Chapter 9 Layout Strategies

Operations Management 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. Answer: TRUE Diff: 1 Skill: knowledge Objective: Global company profile 2) The objective of layout strategy is to develop an effective and efficient layout that will meet the firm's competitive requirements. Answer: TRUE Diff: 1 Skill: knowledge Objective: The strategic importance of layout decisions 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. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 4) The layout approach that addresses trade-offs between space and material handling is called the fixed position layout. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO4 Identify when fixed-position layouts are appropriate 5) Utilization of the total "cube" is the dominant consideration in office layout. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO1 Discuss important issues in office layout 6) One guideline for a retail layout is to locate high-draw items around the periphery of the store. Answer: TRUE Diff: 2 Skill: knowledge Objective: LO2 Define the objectives of retail layout 1 7) Category management is the use of computer software to evaluate the profitability of merchandising plans. Answer: TRUE Diff: 2 Skill: knowledge Objective: LO2 Define the objectives of retail layout 8) Servicescape refers to the physical surrounding in which the service is delivered. Answer: TRUE Diff: 2 Skill: knowledge Objective: LO2 Define the objectives of retail layout 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. Answer: TRUE Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 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." Answer: TRUE Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 11) The dominant problem associated with the fixed-position layout is that workers are fixed in position, and cannot be reassigned. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO4 Identify when fixed-position layouts are appropriate 12) A process-oriented layout is the traditional way to support a product differentiation strategy. Answer: TRUE Diff: 1 Skill: knowledge Objective: LO5 Explain how to achieve a good process-oriented facility layout 13) Job lots are groups or batches of parts processed together. Answer: TRUE Diff: 1 Skill: knowledge Objective: LO5 Explain how to achieve a good process-oriented facility layout 2 14) Process-oriented layouts typically have low levels of work-in-process inventory. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 15) CRAFT is software for balancing assembly lines. Answer: FALSE Diff: 1 Skill: knowledge Objective: LO5 Explain how to achieve a good process-oriented facility layout 16) The most common tactic to arrange departments in a process-oriented layout is to minimize material handling costs. Answer: TRUE Diff: 2 Skill: knowledge Objective: LO5 Explain how to achieve a good process-oriented facility layout 17) The work cell improves process layouts by reducing floor space and by reducing direct labour cost. Answer: TRUE Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 18) The balancing of work cells uses the same procedures as the balancing of an assembly line. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 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. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 20) A fabrication line and an assembly line are both types of repetitive and product-focused layout, but only the fabrication line utilizes workstations. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 3 21) The biggest advantage of a product layout is its flexibility to handle a varied product mix. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 22) The minimum number of workstations depends upon the set of task times and the precedence chart, but not the number of units scheduled. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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. Answer: FALSE Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 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. Answer: TRUE Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 25) Product-oriented layouts tend to have high levels of work-in-process inventories. Answer: FALSE Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 26) One drawback of a product-oriented layout is that work stoppage at any one point ties up the whole operation. Answer: TRUE Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 27) Cycle time is the maximum time that the product is allowed at each workstation. Answer: TRUE Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 4 28) Heuristics are problem-solving procedures that mathematically optimize the solution. Answer: FALSE Diff: 2 Skill: knowledge Objective: LO7 Define product-oriented layout 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 Answer: A Diff: 1 Skill: knowledge Objective: Global company profile 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. Answer: B Diff: 2 Skill: knowledge Objective: The strategic importance of layout decisions 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) maximizing profitability per square foot of floor space. Answer: E Diff: 2 Skill: knowledge Objective: LO2 Define the objectives of retail layout 5 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 Answer: E Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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 Answer: C Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 34) Deloitte & Touche solved the empty desk problem by A) assigning permanent desks. B) implementing a "hoteling" program. C) creating open offices. D) no longer allowing employees to work from home. E) hiring more consultants. Answer: B Diff: 2 Skill: knowledge Objective: LO1 Discuss important issues in office layout 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) process-oriented layout. Answer: E Diff: 2 Skill: knowledge Objective: LO5 Explain how to achieve a good process-oriented facility layout 6 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) job shop D) work cell E) warehouse layout Answer: D Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 