Deck 12: Supplement: Tools for Analyzing, Designing, and Selecting Processes and Layouts

Question 1

15)Which of the following is an excellent communication tool that enables anyone to see when a work order was generated,who worked on it and where,the order's status,the customer's key requirements or concerns,and any past or future communication with the customer?

A)Assembly chart
B)Assembly drawing
C)Route sheet
D)Process chart

Answer 1

C

Question 2

18)______ is a process-mapping technique used to analyze and design the flow of materials and information across multiple processes.

A)A value stream map (VSM)
B)Simulation
C)A service blueprint
D)A process chart

Answer 2

A

Question 3

14)______ is a document that describes the sequence of different operations,places,or people involved in a process.

A)An assembly chart
B)An assembly drawing
C)A route sheet
D)A process chart

Answer 3

C

Question 4

11)______ are often referred to as working drawings.

A)Assembly charts
B)Assembly drawings
C)Job floor drawings
D)Process maps

Question 5

2)________ are the intersection of two lines on a breakeven analysis graph that show the point at which the total cost of two processes are identical.

A)Points of difference
B)Points of indifference
C)Points of correlation
D)Points of contact

Question 6

9)Which of the following is one of the tools used for analyzing and designing processes?

A)breakeven analysis
B)cost analysis
C)volume analysis
D)assembly drawing

Question 7

10)______ is an enlarged view of a product that shows all of its parts and subassemblies,providing complete information for the manufacture or assembly of a product or structure.

A)An assembly chart
B)An assembly drawing
C)A route sheet
D)A process map

Question 8

16)Which of the following uses graphics to show all activities related to a process,including its inputs and outputs,decision points such as approvals and exceptions,and any cross-functional relationships?

A)Value stream map (VSM)
B)Process simulation
C)Route sheet
D)Process chart

Question 9

6)ABC Corporation would like to evaluate three production processes (A,B,and C)to accommodate the changes in demand for its products.The fixed and variable cost per unit are tabled here.Determine the process to be selected when the production volume is 3,000 units.

A)Process A
B)Process B
C)Process C
D)cannot be determined

Question 10

1)______ is one of the simplest tools used to compare and select processes.

A)Cost-volume analysis
B)Value stream mapping
C)Assembly charts
D)Process simulation

Question 11

19)A value stream map provides a ______ view of the process.

A)static
B)dynamic
C)irregular
D)active

Question 12

17)Which of following can be used to pinpoint problems such as bottlenecks and delay points,wasteful activities such as rework,and locations where redundant or unnecessary activities occur?

A)Value stream map (VSM)
B)Process simulation
C)Service blueprint
D)Process chart

Question 13

5)ABC Corporation would like to evaluate three production processes (A,B,and C)to accommodate the changes in demand for its products.The fixed and variable cost per unit are tabled here.Determine the production volume at which costs of Processes B and C are equal.

A)2,000
B)3,000
C)4,000
D)1,000

Question 14

7)ABC Corporation would like to evaluate three production processes (A,B,and C)to accommodate the changes in demand for its products.The fixed and variable cost per unit are tabled here.Determine the process to be selected when the production volume is 6,000 units.

A)Process A
B)Process B
C)Process C
D)cannot be determined

Question 15

12)______ maps how a product's parts go together and the order in which they are assembled.

A)An assembly chart
B)An assembly drawing
C)A route sheet
D)A process map

Question 16

3)ABC Corporation would like to evaluate three production processes (A,B,and C)to accommodate the changes in demand for its products.The fixed and variable cost per unit are tabled here.Determine the most cost-effective process for an expected annual production volume of 2,000 units.

A)Process A
B)Process B
C)Process C
D)cannot be determined

Question 17

20)A ______ provides a dynamic view of the process using computers,multiple inputs,work centers,and processing techniques that can help operation managers look at the variability of the process under different conditions.

A)value stream map (VSM)
B)process simulation
C)service blueprint
D)process chart

Question 18

4)ABC Corporation would like to evaluate three production processes (A,B,and C)to accommodate the changes in demand for its products.The fixed and variable cost per unit are tabled here.Determine the production volume at which costs of Processes A and B are equal.

