Deck 6: A: Process Design and Facility Layout

Question 1

A job shop processing system generally requires less skilled workers than a continuous processing system.

Answer 1

False

Question 2

Production process design is not part of the product design methodology.

Answer 2

False

Question 3

Repetitive process systems are typically used to produce goods for specific customer orders rather than goods to be held as finished product inventory in anticipation of demand.

Answer 3

False

Question 4

The use of robots is one form of programmable automation.

Question 5

Flexible automation consists of high-cost specialized equipment designed for a fixed sequence of operations.

Question 6

The first step in process design is to decide whether to make or buy a product or service.

Question 7

As a general rule,continuous processing systems produce products for a high volume of standardized output.

Question 8

A cafeteria line would be an example of a process layout.

Question 9

Programmable automation requires less changeover time than flexible automation.

Question 10

A job shop processing system tends to utilize highly flexible general-purpose equipment.

Question 11

In general,batch process systems require a more skilled and flexible workforce than job shops because batch processes produce more varied goods and services.

Question 12

Process design is required only when new products or services are planned.

Question 13

Repetitive production processes produce a high volume of standardized products or services.

Question 14

A disadvantage of automation is that it tends to increase variable costs for repetitive operational tasks.

Question 15

Flexible manufacturing systems (FMS)are intended to automate routine work tasks in high volume,low variety mass production industries such as the auto industry.

Question 16

Product layouts can more easily adapt to variations in product requirements than process layouts can.

Question 17

Service process design differs from manufacturing in that it outlines the flow of the customer or something belonging to the customer.

Question 18

The use of operational processes is intermittent in the case of batch processing.

Question 19

Continuous processing is employed when a customized output is required.

Question 20

Process (functional)layouts allow greater flexibility in processing than product (line)layouts.

Question 21

In designing the layout of retail facilities the primary objective is to minimize cost.

Question 22

An assembly line that has a percentage idle time of zero means the line is perfectly balanced.

Question 23

In process layouts production resources are arranged according to similarity of function.

Question 24

In cellular layouts,machines and equipment are grouped according to their function,for instance,all drills in a machine shop would be grouped into a cell.

Question 25

The goal of line balancing is to assign tasks to workstations in such a way that the workstations have approximately equal time requirements.

Question 26

Layouts involving combinations of product (line)layouts and cellular layouts are not possible.

Question 27

With group technology items that are similar in either design or manufacturing requirements are grouped into part families.

Question 28

A process layout is more susceptible to shutdowns caused by equipment breakdowns than a product layout.

Question 29

The design of factories and the design of warehouses are based on a similar set of factors.

Question 30

A grocery store would be categorized as a process layout.

Question 31

Process layouts tend to have lower in-process inventories,and higher equipment utilization rates than product layouts.

Question 32

Product layouts are more likely to be arranged as a U-shaped line than cellular layouts are.

Question 33

Process layouts tend to have low in-process inventories.

Question 34

Product layouts achieve high utilization of labour and equipment.

Question 35

Product (line)layouts are not used in service environments.

Question 36

Some of the benefits of cellular layouts are less material handling and reduced setup time.

Question 37

A possible disadvantage of a product layout is an inflexible response to changes in product mix.

Question 38

A disadvantage of a product layout can be high in-process inventory costs.

Question 39

Cellular layouts are like miniature versions of product layouts.

Question 40

Cellular layouts consist of a large number of computer-controlled machines that produce dissimilar parts.

Question 41

Which of the following is not true about process design?

A) Process design refers to how production of goods or services occurs.
B) Process design occurs only when new products or services are planned.
C) Process design has strategic significance.
D) Process design has major implications for the layout of facilities.
E) Process design is revisited periodically due to technological changes.

Question 42

None of the techniques for line balancing guarantee an optimal solution.

Question 43

An advantage of a U-shaped production line is that it facilitates teamwork and flexibility in work assignments.

Question 44

The type of processing system which is used for high volume,highly standardized products is:

A) continuous.
B) intermittent.
C) job-shop.
D) batch.
E) unit.

Question 45

Heuristic approaches to line balancing guarantee an optimal solution.

Question 46

In which type of operations process are you likely to see products or services produced in low to moderate volumes,with some degree of standardization,and moderate flexibility of the processing equipment used?

A) A project
B) A job shop
C) Repetitive production
D) Batch processing
E) None of the choices are correct.

Question 47

Which type of automation is least suited for a wide variety of products?

A) Fixed automation
B) Programmable automation
C) Flexible automation
D) Flexible manufacturing systems
E) All choices are equally suited for a wide variety of products.

Question 48

"Balance delay" is another name for the percentage of idle time in a product layout.

Question 49

Which of the following is a factor considered in make-or-buy decisions?

A) Available capacity
B) Core capabilities
C) Pattern of demand (steady or temporary)
D) Secrecy of technology
E) All of the choices are factors considered.

Question 50

In which type of processing system would sugar refining be done?

A) Job Shop
B) Batch
C) Assembly
D) Continuous
E) Repetitive

Question 51

The overall efficiency of a production line is equal to the percentage idle time times the number of workstations.

Question 52

The substitution of human labour with machinery that has sensing and control devices is best described by the term:

A) automation.
B) loss of jobs.
C) computer-aided manufacturing.
D) computer-integrated manufacturing.
E) flexible manufacturing system.

Question 53

The closeness ratings approach to design process layouts focuses on one main objective,minimizing the total transportation cost.

Question 54

Cycle time is the maximum time allowed at each workstation to complete its assigned tasks on each unit of production before it moves on.

