Deck 7: Capacity and Facilities Design

Question 1

A relationship diagram provides a standard format for displaying manager preferences for department locations.

Answer 1

True

Question 2

The major layout concern for a process layout is where to locate departments or functional areas relative to each other.

Answer 2

True

Question 3

Capacity can be increased in one large step or incrementally.

Answer 3

True

Question 4

Equipment utilization is typically very high in processes with a fixed-position layout.

Question 5

Material storage and movement are directly affected by facility layout decisions.

Question 6

A process layout groups similar activities together according to the functions they perform.

Question 7

An important advantage of a process layout over a product layout is efficiency.

Question 8

Product layouts are sometimes referred to as functional layouts because they group similar activities together.

Question 9

The capacity cushion for a facility equals one minus utilization.

Question 10

Facility layout refers to the arrangement of machines, processes, departments, and other areas within a facility.

Question 11

Fixed-position layouts are used for projects when the product cannot be easily moved.

Question 12

Minimizing material handling cost is an important objective for a process layout.

Question 13

A process layout arranges activities sequentially.

Question 14

Product layouts have a higher degree of flexibility than process layouts.

Question 15

Line balancing strives to minimize bottlenecks in a process layout.

Question 16

For a given facility, the best operating level equals the percent of capacity utilization that minimizes unit cost.

Question 17

General as opposed to specific purpose equipment is typically found in a process layout.

Question 18

The basic objective of the facility layout decision is to ensure a smooth flow of inventory through the system.

Question 19

The major advantage of a process layout over a product layout is efficiency.

Question 20

Shipbuilding is an example of production system requiring a process layout.

Question 21

The efficiency of a flexible manufacturing system (FMS) comes from reductions in setup and waiting times.

Question 22

Most service facilities utilize fixed-position layouts.

Question 23

With a product layout the purpose of line balancing is to equalize the amount of work at each workstation.

Question 24

The desired cycle time refers to the maximum amount of time a product is allowed to spend at each workstation.

Question 25

A mixed-model assembly line processes each model in large batch sizes.

Question 26

A schematic diagram using weighted lines to denote location preference is called a relationship diagram.

Question 27

The majority of service facilities utilize process layouts.

Question 28

Precedence requirements reflect physical restrictions on the order in which operations are performed in a product layout.

Question 29

The time to complete a task in a mixed-model assembly line can vary from model to model.

Question 30

The maximum amount of time a product spends at any workstation is known as the bottleneck time.

Question 31

Block diagramming is a design tool for process layouts that takes into account the number of adjacent and non-adjacent moves.

Question 32

Line balancing is a procedure that requires cycle time to be the same as flow time.

Question 33

Which of the following is not a capacity expansion strategy?

A) Capacity lead strategy
B) Capacity lag strategy
C) Capacity stability strategy
D) Average capacity

Question 34

Single model and mixed model assembly lines are similar in layout and operation.

Question 35

Cellular layouts combine the flexibility of process layouts with the efficiency of product layouts.

Question 36

The balance delay is calculated by subtracting efficiency in percent from one hundred.

Question 37

A flexible manufacturing system (FMS) combines flexibility with higher efficiency.

Question 38

The line balancing procedure uses heuristics to specify which work elements are allocated to each workstation.

Question 39

Line balancing is constrained by precedence requirements and cycle time restrictions.

Question 40

Cellular layouts reduce transit time and increase set-up.

Question 41

Which of the following describes a process layout?

A) Equipment is general purpose and the workers are unskilled.
B) Equipment is specialized and the workers are highly skilled.
C) Equipment is general purpose and the workers are highly skilled.
D) Equipment is specialized and the workers are unskilled.

Question 42

Which of the following is not an objective of effective layouts?
A) increase the number of bottlenecks

A) reduce material handling costs
B) eliminate waste and redundant activities
C) improve communication and interaction among workstations

Question 43

Facility design has an impact on

A) quality.
B) productivity.
C) both quality and productivity.
D) None of these answer choices is correct.

Question 44

Similar activities are grouped together in departments or work centers according to the function with a __________ layout.

A) process
B) fixed-position
C) hybrid

Question 45

A ____________ provides historical data on the movement of parts and materials between departments.

A) manufacturing chart
B) block diagram
C) relationship diagram
D) load summary chart

Question 46

With a ___________ layout, activities are arranged in a line according to the sequence of operations.

A) product
B) process
C) fixed-position
D) cellular

Question 47

When higher levels of output cost less per unit to produce, the facility realizes

A) best operating level.
B) capacity cushion.
C) diseconomies of scale.
D) economies of scale.

Question 48

The material storage space required for in-process inventory is typically larger in a

A) cellular manufacturing layout.
B) product layout.
C) fixed-position layout.
D) process layout.

Question 49

Which of the following is not an objective of facility layout?

A) Minimize material handling costs
B) Utilize space efficiently
C) Utilize labor efficiently
D) Maximize bottlenecks

Question 50

Capacity is defined as the

A) minimum capability to produce.
B) maximum capability to produce.
C) average capability to produce.
D) None of these answer choices is correct.

Question 51

Which one of the following is not an example of a basic facility layout?

A) Fixed-position
B) Mixed-model
C) Product
D) Process

Question 52

When higher levels of output cost more per unit to produce, the facility realizes

A) best operating level.
B) capacity cushion.
C) diseconomies of scale.
D) economies of scale.

Question 53

Which of the following statements is true?

A) product layouts are flexible; process layouts are efficient
B) product layouts are efficient; process layouts are flexible
C) product and process layouts are equally flexible; neither are efficient
D) product and process layout are equally efficient; neither are flexible

Question 54

A format for displaying manager preferences for departmental locations is known as

A) relationship diagram.
B) process diagram.
C) block diagram.
D) hybrid diagram.