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. Answer: E Diff: 2 Skill: comprehension Objective: Types of layout 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. Answer: E Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 39) Slotting fees A) are charged by wholesalers to stock a product. B) can amount to as much as $100,000. C) are part of Wal-Mart's business practices. D) can increase the ability of small businesses to introduce new products. E) are paid by manufacturers to retailers. Answer: E Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 7 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) arbitrarily selecting the position of the lead-off department Answer: E Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 41) What is the primary reason why retailers tend to locate high-draw items around the periphery of the store? A) More shelf space for those popular items is available around the periphery. B) There will be less congestion of customers than there would be in the middle. C) This arrangement will help to maximize customer exposure to other items in the store. D) It is easier to put large advertisement signs on the outside walls right next to the items. E) This arrangement allows customers to travel through the store as quickly as possible. Answer: C Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 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) a department store Answer: D Diff: 2 Skill: comprehension Objective: LO4 Identify when fixed-position layouts are appropriate 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 Answer: C Diff: 3 Skill: comprehension Objective: LO4 Identify when fixed-position layouts are appropriate 8 44) Because problems with fixed-position layouts are so difficult to solve well onsite, 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 defence contractors. Answer: D Diff: 2 Skill: comprehension Objective: LO4 Identify when fixed-position layouts are appropriate 45) Which of the following is not one of the factors complicating the techniques for addressing the fixed position layout? A) The volume of materials is dynamic. B) At different stages of a project, different materials are needed; therefore, different items become critical as the project develops. C) Takt times at workstations are dynamic. D) There is limited space at virtually all sites. E) There are too few critical items involved. Answer: C Diff: 2 Skill: comprehension Objective: LO4 Identify when fixed-position layouts are appropriate 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. Answer: A Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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 labour assignment. D) smooth and continuous flow of work. E) its ability to handle high volume, low variety. Answer: C Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 9 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. Answer: B Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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 Answer: D Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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. Answer: D Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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 labour. B) maximize the machine utilization. C) allocate the available space equally to all the departments. D) minimize the costs of material handling. E) do not incur distance-related costs. Answer: D Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 10 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 Answer: C Diff: 1 Skill: knowledge Objective: LO1 Discuss important issues in office layout 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 labour assignments C) low variety of products D) high volume of output E) often solved by assembly line balancing Answer: B Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 54) A big advantage of a process-oriented layout is A) its flexibility in equipment and labour assignments. B) its low cost. C) the simplified scheduling problem presented by this layout strategy. D) the ability to employ low-skilled labour. E) its high equipment utilization. Answer: A Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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. Answer: E Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 11 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. Answer: B Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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) It is focused mainly on supplier relations. E) It is focused mainly on large machines. Answer: A Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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 Answer: A Diff: 2 Skill: knowledge Objective: LO1 Discuss important issues in office layout 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 Answer: A Diff: 2 Skill: comprehension Objective: LO1 Discuss important issues in office layout 12 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 Answer: D Diff: 2 Skill: comprehension Objective: LO1 Discuss important issues in office layout 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 Answer: C Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 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. Answer: D Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 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. Answer: E Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 13 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 Answer: E Diff: 2 Skill: knowledge Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 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) reducing the dependence on ASRS. Answer: C Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 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) does not support competitive advantage. Answer: D Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 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) automated stocking and removal system. Answer: A Diff: 1 Skill: knowledge Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 14 68) Which of the following is true of random stocking? A) Because items are stocked randomly, accurate inventory records are not necessary. 