Deck 8: Material Flow Analysis and Facility Layouts

Question 1

A triangle in a material flow map would best represent?

A) A machine
B) A quality inspection that may result in a product being reworked
C) A holding area for WIP inventory
D) The end of an assembly line

Answer 1

C

Question 2

In a material flow map, a rectangle represents?

A) Delay/storage
B) Decision
C) Process operation
D) Start/end of process

Answer 2

C

Question 3

Effective management of flows can drive improvements in all of the following areas except?

A) Quality
B) Increased warranty claims
C) Lead time
D) Capacity

Answer 3

B

Question 4

Paying for a purchase is which type of flow?

A) Customer
B) Information
C) Material
D) Cash

Question 5

A diamond in a material flow map would best represent?

A) A machine
B) A quality inspection that may result in a product being reworked
C) A holding area for WIP inventory
D) The end of an assembly line

Question 6

In a material flow map, a diamond represents?

A) Delay/storage
B) Decision
C) Process operation
D) Start/end of process

Question 7

The completion of a purchase order is which type of flow?

A) Cash
B) Information
C) Material
D) Work

Question 8

A rounded rectangle in a material flow map would best represent?

A) A machine
B) A quality inspection that may result in a product being reworked
C) A holding area for WIP inventory
D) The end of an assembly line

Question 9

A rectangle in a material flow map would best represent?

A) A machine
B) A quality inspection that may result in a product being reworked
C) A holding area for WIP inventory
D) The end of an assembly line

Question 10

In a material flow map, a rounded rectangle represents?

A) Delay/storage
B) Decision
C) Process operation
D) Start/end of process

Question 11

All of the following are terms for material flow mapping except?

A) Process mapping
B) Process flowcharting
C) Value stream mapping
D) Process value mapping

Question 12

Non-value-adding elements in a flow should be?

A) Managed/eliminated
B) Ignored
C) Both managed/eliminated and ignored
D) Neither managed/eliminated nor ignored

Question 13

In a material flow map, a dashed arrow represents?

A) Physical movement/transportation
B) Information flow
C) Physical movement/transportation or information flow
D) Neither physical movement/transportation nor information flow

Question 14

A firm has a simple process where a customer's order form is signed by a manager before being passed to the production team. This process would best be represented by which flow map?

A) Rounded rectangle $\rightarrow$ Rectangle $\rightarrow$ Rounded rectangle
B) Rounded rectangle $\rightarrow$ Diamond $\rightarrow$ Rounded rectangle
C) Rounded rectangle $\rightarrow$ Rounded rectangle $\rightarrow$ Rounded rectangle
D) Rounded rectangle $\rightarrow$ Triangle $\rightarrow$ Rounded rectangle

Question 15

In a material flow map, a solid arrow represents?

A) Physical movement/transportation
B) Information flow
C) Physical movement/transportation or information flow
D) Neither physical movement/transportation nor information flow

Question 16

Transmission and receipt of a purchase order is which type of flow?

A) Cash
B) Information
C) Material
D) Work

Question 17

A dashed line in a material flow map would best represent?

A) Movement of a product down an assembly line
B) A product waiting to be worked on at a machine
C) Passing of quality control information to a decision-maker
D) A product exiting a process

Question 18

Waiting for a product is which type of flow?

A) Customer
B) Information
C) Material
D) Work

Question 19

In a material flow map, a triangle represents?

A) Delay/storage
B) Decision
C) Process operation
D) Start/end of process

Question 20

Material flow mapping involves all of the following except?

A) Understand process flows
B) Identify activity sequences
C) Warranty claims
D) Manage or eliminate non-value-adding activities

Question 21

The bottleneck process represents which of the following?

A) Drum
B) Buffer
C) Rope
D) Neither the drum, buffer, nor the rope

Question 22

Cross-training workers can help?

