 10+10 > 12 minutes. Therefore Task E would be assigned to station B for a total of 10 minutes. Station C would have no assignment.

The assignment method of Part C creates the optimum assignment (2 workstations = theoretical minimum). The company would be wise to eliminate the third workstation or to up production so that cycle time decreases and each workstation would be needed.

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7

161) An assembly line is assigned as follows. Station A- task A, B, and C. Station B- task D. Station C- task E and F. The task times are 7, 3, 2, 9, 4, and 5 minutes respective to A, B, C, D, E, and F. (Assume that there is no precedence relationships between the tasks, ie they can be accomplished in any order)

A. Calculate the efficiency.

B. What would the assignment of tasks to stations be using shortest processing time (assuming the current maximum station time remains the cycle time)?

Station A would be assigned task C for a total of 2 minutes, task B for a total of 5 minutes, Task E for a total of 9 minutes. Task F cannot be assigned because the total would be 14 minutes which is greater than the 12 maximum. Therefore Station B would be assigned task F for a total of 5 minutes and task A for a total of 12 minutes. Finally station C would be assigned task D for a total of 9 minutes.

Diff: 2

Topic: Repetitive and product-oriented layout

AACSB: Analytic Skills

Objective: LO9-7