Deck 6: Manufacturing Processes

Question 1

Engineer-to-order firms will work with the customer to design the product, and then make it from purchased materials, parts, and components.

Answer 1

True

Question 2

The term "assembly line" refers to progressive assembly linked by some material handling device.

Answer 2

True

Question 3

A continuous process indicates production of discrete parts moving from workstation to workstation at a controlled rate.

Answer 3

False

Question 4

An example of an assemble-to-order firm is Dell Computer.

Question 5

The closer the customer is to the customer order decoupling point the longer it takes the customer to receive the product.

Question 6

The closer the customer is to the customer order decoupling point the more quickly the customer receives the product.

Question 7

A project layout is characterized by a relatively low number of units produced in comparison with process and product layout formats.

Question 8

The time needed to respond to a customer's order is called the customer response time.

Question 9

A make-to-order firm will work with the customer to design the product, and then make it from purchased materials, parts, and components.

Question 10

One trade-off illustrated by the product-process matrix is between flexibility and cost.

Question 11

Process selection refers to the strategic decision of selecting which kind of production processes to use to produce a product or provide a service.

Question 12

The product-process matrix shows the relationship between process structures and product volume and variety characteristics.

Question 13

The volume requirements for the product are one determinant of the choice of which process structure to select.

Question 14

One difference between an assembly line process flow and a continuous process flow is that on the assembly line the flow is discrete rather than continuous.

Question 15

The focus in the make-to-stock environment is on providing finished goods where and when the customers want them.

Question 16

The essential issue in satisfying customers in the make-to-stock environment is to balance the cost of the finished item against the willingness of the consumer to pay for it.

Question 17

Process selection refers to the strategic decision of choosing the volume of output to produce in a manufacturing facility depending upon the way that facility produces.

Question 18

Work center layouts allocate dissimilar machines into cells to work on products that have dissimilar processing requirements.

Question 19

The essential issue in satisfying customers in the make-to-stock environment is to balance the level of finished inventory against the level of service to the customer.

Question 20

A project layout is characterized by a high degree of task ordering.

Question 21

For the purposes of assembly-line balancing, the required workstation cycle time is found by dividing production time per day by the required units of output per day.

Question 22

In balancing an assembly line, workstation cycle time has to be less than the time between successive units coming off the end of the line.

Question 23

A process map shows the physical location of the various processes within a supply chain.

Question 24

Using the assembly-line balancing procedure, which of the following is the required cycle time in minutes per unit if the daily production time is 480 minutes and the required daily output is 50 units?

A) 0.104
B) 50
C) 9.6
D) 480
E) Cannot be determined from the information above

Question 25

Little's law states that supply chain processes can be regarded as unrelated and thus treated and analyzed separately.

Question 26

Workstation cycle time is the time between successive units coming off the end of the assembly line.

Question 27

Using the assembly-line balancing procedure, which of the following is the required cycle time if the production time in minutes per day is 1,440 and the required output per day in units is 2,000?

A) 0.72
B) 1.388
C) 250
D) 500
E) Cannot be determined from the information above

Question 28

The assembly-line balancing procedure determines the precedence relationships of manufacturing tasks.

Question 29

If the sum of the task times required to produce a product is 45 minutes and the cycle time for the same product is 10 minutes. Thus, the theoretical minimum number of workstations is 5 using the assembly-line balancing procedure.

Question 30

A high-level map or diagram of a supply chain process can be useful to understand how material flows and where inventory is held.

Question 31

Little's law can be thought of as a relationship between units and time.

Question 32

Using the assembly-line balancing procedure, which of the following is the theoretical minimum number of workstations if the task times for the six tasks that make up the job are 4, 6, 7, 2, 6, and 5 minutes, and the cycle time is 10 minutes?

A) 3
B) 5
C) 6
D) 8
E) None of these

Question 33

In designing a production layout a flexible line layout might have the shape of a "U".

Question 34

Assembling-to-order means moving the customer order decoupling point from finished goods to components.

Question 35

The efficiency of an assembly-line is found by a ratio of the sum of all task times divided by the cycle time.

Question 36

In assembly-line balancing the theoretical minimum number of workstations is found by a ratio of the sum of all task times divided by the cycle time.

Question 37

If the sum of the task times required to produce a product is 80 minutes and the cycle time for the same product is 15 minutes, the theoretical minimum number of workstations is 8 using the assembly-line balancing procedure.

Question 38

Using the assembly-line balancing procedure, which of the following is the theoretical minimum number of workstations if the task times for the eight tasks that make up the job are 7, 4, 7, 8, 9, 4, 3, and 6 minutes, and the cycle time is 8 minutes?

A) 3
B) 5
C) 6
D) 8
E) None of these

Question 39

The term "assembly line" refers to progressive assembly linked by some material handling device.

Question 40

The first step in balancing an assembly line is to specify the precedence relationships among tasks to be performed on the line.