A)2,000
B)3,000
C)4,000
D)1,000

Question 19

8)ABC Corporation would like to evaluate three production processes (A,B,and C)to accommodate the changes in demand for its products.The fixed and variable cost per unit are tabled here.Determine the process to be selected when the production volume is 500 units.

A)Process A
B)Process B
C)Process C
D)cannot be determined

Question 20

13)______ are sometimes called gozinto charts.

A)Assembly charts
B)Assembly drawings
C)Route sheets
D)Process charts

Question 21

36)______is the time required to completely produce an item if only one item is being produced at a time.

A)Idle time
B)Flow time
C)Cycle time
D)Setup time

Question 22

41)Which of the following rules assigns tasks in order of highest position weight?

A)most-following-tasks rule
B)ranked-position-weight rule
C)least-number-of-following-tasks rule
D)shortest-operating-time rule

Question 23

28)The ______ is a technique developed by Richard Muther,used to design new layouts or change old ones based on qualitative criteria.

A)cost optimization method
B)relationship rating method
C)line balancing method
D)factor rating method

Question 24

23)Which of the following characteristics of a good process layout is FALSE?

A)It minimizes material handling.
B)It minimizes transportation costs.
C)It minimizes customer waiting time.
D)It maximizes employee waiting time.

Question 25

27)Which of the following methods is used for process layout analyses using qualitative data?

A)cost optimization method
B)relationship rating method
C)line balancing method
D)Muther's grid

Question 26

31)The letter X on the Muther's grid indicates that ______.

A)closeness is very important
B)closeness is unimportant
C)closeness is undesirable
D)closeness is necessary

Question 27

21)A ______ is a tool for analyzing processes that have high service content by specifying how the service will be provided.

A)value stream map (VSM)
B)process simulation
C)service blueprint
D)process chart

Question 28

24)Which of the following is NOT a factor in determining the total cost of materials handling in manufacturing process layouts?

A)the cost of moving a load between departments
B)the number of loads to be moved between departments
C)the distance between departments
D)the number of employees in each department

Question 29

33)A line is said to be unbalanced when there is ______.

A)a large number of workstations
B)no occurrence of bottlenecks
C)idle time
D)minimal work in progress inventory

Question 30

37)______ is the difference between the total time available and the total time used to complete a process.

A)Idle time
B)Flow time
C)Cycle time
D)Setup time

Question 31

39)In line balancing,the desired cycle time (C)is given by ______.

A)(Daily production time available)/ (Units to be produced daily)
B)(Daily production time available)/ (Number of workstations available)
C)(Units to be produced daily)/ (Daily production time available)
D)(Total time used)/ (Units to be produced daily)

Question 32

25)Which of the following methods is used for process layout analyses using quantitative data?

A)cost optimization method
B)relationship rating method
C)line balancing method
D)factor rating method

Question 33

30)The letters on the Muther's grid indicate ______.

A)repulsion of the location of pairs of departments
B)desirability of the location of pairs of departments
C)distance between the pairs of departments
D)size of the location of pairs of departments

Question 34

34)The ______ is the relationship between two or more tasks that requires certain tasks to be done before others.

A)least priority relationship
B)precedence relationship
C)factor rating
D)contingency relationship

Question 35

40)______ is the measure of how well a process uses the time available to complete it.

A)Total flow time
B)Total cycle time
C)Production volume
D)Balance efficiency

Question 36

38)In line balancing,the number of workstations required (N)is given by ______.

A)cycle time / flow time
B)idle time / cycle time
C)sum of all task times / cycle time
D)sum of all task times / flow time

Question 37

22)Which of the following statements about creating blueprints is FALSE?

A)Identify the services process to be blueprinted and the customers who will experience the service.
B)Envision the service from the organization's perspective.
C)Envision the actions of the service delivery personnel.
D)Consider all likely service scenarios and how they should play out ideally.