Question 55

For a production line,daily capacity can be determined by dividing the daily operating time by the line's cycle time.

Question 56

The advantages of automation include:
I)Reduced output variability
II)Reduced variable costs
III)Machines don't strike or file grievances.
IV)Machines are much more flexible than human labour.

A) I and IV only
B) II and III only
C) I, II, and III only
D) I and III only
E) II and IV only

Question 57

The theoretical minimum number of workstations for a production line is a function of the sum of task times and the cycle time.

Question 58

The goal of line balancing is to assign equal allocations of idle time to all work stations.

Question 59

Which type of processing system tends to produce the most product variety?

A) Assembly
B) Job Shop
C) Batch
D) Continuous
E) Repetitive

Question 60

Which of the following is not generally considered to be a kind of automation?

A) Fixed automation
B) Programmable automation
C) Flexible automation
D) Manual automation
E) All of the choices are kinds of automation.

Question 61

Which of the following is a suggestion to improve customer perception in services?

A) Start the service positively as customers remember the beginning more
B) If the service is pleasurable, combine the segments
C) If the service is painful, divide it into segments
D) Let customers control part or all of the process
E) All of the choices are correct

Question 62

The type of layout which arranges production resources according to similarity of function is:

A) process.
B) product.
C) intermittent.
D) cellular.
E) continuous.

Question 63

Which of the following is not a type of layout?

A) Product (line) layouts
B) Process (functional) layouts
C) Cellular layouts
D) Robotic layouts
E) Warehouse layouts

Question 64

Which type of automation is designed to achieve rapid changeover times when switching from one product to another?

A) Fixed automation
B) Manual automation
C) Robots designed for repetitive, standardized tasks
D) Flexible manufacturing systems
E) All choices have comparable changeover times.

Question 65

The linking of a broad range of manufacturing and other activities through an integrated computer system is referred to as:

A) automation.
B) computer-aided design (CAD).
C) computer-aided manufacturing (CAM).
D) computer-integrated manufacturing (CIM).
E) a flexible manufacturing system (FMS).

Question 66

A group of machining centres including supervisory computer control,automatic material handling,and possibly robots is called:

A) automation.
B) a manufacturing cell.
C) computer-aided manufacturing.
D) computer-integrated manufacturing.
E) a flexible manufacturing system.

Question 67

The overall goals of CIM include all of the following EXCEPT?

A) To achieve rapid response to customer orders
B) To allow rapid production
C) To reduce indirect labour costs
D) Accommodate increased product variety
E) To achieve rapid response to product changes

Question 68

Which of the following is not usually true about process layouts?

A) They involve frequent adjustments to equipment.
B) There is a discontinuous work flow.
C) Variable-path material-handling equipment is used.
D) Highly specialized equipment is used.
E) Workers are usually skilled.

Question 69

N/C machines are best used in cases with all of the following characteristics EXCEPT:

A) mistakes are costly.
B) changes in design are infrequent.
C) parts are processed in small batches.
D) close tolerances are required.
E) all of the choices are characteristics.

Question 70

The type of layout which is used to achieve a smooth and rapid flow of large volumes of standardized goods or services is:

A) process.
B) product.
C) intermittent.
D) cellular.
E) continuous.

Question 71

Which one of the following is not common to product layouts?

A) A high rate of output
B) Specialization of labour
C) Low unit costs
D) Ability to adjust to changes in the product mix demand
E) All of the choices are common

Question 72

The incremental approach to process design involves which of the following?
I)Identifying process boundaries (inputs and outputs)and the level of detail required
II)Following the normal flow of materials through the transformation process
III)Identifying the required activities and resources
IV)Identifying the sequence of activities and resources

A) I and IV only
B) II and IV only
C) I, II, and III only
D) II, III, and IV only
E) I, II, III, and IV only

Question 73

Which one of the following is a type of product layout?

A) Assembly line
B) Job shop
C) Batch process
D) Functional layout
E) Retail layout

Question 74

Which of the following is not used to avoid costly shutdowns in product layouts?

A) Preventive maintenance
B) Inventories of spare parts
C) Having repair personnel available
D) Having idle stand-by plants activated during shutdowns
E) All of the choices are used

Question 75

Which of the following is associated with service process design rather than the design of manufacturing processes?

A) Involves the flow of customers or something belonging to customers
B) Needs to consider the extent of customer contact required
C) Involves process flow diagrams, also known as service blueprinting
D) Identifies potential failure points in the process
E) All of the choices are correct

Question 76

"CIM" stands for which of the following?

A) Customer-integrated manufacturing
B) Consumer-information manufacturing
C) Computer-integrated manufacturing
D) Computer-integrated monitoring
E) Constantly-integrated manufacturing

Question 77

Which of the following is an example of programmable automation?
I)N/C machines
II)Robots
III)Computer-integrated manufacturing

A) I only
B) II only
C) III only
D) I and II only
E) I, II and III

Question 78

In a process flow diagram,the diamond shape shows which of the following?

A) Events of interest
B) Decision points
C) Possible failure points
D) Inventory delays

Question 79

The benefits of flexible manufacturing systems (FMS)include all of the following EXCEPT:

A) reduced labour costs.
B) higher flexibility than fixed automation.
C) quick changeover from part to part.
D) less planning and development time required for new systems.
E) more consistent quality.

Question 80

Which of the following is not true about process layouts when they are compared to product layouts?

A) Lower maintenance costs
B) Easier routing and scheduling
C) Less investment in spare parts
D) Less specialized equipment
E) All of the choices are true