A) Increase flexibility
B) Decrease flexibility
C) Both increase and decrease flexibility
D) Neither increase nor decrease flexibility

Question 23

A solid line in a material flow map would best represent?

A) Movement of a product down an assembly line
B) A product waiting to be worked on at a machine
C) Passing of quality control information to a decision-maker
D) A product exiting a process

Question 24

If a bottleneck process has a processing rate of 20 units per hour, what is the processing rate of the system?

A) Less than 20 units per hour
B) 20 units per hour
C) More than 20 units per hour
D) The processing rate cannot be determined from the information given

Question 25

DBR stands for?

A) Drum, Buffer, Regular
B) Drum, Barrel, Rope
C) Drum, Buffer, Rope
D) Drum, Barrel, Roller

Question 26

The last step in DBR production scheduling is to?

A) Identify the constrained resource(s) or bottleneck(s) in the system
B) Synchronize the release of work
C) Use inventory buffers at the critical bottlenecks
D) Forecast the demand

Question 27

Identifying and improving constrained processes is the focus of the?

A) Theory of Bottlenecks
B) Theory of Constraints
C) Theory of Convergence
D) Theory of Disruptions

Question 28

Having __________ manufacturing flexibility is desirable.

A) Increased
B) Decreased
C) Both increased and decreased
D) Neither increased nor decreased

Question 29

The scheduling of work releases to a system is referred to as the?

A) Drum
B) Buffer
C) Rope
D) Neither the drum, buffer, nor the rope

Question 30

Material flow analysis can help to answer all of the following questions except?

A) How should the product be priced?
B) How often are inventories moved?
C) How often are units discarded due to poor quality?
D) How long are inventories stored?

Question 31

Procedure and behavioral constraints include all of the following except?

A) Manufacturing bottlenecks
B) Poor training programs
C) Poor cultural norms in the organization
D) Poor management decisions

Question 32

Evaluating a process for effectiveness, quality, and productivity is referred to as?

A) Material process development
B) Material process analysis
C) Material flow planning
D) Material flow analysis

Question 33

Inventory held downstream of the bottleneck process is represents which of the following?

A) Drum
B) Buffer
C) Rope
D) Neither the drum, buffer, nor the rope

Question 34

In an organization, something that keeps the firm from achieving its goals is referred to as a?

A) Barrier
B) Wall
C) Blockade
D) Constraint

Question 35

The Theory of Constraints was popularized by which book?

A) The Goal
B) The Objective
C) The Process
D) The Knowledge

Question 36

Automation and standardized procedures are often used to?

A) Increase process variability
B) Decrease process variability
C) Both increase and decrease process variability
D) Neither increase nor decrease process variability

Question 37

Physical constraints include all of the following except?

A) Untrained workers
B) Faulty equipment
C) Lack of preventative maintenance
D) Material bottlenecks in supply chain

Question 38

Constraints can be overcome by all of the following except?

A) Designing effective contingency plans or procedures
B) Enhancing product marketing plans
C) Avoiding having unconstrained resources doing unnecessary work
D) Designing better material routes or layouts

Question 39

The first step in DBR production scheduling is to?

A) Identify the constrained resource(s) or bottleneck(s) in the system
B) Synchronize the release of work
C) Use inventory buffers at the critical bottlenecks
D) Forecast the demand

Question 40

Untreated bottlenecks can lead to all of the following except?

A) Unscheduled overtime
B) Higher inventory
C) Increased on-time deliveries
D) Equipment breakdowns

Question 41

Assembly line balancing is beneficial for all of the following reasons except?

A) Reduction in likelihood of bottlenecks
B) Reduction in severity of bottlenecks
C) Smoother product flow
D) Lower product output levels

Question 42

Which type of layout design is used to achieve high volume output of standardized products?

A) Customer-focused
B) Product-focused
C) Process-focused
D) Assembly-focused

Question 43

A product-focused layout would be mostly closely identified with?