Question 38

32)Which of the following techniques involves assigning production tasks in such a way that the time required to complete them is approximately equal across workstations?

A)the cost optimization method
B)the relationship rating method
C)the line balancing method
D)the factor rating method

Question 39

35)______ is the time required for the line to produce one unit to achieve an output rate that allows a firm to meet its demand requirements.

A)Idle time
B)Flow time
C)Cycle time
D)Setup time

Question 40

29)The ______ is a visual representation of relationship rating in which symbols or letters represent the relationships between departments.

A)cost optimization method
B)relationship rating method
C)line balancing method
D)Muther's grid

Question 41

54)Which of the following is NOT a reason that a route sheet is an excellent communication tool?

A)It enables anyone to see when a work order was generated.
B)It reveals who worked on a work order.
C)It shows the status of the work order.
D)It shows the profit margin on the order.

Question 42

56)The most common way to design a process layout for a manufacturing facility is to arrange departments or work centers such that ______.

A)the total cost of materials handling is minimized
B)the total time for materials handling is minimized
C)the total man hours for materials handling is minimized
D)the total distance travelled for materials handling is minimized

Question 43

59)Working drawings refer to ______.

A)assembly charts
B)detailed instructions for all major parts of the product
C)gozinto charts
D)assembly drawings

Question 44

48)An assembly line to be balanced has six tasks in precedence.The task times are shown in the following table.Based on demand forecasts,the output rate has to be 160 units per day.The line operates 8 hours a day.Compute the balance efficiency E.

A)93%
B)87%
C)80%
D)100%

Question 45

46)An assembly line to be balanced has six tasks in precedence.The task times are shown in the following table.Based on demand forecasts,the output rate has to be 160 units per day.The line operates 8 hours a day.Compute the theoretical number of work stations required (N).

A)3
B)4
C)5
D)6

Question 46

50)An assembly line to be balanced has six tasks in precedence.The task times are shown in the following table.Based on demand forecasts,the output rate has to be 160 units per day.The line operates 8 hours a day.Compute the task sequence using the ranked-position-weight rule.

A)A,C & B,D,E,F
B)A,B & E,C,D,F
C)A,B,C,D,E,F
D)A,B,C,D & E,F

Question 47

51)Real-life layout problems can be solved ______.

A)manually
B)graphically
C)using software
D)easily

Question 48

43)Which of the following statements is true about the least-number-of-following-tasks rule?

A)assigns tasks in order of the most number of following tasks
B)assigns tasks in order of the tasks with the longest operating time
C)assigns tasks in order of the tasks with the shortest operating time
D)assigns tasks in order of the least number of following tasks

Question 49

61)A route sheet is ______.

A)also known as a gozinto sheet
B)a document that describes the sequence of different operations,places,or people involved in a process
C)used to identify points of cost intersection
D)used to show the materials used in a production process

Question 50

42)Which of the following statements is true about the most-following-tasks rule?

A)assigns tasks in order of the most number of following tasks
B)assigns tasks in order of the tasks with the longest operating time
C)assigns tasks in order of the tasks with the shortest operating time
D)assigns tasks in order of the least number of following tasks

Question 51

52)Which of the following statements is FALSE about the use of computer software to solve layout problems?

A)Computer software rely to a great extent on heuristic approaches.
B)Large line balancing problems for product layouts can be solved using IBM's COSMOL or GE's ASYBL.
C)Computer software can be used to solve real-life,complex layout problems that cannot be solved manually.
D)Computer programs guarantee optimal solutions.