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) It maintains accurate records of existing inventory and its locations. Answer: E Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 69) Cross-docking is A) seldom 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) not applicable for a low-cost strategy. E) not useful in reducing product handling costs. Answer: A Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 70) Which one of the following is not common to repetitive and product-oriented layouts? A) a high rate of output B) specialization of labour C) ability to adjust to changes in demand D) low unit costs E) reduced work in process inventory Answer: C Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 71) Which of the following is not an advantage of work cells? A) reduced direct labour 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 Answer: B Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 15 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. Answer: B Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 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. Answer: A Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 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 Answer: D Diff: 2 Skill: application Objective: LO5 Explain how to achieve a good process-oriented facility layout 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. Answer: A Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 16 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 Answer: B Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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 Answer: B Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 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 Answer: B Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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 Answer: A Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 17 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 Answer: B Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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 are an appropriate assumption. Answer: C Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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) warehouse layout D) product-oriented layout E) work cell layout Answer: D Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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) They are usually not machine-paced. Answer: D Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 18 84) The central problem in product-oriented layout planning is A) minimizing material handling within workstations. B) minimizing labour 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. Answer: E Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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 are a disadvantage of product-oriented layouts. Answer: D Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 86) The main advantage of a product-oriented layout is typically A) high customer exposure rates. B) employability of highly skilled labour. C) high flexibility. D) low capital cost. E) low variable cost per unit. Answer: E Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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. Answer: D Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 19 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. Answer: D Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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) inverse of the minimum number of workstations needed. D) sum of all the task times divided by the maximum number of workstations. E) equivalent of the maximum task time among all tasks. Answer: B Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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. Answer: B Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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. After line balancing, the longest possible assigned task time is ________ and the shortest possible assigned task 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 Answer: C Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 20 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. Answer: D Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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. Answer: A Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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 Answer: A Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 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 Answer: C Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 21 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 Answer: D Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 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 Answer: C Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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. Answer: E Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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) average takt time Answer: D Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 22 100) An assembly line consists of 21 tasks grouped into 5 workstations. The sum of the 21 task times is 85 minutes. The largest assigned cycle time is 20 minutes. The efficiency of this line is A) 4.2%. B) 17%. C) 85%. D) 100%. E) 126%. Answer: C Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 101) An assembly line consists of 158 tasks grouped into 32 workstations. The sum of all task times is 105 minutes. The largest assigned cycle time is 4 minutes. The efficiency of this line is approximately A) 8%. B) 21%. C) 82%. D) 100%. E) 158%. Answer: C Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 102) McDonald's "Made for You" kitchen system represents a ________ use of layout decisions. Answer: strategic Diff: 1 Skill: knowledge Objective: LO5 Explain how to achieve a good process-oriented facility layout 103) ________ layouts deal with low-volume, high-variety production with like machines and equipment grouped together. Answer: Process-oriented Diff: 1 