BSOP 209 Ch 9 Test Bank

8/13/2019 BSOP 209 Ch 9 Test Bank

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Operations Management, 10e (Heizer/Render)

Chapter 9 Layout Strategies

1) McDonald's "Made for You" kitchen system represents a strategic layout decision eventhough an obvious benefit of the system is a dramatic reduction in the inventory of foodprepared in advance.

Anser! #$%Diff! 1opic! &lobal company profileb(ective! no

*) he ob(ective of layout strategy is to develop an effective and efficient layout that illmeet the firm's competitive re+uirements.Anser! #$%Diff! 1opic! he strategic importance of layout decisionsb(ective! no

,) he ork cell layout- a special arrangement of machinery and e+uipment to focus on theproduction of a single product or group of related products- is for manufacturing applications

and has no relevance to services.Anser! A/%Diff! *opic! ypes of layoutb(ective! 02

3) he layout approach that addresses tradeoffs beteen space and material handling iscalled the fi4ed position layout.Anser! A/%Diff! *opic! ypes of layoutb(ective! 03

5) $tili6ation of the total "cube" is the dominant consideration in office layout.Anser! A/%Diff! *opic! ffice layoutb(ective! 01

2) ne guideline for a retail layout is to locate highdra items around the periphery of thestore.Anser! #$%Diff! *opic! #etail layoutb(ective! 0*

7) 8ategory management is the use of computer softare to evaluate the profitability ofmerchandising plans.Anser! #$%Diff! *opic! #etail layoutb(ective! 0*

9) /ervicescape refers to the physical surrounding in hich the service is delivered.Anser! #$%Diff! *opic! #etail layout

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b(ective! 0*

0) ne guideline for determining the arrangement and space allocation of a retail store is toplace highimpulse and highmargin items such as houseares and beauty aids in prominentlocations.Anser! #$%Diff! *

opic! #etail layoutb(ective! 0*

1;) 8rossdocking processes items as they are received- rather than placing them instorage> this helps e4plain hy "arehouses" are no called "distribution centers."Anser! #$%Diff! *opic! ?arehousing and storage layoutsb(ective! 0,

11) he dominant problem associated ith the fi4edposition layout is that orkers are fi4edin position- and cannot be reassigned.Anser! A/%Diff! *opic! i4edposition layoutb(ective! 03

1*) A processoriented layout is the traditional ay to support a product differentiationstrategy.Anser! #$%Diff! 1opic!


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Anser! #$%Diff! *opic! ?ork cellsb(ective! 02

19) he balancing of ork cells uses the same procedures as the balancing of an assemblyline.

Anser! A/%Diff! *opic! ?ork cellsb(ective! 02

10) A focused ork center is ell suited to the production of a large family of productsre+uiring similar processing- even if their demands are not very stable.Anser! A/%Diff! *opic!


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*,) A product re+uires *3 separate tasks- and the sum of those task times is 13 minutes> ifthe cycle time is * minutes- then at least 1* orkstations ill be needed.Anser! A/%Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

*3) =f the schedule calls for the production of 1*; units per day and 39; minutes ofproduction time are available per day- the ma4imum cycle time ould be 3 minutes.Anser! #$%Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

*5)


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*0) ?hich of the folloing is notone of McDonald's "seven ma(or innovations"CA) the Bappy Meal) drivethrough indos8) breakfast menusD) play areas%) "Made by You" kitchen system

Anser! ADiff! *opic! &lobal company profileb(ective! no

,;) he ob(ective of layout strategy is toA) minimi6e cost) develop an efficient and effective system that meets competitive re+uirements8) ma4imi6e fle4ibilityD) minimi6e space used%) minimi6e material handling costsAnser! Diff! *opic! he strategic importance of layout decisions

b(ective! no

,1) he main goal of retail layout isA) minimi6ing material handling cost) ma4imi6ing highmargin sales8) minimi6ing storage costsD) minimi6ing space re+uired%) none of the aboveAnser! Diff! *opic! ypes of layoutb(ective! 0*

,*) ?hich layout's main ob(ective is to e+uali6e the task time for each stationC

A) ork cell) fi4ed position8) process orientedD) (ob shop%) product orientedAnser! %Diff! *opic! ypes of layoutb(ective! 07

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,,) A hospital's layout most closely resembles hich of the folloingCA) product oriented) ork cell8) (ob shopD) pro(ect%) none of the above

Anser! 8Diff! *opic! ypes of layoutb(ective! 05

,3) Deloitte ouche solved the empty desk problem byA) eliminating permanent desks) implementing a "hoteling" program8) creating open officesD) none of the aboveAnser! Diff! *opic! ypes of layoutb(ective! 01

,5) he layout strategy that deals ith low-volume- high-varietyproduction isA) fi4edposition layout) retail layout8) arehouse layoutD) office layout%) none of the aboveAnser! %Diff! *opic! ypes of layoutb(ective! 05

,2) "A special arrangement of machinery and e+uipment to focus on production of a singleproduct or group of related products" describes hat layout typeC

A) fi4edposition layout) intermittent production8) focused factoryD) ork cell%) arehouse layoutAnser! DDiff! *opic! ypes of layoutb(ective! 02

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,7) A good layout re+uires determiningA) material handling re+uirements) capacity and space re+uirements8) environment and aestheticsD) cost of moving beteen various ork areas%) all of the above