A) Flow shops
B) Cellular manufacturing
C) Job shops
D) Assembly lines

Question 44

Which of the following is a common mass customization practice?

A) Postponement
B) Distribution delay
C) Cancellation
D) Reimbursement

Question 45

Manufacturing flexibility refers to all of the following except?

A) Create different product types
B) Efficiently dispose of damaged WIP
C) Change the order in how processes are operated
D) Change process capacities

Question 46

CAM, in the context of manufacturing flexibility, refers to?

A) Computer applied manufacturing
B) Computer asserted manufacturing
C) Computer aided manufacturing
D) Computer assisted manufacturing

Question 47

The design of a product using standardized parts while incorporating a degree of customized assembly prior to delivery to customers is referred to as?

A) Product standardization
B) Mass standardization
C) Mass customization
D) Product differentiation

Question 48

CAD, in the context of manufacturing flexibility, refers to?

A) Computer aided drafting
B) Computer aided design
C) Computer aided division
D) Computer aided detailing

Question 49

FMS, in the context of manufacturing flexibility, refers to?

A) Fast manufacturing system
B) Focused manufacturing system
C) Flash manufacturing system
D) Flexible manufacturing system

Question 50

Manufacturers generally prefer?

A) Product differentiation
B) Product standardization
C) Neither product differentiation nor product standardization
D) The preferences of manufacturers are impossible to assess

Question 51

Machines that are programmable and able to complete repetitive steps in a manufacturing process are?

A) CAM
B) CAD
C) CIM
D) CNC

Question 52

In an assembly line, the process of machine reprogramming, retooling, and inventory changes between production runs is referred to as a?

A) Setup
B) Stoppage
C) Shortage
D) Slowdown

Question 53

Collections of manufacturing workstations that are dedicated to the production of similar parts or part families are?

A) Production corrals
B) Group technology cells
C) Cellular cages
D) Production houses

Question 54

The use of computer graphics applications in the product design process is referred to as?

A) CAM
B) CAD
C) CIM
D) CNC

Question 55

Which type of layout design is also referred to as an assembly line layout?

A) Customer-focused
B) Product-focused
C) Process-focused
D) Assembly-focused

Question 56

CNC, in the context of manufacturing flexibility, refers to?

A) Computer neutral complex machining
B) Computer necessary controlled machines
C) Computer numerically controlled machines
D) Computer nailing control

Question 57

The use of computers in the manufacturing process is referred to as?

A) CAM
B) CAD
C) CIM
D) CNC

Question 58

Ideally, assembly lines are?

A) Unbalanced
B) Balanced
C) Neither unbalanced nor balanced
D) The balancing of an assembly line is unimportant

Question 59

Dividing assembly tasks as equally as possible to each workcenter in an assembly line is referred to as?

A) Assembly line division
B) Assembly line allocation
C) Assembly line smoothing
D) Assembly line balancing

Question 60

Product-focused layouts are designed to achieve?

A) High volume output
B) Production of standardized products
C) Both high volume output and production of standardized products
D) Neither high volume output nor production of standardized products

Question 61

Process-focused layouts are used for?

A) Production of different products
B) Production in small volumes
C) Both production of different products and in small volume
D) Neither production of different products nor production in small volume

Question 62

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 12, 15, and 10 minutes per unit, respectively. If the assembly line operates for 480 minutes per day with a desired output of 50 units per day, what is the takt time?

A) 0.1 units per minute
B) 13 units per minute
C) 9.6 units per minute
D) Cannot be determined from the information given

Question 63

If an assembly line has an efficiency of 80% with 3 workcenters, how would adding a fourth workcenter affect assembly line efficiency?

A) Efficiency would increase
B) Efficiency would decrease
C) Efficiency would not change
D) Efficiency would increase, but may become infeasible

Question 64

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 12, 15, and 10 minutes per unit, respectively. If the assembly line operates for 480 minutes per day with a desired output of 50 units per day, what is assembly line efficiency?