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 104) A(n) ________ is a special product-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility. Answer: work cell Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 23 105) A(n) ________ groups workers, their equipment, and spaces/offices to provide for comfort, safety, and movement of information. Answer: office layout Diff: 2 Skill: comprehension Objective: LO1 Discuss important issues in office layout 106) The ________ is a non-numeric method for determining which departments are located near one another, and which departments are kept farther apart. Answer: office relationship chart or relationship chart Diff: 2 Skill: comprehension Objective: LO1 Discuss important issues in office layout 107) A(n) ________ addresses flow, allocates space, and responds to customer behavior. Answer: retail layout Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 108) ________ are fees manufacturers pay to get their products displayed. Answer: Slotting fees Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 109) ________ refers to the physical surroundings in which a service takes place, and how they affect customers and employees. Answer: Servicescape Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 110) ________ avoids placing materials or supplies in storage by processing them as they are received for shipment. Answer: Cross-docking Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 111) The project remains in one place and workers and equipment come to that one work area in a ________ layout. Answer: fixed-position Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 24 112) ________ is the use of computer software to evaluate the profitability of merchandising plans in a retail layout. Answer: Category management Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 113) ________ is that element of balancing a work cell that superficially resembles cycle time. Answer: Takt time Diff: 2 Skill: comprehension Objective: LO6 Define work cell and the requirements of a work cell 114) A(n) ________ line is a machine-paced product-oriented facility for building components. Answer: fabrication Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 115) ________ is the maximum time that the product is available at each workstation. Answer: Cycle time Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 116) Identify McDonald's "seven major innovations." Answer: The seven major innovations are indoor seating, drive-through windows, breakfast menus, play areas, the "Made for You" kitchen system, the self-service kiosk, and the 21st century look. Diff: 2 Skill: comprehension Objective: Global company profile 117) In what specific areas does the layout decision establish a firm's competitive priorities? Answer: Layout decisions establish a firm's competitive priorities in the following areas: processes, flexibility, cost, capacity, and quality of work life. Diff: 2 Skill: comprehension Objective: The strategic importance of layout decisions 118) To develop a good facility layout, what must be determined? Answer: You need to consider the following to determine a good layout: selection of material handling equipment, capacity and space requirements, environment and aesthetics, flows of information, and cost of moving between various work areas. Diff: 2 Skill: comprehension Objective: Types of layout 25 119) Identify the seven fundamental layout strategies. Describe the use of each one very briefly. Answer: 1. Office layout: Positions workers, their equipment, and spaces/offices to provide for movement of information. 2. Retail layout: Allocates shelf space and responds to customer behaviour. 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 Skill: comprehension Objective: LO1 Discuss important issues in office layout 120) What techniques can be used to overcome the inherent problems of fixed-position layouts? Answer: Some actions that can be taken to overcome the problems of a fixed-position layout are to develop good schedules, accurately define requirements, and take a rational approach to the layout, as opposed to politicizing the decision. Diff: 2 Skill: comprehension Objective: LO4 Identify when fixed-position layouts are appropriate 121) "Having a focused work centre is like having a factory within a factory." Discuss. Include in your discussion what conditions make focused work centers appropriate. Answer: A focused work centre is a permanent product-oriented set of equipment within a process-oriented facility. It requires group technology or equivalent, a high level of staff training and flexibility, and good support or imagination to get started. Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 122) Why do work cells increase the use of equipment and machinery? Answer: Work cells increase the use of equipment and machinery because of better scheduling and faster material flow. Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 123) What are the advantages of focused factories? Answer: Focused factories are better able to stay in tune with their customers, produce quality products, and operate at higher margins. Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 26 124) Explain how a load-distance model helps solve problems in process layout. Answer: The problem in process layout is to hold down material movement and material handling. The load-distance model calculates these movements from department to department, and can find that set of departmental space assignments that minimize the aggregate material handling cost. This is an optimal layout for a process layout, given the pattern of loads and distances. Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 125) Identify the four requirements for cellular production. Answer: (1) identification of families of products, often through the use of group technology codes or equivalents; (2) a high level of training, flexibility, and empowerment of employees; (3) being self-contained, with its own equipment and resources; and (4) test (poka-yoke) at each station in the cell. Diff: 2 Skill: comprehension Objective: LO5 Explain how to achieve a good process-oriented facility layout 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. Answer: The manager should not be so quick to reject models that find satisfactory, but not necessarily optimal, solutions. The load-distance model can optimize relatively small problems, but large problems are beyond the explicit enumeration required for optimization. That's why CRAFT and other software seek "acceptable" solutions. The office relationship diagram is not an optimizing tool at all, as it uses labels, not numbers, to indicate desirability of closeness. Diff: 2 Skill: comprehension Objective: LO1 Discuss important issues in office layout 127) What design guidelines help retail layouts to maximize customer exposure to products? Answer: Design guidelines that help retail layouts maximize customer exposure to products include: 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 Skill: comprehension Objective: LO2 Define the objectives of retail layout 27 128) 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.) Answer: (Suggested response) The five ideas are: 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 image of the store by careful selection in the positioning of the lead-off department. Supermarkets make more use of aisles, where ideas 3 and 4 are featured. Department stores are meandering, so there's less use of end-caps. Both types of retail seem to follow ideas 1 and 5. Idea 2 seems to be implemented with impulse items near the checkouts for both retail types. The supermarket's straight lines convey its strategy of low cost; the department store's display areas convey its focus on image, browsing, etc. Diff: 3 Skill: application Objective: LO2 Define the objectives of retail layout 129) Briefly explain what "slotting" is. Why is slotting considered a "controversial" practice? What ethical issues might arise with regard to slotting? Answer: Slotting is the practice of manufacturers paying for retail shelf space. It is controversial because some managers approve of the practice, but others do not. Ethical issues involved with slotting are (1) such payments might be considered bribery, (2) such payments cost consumers more, and (3) such payments may interfere with efficient and profitable use of retail space. Diff: 3 Skill: application Objective: LO2 Define the objectives of retail layout 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? Answer: Servicescape describes the physical surroundings in which a service takes place. Rather than design a retail space strictly for profitability, managers must consider how the surroundings —the layout—have a humanistic effect on customers and employees. The three elements are ambient conditions, spatial layout/functionality, and signs, symbols, and artifacts. Diff: 2 Skill: comprehension Objective: LO2 Define the objectives of retail layout 131) What is cross-docking? Why is it appropriate for some forms of warehouse layout? Answer: Cross-docking avoids placing materials or supplies in storage by processing them as they are received for shipment. It avoids storing the product, saves space and receiving time, and speeds up shipment to the ultimate destination. Diff: 2 Skill: comprehension Objective: LO3 Discuss modern warehouse management and terms such as ASRS, crossdocking, and random stocking 28 132) What are the two basic types of product layouts? Explain how they are alike, and how they are different. Answer: The two types are fabrication lines and assembly lines. Fabrication lines build components on a series of machines, while assembly lines put the fabricated parts together at a series of workstations. Fabrication lines tend to be machine paced and require mechanical changes to facilitate balance, while assembly lines tend to be paced by work tasks assigned to individuals or to workstations and are therefore balanced by moving tasks from one individual to another. Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 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. Answer: Assembly line balancing attempts to put equal amounts of work into each of the workstations that assemble a product. The technique begins with a task list and precedence chart; to this is added demand data, from which cycle time can be computed. This is the speed at which the line must move. Then the theoretical number of stations is calculated. Each required task is then assigned into one workstation. This approach holds down the amount of idle time in a product layout, and leads to higher utilization of the plant, and to higher volume of output. Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 134) Define the following terms that occur in assembly line balancing: cycle time, minimum number of workstations, and efficiency. Answer: Cycle time is the ratio of allowed work time to units scheduled. The theoretical minimum number of workstations in an assembly line is determined by dividing the total taskduration time for the product by the cycle time. The efficiency of a line balance is determined by dividing the total task time assigned by the product of the number of workstations times the cycle time. Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 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. Answer: Heuristics are used in problems too complex to model explicitly, such as assembly line balancing problems, fixed-position layouts, office layouts, and retail layouts. All of these layout types are quite complex, featuring very large numbers of alternative solutions and no single numeric objective for evaluating them. Diff: 2 Skill: comprehension Objective: LO7 Define product-oriented layout 29 136) 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. Answer: No, they should not be surprised. Efficiency is the ratio of actual work needed per unit to time available. Work needed is clearly the same in both cases as the product is the same. Work available is also the same, since both lines have the same number of stations and the same cycle time. Once cycle time and number of stations are known, so is efficiency, no matter what tasks are assigned to what stations within that framework. Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 137) What are the advantages and disadvantages of product layouts? Answer: The advantages of a product layout are: • 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 Skill: comprehension Objective: LO7 Define product-oriented layout 30 138) 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? Immediate Task Time (seconds) Predecessor(s) A 70 B 60 A C 120 B D 60 E 240 C, D F 100 A G 190 E, F Answer: The theoretical minimum number of workstations is 3. Balance places ABDF in station 1, C in station 2, E in station 3, and G in station 4. The solution uses four stations, not three. The POM for Windows solution is shown below. Idle time is distributed 10, 180, 60, and 110 per station. There are 360 seconds of idle time in the system. Efficiency is 70.0%. Work Task 31 Station Task Time (seconds) 1 A F D B C E G 70. 100. 60. 60. 120. 240. 190. 2 3 4 Summary Statistics Cycle time 300 seconds Time allocated (cycle time * #) 1200 seconds/cycle Time needed (sum of task times) 840 seconds/unit Idle time (allocated-needed) 360 seconds/cycle Efficiency (needed/allocated) 70% Balance Delay (1-efficiency) 30% Min (theoretical) # of stations 3 Diff: 2 Skill: application Objective: LO7 Define product-oriented layout Time left Ready (seconds) tasks A,D 230. D,B,F 130. D,B 70. B 10. C 180. E 60. G 110. 139) An assembly line has been designed to make battery-powered beverage mixers. Task details are shown in the table below: Station 1 2 3 4 5 6 Task Assigned 1 3; 4 2; 5; 6 7 8 9; 10; 11 Task Time (minutes) 3.0 1.5; 2.0 1.5; 1.5; 1.0 3.0 2.5 2.0; 1.0; 1.0 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? Answer: Cycle time is 4.0 minutes (governed by stations 3 and 6). Maximum output is 60/4 = 15.0 units per hour. Idle time is 1.0 + 0.5 + 0.0 + 1.0 + 1.5 + 0 = 4.0 minutes. Efficiency is 20.0/24.0 = 83.3%. Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 32 140) 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? Answer: (a) The material handling total of A-1, B-2, C-3, D-4 is 5500. Details: 1-2 (A-B): 20 × 30 + 20 × 5 = 700; 1-3 (A-C): 40 × 5 + 40 × 0 = 200; 1-4 (A-D): 60 × 20 + 60 × 10 = 1800; 2-3 (B-C): 20 × 40 + 20 × 10 = 1000; 2-4 (B-D): 40 × 20 + 40 × 5 = 1000; and 3-4 (C-D): 20 × 40 + 20 × 0 = 800. The sum of these six elements is 5,500. (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): 20 × 20 + 20 × 10 = 600; 1-3 (A-B): 40 × 30 + 40 × 5 = 1400; 1-4 (A-C): 60 × 5 + 60 × 0 = 300; 2-3 (B-D): 20 × 20 + 20 × 5 = 500; 2-4 (C-D): 40 × 40 + 40 × 0 = 1600; and 3-4 (B-C): 20 × 40 + 20 × 10 = 1000. These six elements sum to 5400. Diff: 3 Skill: application Objective: LO5 Explain how to achieve a good process-oriented facility layout 33 141) 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 D2, 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? Flow Table A B C D A 0 0 0 5 B 5 0 2 12 C 8 7 0 4 D 3 6 9 0 Fixed room Distance Table Room 1 Room 2 Room 3 Room 4 Room 1 0 30 60 80 Room 2 30 0 30 50 Room 3 60 30 0 20 Room 4 80 50 20 0 Answer: The six elements of movement in the original solution are 1-2 (B-D): 6 × 30 + 12 × 30 = 540; 1-3 (B-C): 7 × 60 + 2 × 60 = 540; 1-4 (A-B): 5 × 80 + 0 × 80 = 400; 2-3 (C-D): 9 × 30 + 4 × 30 = 390; 2-4 (A-D): 3 × 50 + 5 × 50 = 400; and 3-4 (A-C): 8 × 20 + 0 × 20 = 160. The sum of these six elements is 2430. This solution is not necessarily optimal because the pairwise comparison technique does not inspect all possible solutions. Another possible solution is A-4, B-1, C-2, and D-3, which has a total movement of 2700. The optimal assignment of departments to rooms is A-1, B-4, C-2, and D-3, which has a total movement of 2320. C is thus put farther from B and closer to A, which helps reduce movement. Diff: 3 Skill: application Objective: LO5 Explain how to achieve a good process-oriented facility layout 34 142) 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. Task A B C D E F G Performance Time (minutes) 1 2 3 2 4 1 2 Task must follow Task listed below A B B C, D E F a. What is the cycle time for this assembly operation? b. What is the theoretical minimum number of workstations? c. Draw the precedence diagram. Answer: (a) The cycle time is 480 minutes per day / 80 ovens = 6 minutes/oven. (b) The theoretical minimum number of workstations is the sum of all task times, 15 minutes, divided by the cycle time, 6 minutes; 15 / 6 = 2.5 or 3 workstations. (c) The precedence diagram appears below. Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 35 143) An electronics manufacturer makes remote control devices for interactive-cable-TV systems. The following assembly tasks must be performed on each device. Task Description Predecessor(s) Time (min.) A Place circuit into circuit frame -0.50 Solder circuit connections to central circuit A 0.70 B control C Place circuit assembly in device frame B 0.40 D Attach circuit assembly to device frame C 0.30 E Place and attach display to frame -0.30 F Place and attach keypad to frame -0.20 G Place and attach top body of device to frame E, F 0.35 H Place and attach battery holder to frame D 0.40 Place and attach bottom body of device to I G, H 0.60 frame J Test device I 0.30 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? Answer: The sum of the task times is 4.05 minutes. The cycle time for 200 units output is 600/200 = 3 minutes. The theoretical minimum number of stations is 4.05/3 = 1.35 or 2. Both solutions use two stations and have 67.5% efficiency. 36 Station Task Time (minutes) Time left (minutes) 1 A B C E F D G H I J 0.5 0.7 0.4 0.3 0.2 0.3 0.35 0.4 0.6 0.3 2.5 1.8 1.4. 1.1 0.9 0.6 0.25 2.6 2. 1.7 2 Summary Statistics Cycle time 3 Time allocated (cycle time ∗ #) 6 Time needed (sum of task times) 4.05 Idle time (allocated-needed) 1.95 Efficiency (needed/allocated) 67.5% Balance Delay (1-efficiency) 32.5% Min (theoretical) # of stations2 minutes minutes/cycle minutes/unit minutes/cycle 37 Ready tasks (#followers) A(6),E(3),F(3) E(3),F(3),B(5) E(3),F(3),C(4) E(3),F(3),D(3) F(3),D(3) D(3),G(2) G(2),H(2) H(2) I(1) J(0) Station 1 2 Time Time left (minutes) (minutes) Task A B C E D H F G I J 0.5 0.7 0.4 0.3 0.3 0.4 0.2 0.35 0.6 0.3 2.5 1.8 1.4. 