Question 52

An assembly line to be balanced has six tasks in precedence.The task times are shown in the following table.Based on demand forecasts,the output rate has to be 160 units per day.The line operates 8 hours a day.Compute the task sequence using the most-following-tasks rule.

$$\begin{array} { | l | l | l | } \hline \text { Tasks } & \text { Immediate Predecessor } & \begin{array} { l } \text { Task Time in } \\\text { Minutes }\end{array} \\\hline \mathrm { A } & \text { NONE } & 3 \\\hline \mathrm { B } & \mathrm { A } & 1 \\\hline \mathrm { C } & \mathrm { A } & 2 \\\hline \mathrm { D } & \mathrm { B } , \mathrm { C } & 3 \\\hline \mathrm { E } & \mathrm { C } & 3 \\\hline \mathrm { F } & \mathrm { D } , \mathrm { E } & 2 \\\hline\end{array}$$

A)A,C & B,D,E,F
B)A,B & E,C,D,F
C)A,B,C,D,E,F
D)A,B,C,D & E,F

Question 53

60)Which of the following shows how a product's parts go together and the order in which they are assembled?

A)Pareto chart
B)assembly chart
C)process chart
D)value stream mapping (VSM)

Question 54

55)Which of the following is NOT one of the symbols usually used in a process chart?

A)a hexagon
B)a diamond
C)a rectangle
D)an arrow

Question 55

57)In selecting a process,we can plot the costs for each process in a breakeven analysis graph.When the costs of different processes are identical at different points,the lines representing these costs intersect each other.These points of intersection are known as ______.

A)points of indifference
B)relationship rating points
C)identical points
D)breakeven points

Question 56

An assembly line to be balanced has six tasks in precedence.The task times are shown in the following table.Based on demand forecasts,the output rate has to be 160 units per day.The line operates 8 hours a day.Calculate the desired cycle time C.
$$\begin{array} { | l | l | l | } \hline \text { Tasks } & \text { lmmediate Predecessor } & \text { Task Time in Minutes } \\\\\hline \text { A } & \text { NONE } & 3 \\\hline \text { B } & \text { A } & 1 \\\hline \text { C } & \text { A } & 2 \\\hline \text { D } & \mathrm { B } , \mathrm { C } & 3 \\\hline \text { E } & \mathrm { C } & 3 \\\hline \text { F } & \mathrm { D } , \mathrm { E } & 2 \\\hline\end{array}$$

A)3 minutes/unit
B)4 minutes/unit
C)5 minutes/unit
D)6 minutes/unit

Question 57

Which of the following rules assigns tasks in order of the task with shortest operating time?

A)most-following-tasks rule
B)ranked-position-weight rule
C)least-number-of-following-tasks rule
D)shortest-operating-time rule

Question 58

58)An assembly drawing shows ______.

A)an enlarged view of a product with details of all of its parts and subassemblies
B)how a product's parts go together
C)the order in which they are assembled
D)detailed instructions for all major parts of the product

Question 59

53)Which of the following is NOT a tool for analyzing and designing processes?

A)assembly drawings
B)process simulation
C)value stream mapping (VSM)
D)ABC analysis

Question 60

An assembly line to be balanced has six tasks in precedence.The task times are shown in the following table.Based on demand forecasts,the output rate has to be 160 units per day.The line operates 8 hours a day.Compute the theoretical minimum amount of idle time (I).
$$\begin{array} { | l | l | l | } \hline \text { Tasks } & \text { Immediate Predecessor } & \begin{array} { l } \text { Task Time in } \\\text { Minutes }\end{array} \\\hline \mathrm { A } & \text { NONE } & 3 \\\hline \mathrm { B } & \mathrm { A } & 1 \\\hline \mathrm { C } & \mathrm { A } & 2 \\\hline \mathrm { D } & \mathrm { B } , \mathrm { C } & 3 \\\hline \mathrm { E } & \mathrm { C } & 3 \\\hline \mathrm { F } & \mathrm { D } , \mathrm { E } & 2 \\\hline\end{array}$$

A)0
B)1
C)2
D)3

Question 61

62)Which of the following helps organize work orders by tracking the parts for products and the status of jobs during their scheduling,production,and quality control phases?

A)route sheet
B)Pareto chart
C)assembly chart
D)assembly drawing

Question 62

79)The daily output required from an assembly line is 80 units.If the line operates 4 hours a day,what is the cycle time per unit?

A)3 hours
B)3 minutes
C)3 seconds
D)3 days

Question 63

78)The daily output required from an assembly line is 600 units.If the line operates 12 hours a day,what is the cycle time per unit?

