Deck 8: Process Design and Facility Layout

Question 1

Programmable automation requires less changeover time than flexible automation.

Answer 1

False

Question 2

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

Answer 2

True

Question 3

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

Answer 3

True

Question 4

Continuous processing is employed when a customized output is required.

Question 5

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

Question 6

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

Question 7

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

Question 8

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

Question 9

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

Question 10

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

Question 11

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

Question 12

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

Question 13

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 14

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

Question 15

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

Question 16

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 17

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.

Question 18

The use of robots is one form of programmable automation.

Question 19

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

Question 20

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

Question 21

Process layouts tend to have low in-process inventories.

Question 22

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

Question 23

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

Question 24

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

Question 25

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

Question 26

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

Question 27

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

Question 28

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

Question 29

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

Question 30

A grocery store would be categorized as a process layout.

Question 31

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

Question 32

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

Question 33

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 34

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

Question 35

Product layouts achieve high utilization of labour and equipment.

Question 36

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

Question 37

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

Question 38

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

Question 39

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

Question 40

Cellular layouts are like miniature versions of product layouts.

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

The process flow diagram for services is called a service blueprint.

Question 43

Heuristic approaches to line balancing guarantee an optimal solution.

Question 44

Process design determines the structure of a process-that is,the sequence of operations (the workflow),resources,and controls needed for a particular process

Question 45

Process design determines the structure of a process-that is,the sequence of operations (the workflow),resources,and controls needed for a particular process.

Question 46

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

Question 47

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 48

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

Question 49

Which of the following is not 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)Proximity of internal resources

Question 50

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

Question 51

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

Question 52

A core process is a process that assists the operations of an organization.

Question 53

Automation is the application of scientific discoveries to the development and innovation of goods and services and/or the processes that produce them.

Question 54

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)Continuous

Question 55

A precedence network matrix shows the combination of a product's quantity and variety,and the flexibility of the processes that make it.

Question 56

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

Question 57

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

Question 58

A swim lane diagram is a process map in which each function/role's activities are in its row/lane.

Question 59

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

Question 60

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

Question 61

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 62

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 63

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)Limit interaction between the customer and server.

Question 64

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 65

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 66

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

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

Question 67

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 68

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 69

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

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

Question 70

Which of the following is not 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)Location of departments,work centres or equipment in the facility/factory/plant.

Question 71

Which of the following is not an advantage of automation?

A)Reduced output variability
B)Reduced variable costs
C)Machines are much more flexible than human labour
D)Machines don't strike or file grievances.
E)Machines run automatically

Question 72

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.

Question 73

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 74

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

Question 75

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 76

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)Flexible manufacturing system

Question 77

"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 78

The incremental approach to process design does not involve which of the following?

A)Identifying process boundaries (inputs and outputs)and the level of detail required.
B)Following the normal flow of materials through the transformation process.
C)Identifying the required activities and resources.
D)Identifying the sequence of activities and resources.
E)Determine how complete the input materials should be.

Question 79

Which of the following is not an example of programmable automation?

A)N/C machines
B)Robots
C)Computer-integrated manufacturing
D)Flexible manufacturing systems
E)I Manual automation

Question 80

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