1.1 0.9 0.4 0.2 2.65 2.05 1.75 Summary Statistics Cycle time 3 minutes Time allocated (cycle time * #) 6 minutes/cycle Time needed (sum of task times) 4.05 minutes/unit Idle time (allocated-needed) 1.95 minutes/cycle Efficiency (needed/allocated) 67.5% Balance Delay (1-efficiency) 32.5% Min (theoretical) # of stations 2 Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 38 Ready tasks A,E,F E,F,B E,F,C E,F,D F,D F.H F G I J 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. Task Predecessor(s) A B C D E F A B, D C, E Time (seconds) 50 36 26 22 70 30 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? Answer: The network diagram appears below. Minimum cycle time is 70 seconds (the longest task time); maximum cycle time is 234 seconds (sum of the task times). Required cycle time is 480/400 = 1.2 minutes or 72 seconds (which is barely feasible). The theoretical minimum number of stations required is at least 234/72 = 3.25 or 4. 39 Station Task Time (seconds) 1 A D B C E F 50. 22. 36. 26. 70. 30. 72 Seconds 288 seconds/cycle 2 3 4 Summary Statistics Cycle time Time allocated (cycle time ∗ #) Time needed (sum of task times) Idle time (allocated-needed) Time left Ready (seconds) tasks A,C,D 22. C,D,B 0. C,B 36. C,E 10. E 2. F 42. 234 seconds/unit 54 seconds/cycle 81.25 Efficiency (needed/allocated) % 18.75 Balance Delay (1-efficiency) % Min (theoretical) # of stations4 Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 40 145) 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. Task Predecessor(s) A B C D E F G H --A, B --C E, F D, G Duration (minutes) 1.4 0.8 0.4 1.8 0.4 2.1 2.0 1.2 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? Answer: The precedence diagram appears below. The desired cycle time for 80 units is 6 minutes. The theoretical minimum number of stations is 10.1 / 6 = 1.68 or 2. 41 Station Task Time (minutes) 1 A B C E F D G H 1.4 0.8 0.4 0.4 2.1 1.8 2. 1.2 2 Time left Ready tasks (minutes) (#followers) A(4),B(4),D(1),E(2) 4.6 B(4),D(1),E(2) 3.8 D(1),E(2),C(3) 3.4 D(1),E(2),F(2) 3. D(1),F(2) 0.9 D(1),G(1) 4.2 G(1) 2.2 H(0) 1. Summary Statistics Cycle time 6 minutes Time allocated (cycle time ∗ #) 12 minutes/cycle Time needed(sum of task times) 10.1 minutes/unit Idle time (allocatedneeded) 1.900001 minutes/cycle Efficiency (needed/allocated) 84.16666% Balance Delay (1efficiency) 15.83334% Min (theoretical) # of stations 2 Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 42 146) A firm operates a flow shop building kitchen cabinetry for recreational vehicles. The major activities of this process are listed below. Task A B C D E F G H Duration Predecessors (hours) 4 -6 -2 A 6 A 3 B, C 3 B, C 5 D, E, F 1 G 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? Answer: 43 Station Task Time (hours) 1 A C B D E F G H 4. 2. 6. 6. 3. 3. 5. 1. 2 3 4 5 Time left Ready tasks (hours) (#followers) A(6),B(4) 4. B(4),C(4),D(2) 2. B(4),D(2) 2. D(2),E(2),F(2) 2. E(2),F(2) 5. F(2) 2. G(1) 3. H(0) 2. Summary Statistics Cycle time 8 hours Time allocated (cycle time ∗ #) 40 hours/cycle Time needed (sum of task times) 30 hours/unit Idle time (allocatedneeded) 10 hours/cycle Efficiency (needed/allocated) 75% Balance Delay (1efficiency) 25% Min (theoretical) # of stations 4 (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%. Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 44 147) 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 B C A -45 60 B 20 -0 C 0 25 -- 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? Answer: (a) There are 3! = 6 assignments, listed in the table below. (b) The cost, in feet, of each assignment appears in the table below. (c) The lowest cost assignment is A-2, B-1, C-3. A B C Cost 1 2 3 10,100 1 3 2 10,400 2 1 3 8,700 2 3 1 8,800 3 1 2 11,100 3 2 1 10,900 Diff: 3 Skill: application Objective: LO5 Explain how to achieve a good process-oriented facility layout 45 148) 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. Task A B C D E F Immediate Predecessors -A -B, C D E Time to perform (min.) 5.40 3.20 1.50 2.80 17.10 12.80 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. Answer: (a) The appropriate diagram appears below. (b) The absolute minimum cycle time is 17.10 minutes (the longest operation). The absolute maximum cycle time is 42.80 minutes (the sum of all task times). (c) The theoretical minimum number of stations is 42.8/22.5 = 1.90 or 2, but the actual number of stations needed is 3. (d) The required cycle time is 450/20 = 22.5 minutes. (e) The balanced line appears below. (f) The line's efficiency is only 63%. (g) There is idle time at all stations; removing the smallest amount of idle time (5.4 minutes) from all stations reduces the cycle time from 22.5 minutes to 17.1 minutes. The efficiency of the line rises to 83%. 46 Station Task Time (minutes) 1 A C B D E F 5.4 1.5 3.2 2.8 17.1 12.8 2 3 Summary Statistics Cycle time 22.5 minutes Time allocated (cycle time ∗ #) 67.5 minutes/cycle Time needed (sum of task times) 42.8 minutes/unit Idle time (allocatedneeded) 24.7 minutes/cycle Efficiency (needed/allocated) 63.40741% Balance Delay (1efficiency) 36.59259% Min (theoretical) # of stations 2 47 Time left Ready tasks (minutes) (#followers) A(4),C(3) 17.1 C(3),B(3) 15.6 B(3) 12.4 D(2) 9.6 E(1) 5.4 F(0) 9.7 Station 1 Task A C B D E F Time (minutes) 5.4 1.5 3.2 2.8 17.1 12.8 2 3 Summary Statistics Cycle time 17.1 minutes Time allocated (cycle time ∗ #) 51.3 minutes/cycle Time needed (sum of task times) 42.8 minutes/unit Idle time (allocatedneeded) 8.500004 minutes/cycle Efficiency (needed/allocated) 83.43079% Balance Delay (1efficiency) 16.56921% Min (theoretical) # of stations 2 Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 48 Time left Ready (minutes) tasks 11.7 C(3),B(3) 10.2 B(3) 7. D(2) 4.2 E(1) 0. F(0) 4.3 149) 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: Task A B C D E F G H I Time to Preceding Task perform (min.) -.69 A .55 B .92 B .59 B .70 B 1.10 C, D, E .75 G, F .43 H .29 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? Answer: (a) The appropriate diagram appears below. (b) Cycle time is 57/40 = 1.425 minutes. (c) The theoretical minimum number of stations required is 6.02/1.425 = 4.22 or 5. (d) The balanced line appears in the