Question 55

One of the best known computerized packages available for designing process layouts is CRAFT. CRAFT stands for

A) computerized relationship activity and flow technique.
B) computerized relative allocation of facilities technique.
C) computerized relative assembly and flow technology.
D) computerized relationship assembly flow time.

Question 56

Material handling equipment that can follow multiple paths, move in any direction, and carry large loads of in-process inventory is most likely to be associated with a _________ layout

A) process
B) product
C) fixed-position
D) None of these answer choices is correct.

Question 57

Two techniques used to design process layouts are

A) block diagramming and assembly line balancing.
B) relationship diagramming and assembling line balancing.
C) relationship diagramming and assembly line balancing.
D) block diagramming and relationship diagramming.

Question 58

The ______________________ for a facility is the percent of capacity utilization that minimizes cost.

A) best operating level
B) capacity cushion
C) diseconomies of scale
D) economies of scale

Question 59

The ______________________ is the percent of demand held in reserve for unexpected occurrences.

A) best operating level
B) capacity cushion
C) diseconomies of scale
D) economies of scale

Question 60

The two critical decisions concerning capacity include

A) When to increase and how much to increase.
B) When to increase and where to locate.
C) How much to increase and where to locate.
D) None of these answer choices is correct.

Question 61

With line balancing the maximum amount of time the product is allowed to spend at each workstation is known as the

A) cycle time.
B) flow time.
C) efficiency of the line.
D) balance delay.

Question 62

Which of the following is not an area of advantage of cellular layouts?

A) material handling
B) setup time
C) capital investment
D) control

Question 63

If the line currently assembles 10 units every hour when fully functional, then the line's balance delay at this rate of output is

A) 66.67 %
B) 33.33%
C) 80.00%
D) 20.00%

Question 64

An assembly line consists of three workstations (WS) with each station's activity time as shown. The cycle time for this line is

A) 5 minutes.
B) 3 minutes.
C) 4 minutes.
D) 12 minutes.

Question 65

A schematic diagram that uses weighted lines to denote location preference is known as a

A) block grid.
B) block diagram.
C) a relationship grid.
D) a relationship diagram.

Question 66

Which of the following is not an area of disadvantage of cellular layouts?

A) cell balance
B) work-in-process inventory
C) capital investment
D) training and scheduling

Question 67

In a product layout, the process of assigning tasks to work stations is referred to as _________ balancing.

A) station
B) product
C) line
D) work

Question 68

An assembly line consists of three workstations (WS) with each station's activity time as shown. When fully operational this line could assemble _______ completed items every 60 minutes.

A) 20
B) 15
C) 12
D) 5

Question 69

A company produces shovels in five departments. The average number of loads transported between the five departments per month is given in the load summary chart. (Insert 2 x 3 grid - see page 268)
Load Summary Chart
From/to Department
Department 1 2 3 4 5
1 - 10 - - -
2 - - 30 25 -
3 30 - - - -
4 - 40 - - 20
5 - 15 - - -
Determine the number nonadjacent loads.

A) 25
B) 30
C) 50
D) 60

Question 70

Cycle time refers to the

A) time required for a product to go through a process layout.
B) time between finished units coming off an assembly line.
C) time needed to complete the tasks at a workstation.
D) difference between task time and workstation time.

Question 71

A company wants to produce 150 units during a 7-hour day. The desired cycle time needed to achieve this level of output is

A) 3.5 minutes.
B) 3.25 minutes.
C) 3.00 minutes.
D) 2.8 minutes.

Question 72

An assembly line consists of three workstations (WS) with each station's activity time as shown. The flow time for items on this line would be

A) 5 minutes.
B) 3 minutes.
C) 4 minutes.
D) 12 minutes.

Question 73

A company hopes to achieve a daily output of 200 units during 6 hours of production time. Assuming there is no lost time during the 6 hours of production, the desired cycle time to achieve the targeted level of output is

A) 3.0 minutes
B) 1.8 minutes
C) 1.5 minutes
D) 0.03 minutes

Question 74

To maximize an assembly line's efficiency the

A) line's balance delay must be minimized.
B) line's balance delay must be maximized.
C) cycle time must be less than the flow time.
D) flow time must be less than the cycle time.

Question 75

An assembly line consists of three workstations (WS) with each station's activity time as shown. When fully operational the maximum output for this line in 8 hours of production time would be

A) 40 units
B) 96 units
C) 120 units
D) 160 units

Question 76

A type of service layout designed to encourage browsing and increase impulse purchasing is known as a

A) freeflow layout.
B) grid layout.
C) loop layout.
D) spine layout.

Question 77

A company has a target output rate of 40 units every five hours when its line is fully operational. To achieve this target the firm must have a desired cycle time of

A) more than 12.50 minutes.
B) more than 10.00 minutes.
C) 7.5 minutes or less.
D) 8 minutes or less.

Question 78

A company produces shovels in five departments. The average number of loads transported between the five departments per month is given in the load summary chart. (Insert 2 x 3 grid - see page 268)
Load Summary Chart
From/to Department
Department 1 2 3 4 5
1 - - 30 - -
2 - - 30 25 -
3 30 - - - 20
4 - 40 - - 20
5 - 30 - - -
Determine the number nonadjacent loads.

A) 25
B) 30
C) 50
D) 60

Question 79

A ________layout encourages customer familiarity, has low costs, and is easy to clean.

A) freeflow layout
B) grid layout
C) spine layout
D) loop layout

Question 80

Most service organizations use

A) product layouts.
B) fixed-position layouts.
C) process layouts.
D) cellular layouts.