Question 41

You have just determined the actual number of workstations that will be used on an assembly line to be 8 using the assembly-line balancing procedure. The cycle time of the line is 10 minutes and the sum of all that tasks required on the line is 60 minutes. Which of the following is the correct value for the resulting line's efficiency?

A) 0.500
B) 0.650
C) 0.750
D) 0.850
E) None of these

Question 42

In studying positioning of inventory in supply chains, which, if any, of the following is most appropriate? (Select all that apply.)

A) As order decoupling point moves towards source, inventory investment goes down.
B) As order decoupling point moves towards the source, customer lead time gets longer.
C) As order decoupling point moves towards the source, inventory investment increases.
D) As order decoupling point moves towards the source, customer lead time is unchanged.

Question 43

Which of the following is a basic type of process structure?

A) Process flow diagram
B) Product matrix
C) Process matrix
D) Workcenter
E) Manual assembly

Question 44

According to Little's Law, which of the following can be used to estimate work-in-process inventory?

A) Process time/Cycle time
B) Throughput rate times Flow time
C) Process velocity/Flow time
D) Set up time/Throughput rate
E) Value added time/Process velocity

Question 45

Which of the following is not a step in developing a manufacturing cell layout?

A) Grouping parts into families that follow a common sequence of steps
B) Identifying dominant flow patterns of parts families as a basis for location of processes
C) Physically grouping machines and processes into cells
D) Disposing of left-over machinery and outsourcing ungrouped processes
E) None of the above

Question 46

You have just determined the actual number of workstations that will be used on an assembly line to be 6 using the assembly-line balancing procedure. The cycle time of the line is 5 minutes and the sum of all that tasks required on the line is 25 minutes. Which of the following is the correct value for the resulting line's efficiency?

A) 0.500
B) 0.833
C) 0.973
D) 0.990
E) None of these

Question 47

Regarding the measures of inventory managing efficiency, identify the most appropriate answer. (Select all that apply.)

A) Total average value of inventory is equal to the selling price multiplied by finished goods inventory.
B) Inventory turn is the annual cost of goods sold multiplied by average inventory.
C) Days of supply is the inverse of inventory turns × 365.
D) Inventory turn is the annual cost of goods sold divided by average inventory.

Question 48

Which of the following is not a basic type of process structure?

A) Product-process matrix
B) Workcenter
C) Manufacturing cell
D) Assembly line
E) Continuous process

Question 49

A firm will work with a customer to design the product, and then make it from purchased materials, parts, and components. This firm is called:

A) a make to order firm.
B) an engineer to order firm.
C) a make to stock firm.
D) a customer service firm.
E) an assemble to order firm.

Question 50

Which of these expressions is Little's Law?

A) Inventory/Flow time = Throughput rate:
B) Inventory/Throughput Rate = Flow time
C) Inventory = Throughput rate × Flow time
D) Throughput Rate/Inventory = 1/Flow Time
E) All of the above

Question 51

In studying product-process matrix describing layout strategies, which of the following is most appropriate? (Select all that apply.)

A) As you move from project to manufacturing cell to continuous process, product volume increases while standardization increases.
B) As you move from project to manufacturing cell to continuous process, product volume decreases while standardization decreases.
C) As you move from project to manufacturing cell to continuous process, product volume increases while standardization decreases.
D) As you move from project to manufacturing cell to continuous process, product volume decreases while standardization increases.

Question 52

Which of the following is not considered a major work flow structure?

A) Work Center
B) Project
C) Assembly line
D) Fabrication
E) Continuous Flow

Question 53

A difference between project and continuous flow categories of process flow structures is which two of the following?

A) The size and bulk of the product
B) Discrete parts moving from workstation to workstation
C) Degree of equipment specialization
D) Being a "Virtual Factory"
E) Profit per unit

Question 54

According to Little's Law, which of the following ratios is used to find throughput rate?

A) Cycle time/Process time
B) Throughput time/Process velocity
C) Process velocity/Throughput time
D) Inventory /Flow time
E) Value added time/Process velocity

Question 55

The placement of which of the following is not determined by production process organization decisions?

A) Departments
B) Workgroups
C) Workstations
D) Machines
E) Emergency exits

Question 56

Which of the following basic types of process structures is one which similar equipment or functions are grouped together?

A) Project
B) Workcenter
C) Manufacturing cell
D) Assembly line
E) Continuous process

Question 57

When balancing an assembly line, which of the following is not a way to reduce the longest task time below the required workstation cycle time?

A) Upgrade the equipment
B) Assign a roaming helper to support the line
C) Split the task between two workstations
D) Speed up the assembly line transfer mechanism
E) Use a more skilled worker

Question 58

A firm fills its customer's orders from finished goods inventory. It is a:

A) make to order firm.
B) engineer to order firm.
C) make to stock firm.
D) customer service firm.
E) assemble to order firm.

Question 59

Which of the following basic types of process structures is one which equipment or work processes are arranged according to the progressive steps by which the product is made?

A) Project
B) Workcenter
C) Manufacturing cell
D) Assembly line
E) Continuous process