A)1 minute and 12 seconds
B)3 minutes and 18 seconds
C)6 minutes and 44 seconds
D)8 minutes and 28 seconds

Question 64

65)A technique that provides a dynamic view of a process using computers,multiple inputs,work centers,and processing techniques to help an operations manager look at the variability of a process under different conditions is known as ______.

A)a value stream map
B)a process simulation
C)a Pareto mapping
D)an assembly chart

Question 65

70)The relationship between two or more tasks that requires certain tasks to be done before others is known as ______.

A)a precedence relationship
B)a Muther's grid relationship
C)points of indifference
D)an assembly relationship

Question 66

64)A graphic used to analyze and design the flow of materials and information across multiple processes is known as ______.

A)a value stream mapping (VSM)
B)a Pareto chart
C)an assembly chart
D)an assembly drawing

Question 67

74)The measure of how well a process uses the time available to complete it is called ______.

A)cycle time
B)flow time
C)idle time
D)balance efficiency

Question 68

71)The time required for the line to produce one unit to achieve an output rate that allows a firm to meet its demand requirements is known as ______.

A)cycle time
B)flow time
C)idle time
D)balance efficiency

Question 69

68)A Muther's grid ______.

A)is a visual representation of relationship rating in which symbols or letters represent the relationships between departments
B)helps us to assign production tasks in such a way that the time required to complete them is approximately equal across workstations
C)shows the relationship between two or more tasks that requires certain tasks to be done before others
D)identities the time requirements for a line of production to produce one unit

Question 70

81)The sum of all task times in producing a product is 72 minutes.If the cycle time is 72 minutes,then the number of workstations required is ______.

A)one
B)two
C)three
D)four

Question 71

69)Line balancing refers to ______.

A)the organization of production such that costs of different process are equal
B)the assignment of production tasks in such a way that the time required to complete them is approximately equal across workstations
C)the identification of time requirements for a line of production to produce one unit
D)the organization of production tasks in such a way that the cost of parts required to complete them is approximately equal across workstations

Question 72

66)A service blueprint refers to ______.

A)a tool for analyzing processes that have high service content by specifying how the service will be provided
B)a technique that provides a dynamic view of a process using computers,multiple inputs,work centers,and processing techniques to help an operations manager look at the variability of a process under different conditions
C)a graphic used to analyze and design the flow of materials and information across multiple processes
D)a diagram that uses graphics to show all activities related to a process,including its inputs and outputs,decision points such as approvals and exceptions,and any cross-functional relationships

Question 73

72)The time required to completely produce an item if only one unit is being produced at a time is known as ______.

A)cycle time
B)flow time
C)idle time
D)balance efficiency

Question 74

63)Which of the following is NOT true of a process chart?

A)It shows inputs and outputs in a process.
B)It shows decision points such as approvals and exceptions.
C)It shows any cross-functional relationships.
D)It shows costs and points of indifference.

Question 75

73)The difference between the total time available and the total time used to complete a process is known as ______.

A)cycle time
B)flow time
C)idle time
D)balance efficiency

Question 76

80)The sum of all task times in producing a product is 15 minutes.Eighty units need to be produced in 4 hours.What is the number of workstations required?

A)five
B)six
C)seven
D)eight

Question 77

76)The daily output required from an assembly line is 120 units.If the line operates 8 hours a day,what is the cycle time per unit?

A)4 hours
B)4 minutes
C)15 seconds
D)1 hour

Question 78

67)A technique developed by Richard Muther used to design new layouts or change old ones based on qualitative criteria is known as ______.

A)Muther's grid
B)relationship rating
C)precedence relationships
D)line balancing

Question 79

77)The daily output required from an assembly line is 300 units.If the line operates 5 hours a day,what is the cycle time per unit?

A)1 hour
B)4 minutes
C)1 minute
D)25 seconds

Question 80

75)Idle time is computed by using which formula?

A)Total time used - Total time available
B)Total time used + Total time available
C)Total time available - Total time used
D)Total time used / Total time available