A) Less than 90%
B) 96%
C) Greater than 98%
D) Cannot be determined from the information given

Question 65

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 7, 17, and 6 minutes per unit, respectively. What is the sum of task times?

A) 30 minutes per unit
B) 10 minutes per unit
C) 6 minutes per unit
D) Cannot be determined from the information given

Question 66

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 9, 9, and 11 minutes per unit, respectively. Which task is the bottleneck?

A) A
B) Both A and B
C) C
D) Cannot be determined from the information given

Question 67

Wait time in a process-focused layout is likely to be ______ when compared to a product-focused layout?

A) Shorter
B) Longer
C) About the same
D) Wait times cannot be compared between the two layouts

Question 68

A focus of material flow in a process-focused layout should be on?

A) Placing frequently used departments close to each other
B) Placing rarely used departments close to each other
C) Placing rarely used departments far from each other
D) Placing frequently used departments far from each other

Question 69

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 9, 9, and 11 minutes per unit, respectively. If the assembly operates for 400 minutes per day with a desired output of 70 units per day, what is the efficiency of the assembly line?

A) 84%
B) 64%
C) 94%
D) Cannot be determined from the information given

Question 70

If an assembly line has an efficiency of 80% with 3 workcenters, how would removing a workcenter affect efficiency?

A) Efficiency would increase
B) Efficiency would decrease
C) Efficiency would not change
D) Efficiency would increase, but may become infeasible

Question 71

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 12, 15, and 10 minutes per unit, respectively. Which task is the bottleneck?

A) A
B) B
C) C
D) Cannot be determined from the information given

Question 72

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 9, 9, and 11 minutes per unit, respectively. If the assembly operates for 400 minutes per day with a desired output of 70 units per day, what is minimum number of workstations?

A) 4
B) 6
C) 8
D) Cannot be determined from the information given

Question 73

If an assembly line has a target takt time of 10 minutes per unit (due to capacity constraints), how many units per day can be produced? Assume that a production day is 480 minutes.

A) 10 units
B) 48 units
C) 400 units
D) Cannot be determined from the information given

Question 74

Takt time is calculated by which of the following?

A) Desired output per day/Daily operating time
B) Cycle time/Daily operating time
C) Daily operating time/Desired output per day
D) Sum of all task times/Cycle time

Question 75

If an assembly line operates for 420 minutes per day and its demand forecast calls for production of 20 units per day, what is the assembly line's takt time?

A) 420 minutes per unit
B) 20 minutes per unit
C) 21 minutes per unit
D) 0.05 minutes per units

Question 76

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 9, 9, and 11 minutes per unit, respectively. If the assembly line operates for 400 minutes per day with a desired output of 70 units per day, what is the takt time?

A) 13.8 units per minute
B) 5.7 units per minute
C) 0.4 units per minute
D) Cannot be determined from the information given

Question 77

Assembly line efficiency is calculated by which of the following?

A) Takt time/(Sum of all task times x Number of workcenters)
B) Sum of all task times + (Number of workcenters x Takt time)
C) Number of workcenters/Sum of all task times
D) Sum of all task times/(Number of workcenters x Takt time)

Question 78

Assume that an assembly line has three tasks that must be completed (in order, A, B, and C). The tasks have processing times of 12, 15, and 10 minutes per unit, respectively. If the assembly line operates for 480 minutes per day with a desired output of 50 units per day, what is minimum number of workstations?

A) 1
B) 3
C) 4
D) Cannot be determined from the information given

Question 79

Product-focused process layouts can lead to all of the following effects except?

A) Decreased worker injuries
B) Worker turnover
C) Worker boredom
D) Lower worker job satisfaction

Question 80

A good process-focused layout should seek to?

A) Maximize product lead times
B) Maximize WIP inventory
C) Minimize time in system
D) Minimize total distance traveled