software output panel below. (e) The line's efficiency is 6.02 / 8.55 = 70.4% 49 Station Task Time (minutes) 1 A B F C E D G H I 0.69 0.55 1.1 0.92 0.7 0.59 0.75 0.43 0.29 2 3 4 5 6 Summary Statistics Cycle time 1.425 minutes Time allocated (cycle time ∗ #) 8.549999 minutes/cycle Time needed (sum of task times) 6.02 minutes/unit Idle time (allocatedneeded) 2.529999 minutes/cycle Efficiency (needed/allocated) 70.40936% Balance Delay (1efficiency) 29.59064% Min (theoretical) # of stations 5 Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 50 Time left Ready (minutes) tasks A 0.735 B 0.185 C,D,E,F 0.325 C,D,E 0.505 D,E 0.725 D 0.135 G 0.675 H 0.245 I 1.135 150) 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 1 2 3 4 5 6 1 -- 2 5 -- 3 30 40 -- 4 20 15 50 -- 5 15 10 20 10 -- 6 20 10 5 35 5 -- The matrix of work flow (estimated trips per day) is among centers A B C D E F A -20 0 30 40 0 B 15 -50 60 0 0 C 20 50 -20 0 30 D 0 0 30 -10 20 E 30 160 0 70 -50 F 0 10 30 0 60 -- 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? Answer: (a) The current assignment costs 14,000 meters, or $56,000. (b,c) The optimal solution is 10,450 meters, or $41,800, with A-3, B-5, C-4, D-1, E-6, and F-2. Students may find improved solutions other than the optimal solution. Diff: 3 Skill: application Objective: LO5 Explain how to achieve a good process-oriented facility layout 51 151) 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? Answer: Minimum cycle time is 2.4 minutes. Maximum cycle time is 18 minutes. Maximum output is 600/2.4 = 250; minimum output is 600/18 = 33.3. For maximum output, 18/2.4 = 7.5 or 8 stations will be needed. To produce 200 units per day requires a 3-minute cycle time. Diff: 2 Skill: application Objective: LO7 Define product-oriented layout 52 152) 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. Task Preceding Task A B C D E F G H ----A D, B, C E F, G Time to perform (sec.) 20 30 25 10 55 30 25 40 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? Answer: (a) The precedence diagram appears below. (b) Required cycle time is 96 seconds. (c) 2.45 or 3 workstations are needed. (d) The computer output places tasks A-B-C-D in station 1, EF in station 2, and G-H in station 3. (e) Efficiency is about 82%. 53 Station Task Time (seconds) 1 B C A D E F G H 30. 25. 20. 10. 55. 30. 25. 40. 2 3 Time left Ready (seconds) tasks A,B,C,D 66. A,C,D 41. A,D 21. D,E 11. E,F 41. F,G 11. G 71. H 31. Summary Statistics Cycle time 96 seconds Time allocated (cycle time ∗ #) 288 seconds/cycle Time needed (sum of task times) 235 seconds/unit Idle time (allocatedneeded) 53 seconds/cycle Efficiency (needed/allocated) 81.59722% Balance Delay (1efficiency) 18.40278% Min (theoretical) # of stations 3 Diff: 3 Skill: application Objective: LO7 Define product-oriented layout 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? Answer: Takt time = 420 minutes / 200 units required = 2.1 minutes Diff: 2 Skill: application Objective: LO6 Define work cell and the requirements of a work cell 154) A work cell is scheduled to build 120 digital light processor (DLP) assemblies each week. These assemblies are later installed into home theatre 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? Answer: The cell has 7.5 × 6 = 45 hours (or 2700 minutes) of work time each week. Takt time = 2700 / 120 = 22.5 minutes. Diff: 2 Skill: application Objective: LO6 Define work cell and the requirements of a work cell 54 155) 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? Answer: Takt time = 420 minutes / 80 units = 5.25 minutes. Total operation time is 1.0 + 1.8 + 2.4 + 2.5 + 1.4 = 9.1 minutes. Workers required = 9.1 / 5.25 = 1.73 or 2. Diff: 2 Skill: application Objective: LO6 Define work cell and the requirements of a work cell 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. Answer: Takt time = 420 / 140 = 3 minutes/unit. Total operation time = 3.0 + 1.8 + 2.4 + 2.5 + 1.4 = 11.1 minutes. A minimum of four workers are required (11.1 / 3 = 3.7), but to balance at 3 min./unit requires five. The balance chart appears below. Diff: 3 Skill: application Objective: LO6 Define work cell and the requirements of a work cell 55 157) 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. Airline Trips to A Trips to B Trips to C Terminal Distance to Terminal 1 Distance to Terminal 2 Distance to Terminal 3 A 50 100 1 B 60 75 2 C 80 120 3 - 4000 5000 4000 - 6000 5000 6000 - Answer: There are 6 possible assignments and the distance traveled for each scenario is 110(Distance A-B) + 195(Distance C-B) + 180(Distance A-C) = total distance 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: 3 Skill: application Objective: LO5 Explain how to achieve a good process-oriented facility layout 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 Answer: Takt time = (6 hours/day ∗ 20 days/month)/(250 units/month) = .48 hours per computer. Total operation time = 2 + 5 + 1 = 8 hours. Workers required = Operation time/Takt Time = 8/.48 = 16.67 = 17 workers required. Diff: 2 Skill: application Objective: LO6 Define work cell and the requirements of a work cell 56 159) 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? Answer: Total operation time = Workers required ∗ Takt time = 10(7 minutes) = 70 minutes Time worked = Takt time ∗ Units Delivered ∗ # workers = 7 minutes∗(68)∗10 = 4760 minutes = 79.33 hours 10 workers ∗ 8 hours/day = 80 hours per day are available. From B only 79.33 are required, so the workers can meet demand. Diff: 2 Skill: application Objective: LO6 Define work cell and the requirements of a work cell 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? Answer: Required cycle time = Production time available / Units required = 8 hours ∗ 60 minutes / 40 units = 12 minutes 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 Skill: application Objective: LO7 Define product-oriented layout 57 161) 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)? Answer: Efficiency = Sum of task time / (# Stations ∗ Longest Station duration) = (7 + 3 + 2 + 9 + 4 + 5)/(3∗12) = 83.3% 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 Skill: application Objective: LO7 Define product-oriented layout 58