Anser! %Diff! *opic! ypes of layoutb(ective! no

,9) #etail layouts thrive on the notion thatA) handling costs should be minimi6ed) storage costs should be minimi6ed8) average customer visit duration should be ma4imi6edD) space used should be minimi6ed%) ma4imi6ing customer e4posure rate ma4imi6es sales and profitAnser! %Diff! *opic! #etail layout

b(ective! 0*

,0) /lotting feesA) are charged by retailers to stock a product) can amount to over E*5-;;;8) are not a part of ?alMart's business practicesD) can reduce the ability of small businesses to introduce ne products%) all of the aboveAnser! %Diff! *opic! #etail layoutb(ective! 0*

3;) ?hich of the folloing is not a retail layout practiceC

A) highdra items along periphery) distribute poer items throughout store8) endaisle locations are used to ma4imi6e product e4posureD) highmargin and impulse items in prominent locations%) All of the above are retail layout practices.Anser! %Diff! *opic! #etail layoutb(ective! 0*

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31) Bo are retail layouts (udgedCA) sales FE) per s+. ft. For linear foot in certain situations)) total storage cost8) average customer trip durationD) minimi6ing total space re+uired%) Any of the above are effective measures.

Anser! %Diff! *opic! #etail layoutb(ective! 0*

3*) he fi4edposition layout ould be most appropriate in hich of the folloing settingsCA) a fastfood restaurant) a doctor's office8) a casual dining restaurantD) a cruise ship assembly facility%) none of the aboveAnser! DDiff! *opic! i4edposition layout

b(ective! 03

3,) or hich of the folloing operations ould a fi4edposition layout be most appropriateCA) assembling automobiles) producing G sets8) constructing a highay tunnel or bridgeD) refining of crude oil%) running an insurance agencyAnser! 8Diff! ,opic! i4edposition layoutb(ective! 03

33) ecause the fi4edposition layout problem is so difficult to solve onsite- operations

managersA) virtually never employ this layout strategy) utili6e this approach only for construction pro(ects such as bridges and office toers8) increase the si6e of the siteD) often complete as much of the pro(ect as possible offsite%) utili6e this layout only for defense contractorsAnser! DDiff! *opic! i4edposition layoutb(ective! 03

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35) ne factor impacting the fi4edposition layout strategy isA) minimi6ing difficulties caused by material flo varying ith each product) re+uiring fre+uent contact close to one another8) the provision of locost storage ith locost material handlingD) the movement of material to the limited storage areas around the site%) balancing product flo from one ork station to the ne4t

Anser! DDiff! *opic! i4edposition layoutb(ective! 03

32) he type of layout hich features departments or other functional groupings in hichsimilar activities are performed isA) processoriented) productoriented8) fi4edpositionD) mass production%) unit productionAnser! ADiff! *

opic!


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30) ?hich of the folloing is not an information re+uirement for solving a loaddistanceproblemCA) a list of departments or ork centers) a pro(ection of ork flos beteen the ork centers8) the distance beteen locationsD) a list of product cycle times

%) the cost per unit of distance to move loadsAnser! DDiff! *opic!


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5,) ?hich of the folloing is true for process layouts- but false for productoriented layoutsCA) lo inprocess inventories) fle4ibility in e+uipment and labor assignments8) lo variety of productsD) high volume of output%) often solved by assembly line balancing

Anser! Diff! *opic!


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57) ?hich of the folloing is true of a focused factoryCA) =t may be focused in ays other than by product or layout.) =t may be focused only by processing re+uirements.8) =t is much like a product facility ithin an otherise process facility.D) All of the above are true.%) Ione of the above is true.

Anser! ADiff! *opic!


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21) ?hich of the folloing does not support the retail layout ob(ective of ma4imi6ingcustomer e4posure to productsCA) locate highdra items around the periphery of the store) use prominent locations for highimpulse and highmargin items8) ma4imi6e e4posure to e4pensive itemsD) use endaisle locations

%) convey the store's mission ith the careful positioning of the leadoff departmentAnser! 8Diff! *opic! #etail layoutb(ective! 0*

2*) Ambient conditions- spatial layout and functionality- and signs- symbols- and artifactsare allA) indicators of imbalance on an assembly line) indicators that crossdocking has been successful8) elements of customi6ation in a arehouse layoutD) elements of servicescapes%) elements of successful office layoutsAnser! D

Diff! *opic! #etail layoutb(ective! 0*

2,) alancing locost storage ith locost material handling is important in aFn)A) fi4edposition layout) processoriented layout8) office layoutD) repetitive and productoriented layout%) arehouse layoutAnser! %Diff! *opic! ?arehousing and storage layoutsb(ective! 0,

23) ?hich of the folloing requiresan information system that provides inbound productidentification- its destination- and routing of the product to the designated outboundvehicleCA) phantomdocking) random stocking8) A/#/D) customi6ing%) crossdockingAnser! %Diff! *opic! ?arehousing and storage layoutsb(ective! 0,

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25) he ma(or problem addressed by the arehouse layout strategy isA) minimi6ing difficulties caused by material flo varying ith each product) re+uiring fre+uent contact close to one another8) addressing tradeoffs beteen space and material handlingD) balancing product flo from one ork station to the ne4t%) none of the above

Anser! 8Diff! *opic! ?arehousing and storage layoutsb(ective! 0,

22) he concept of customi6ing in a arehouse layoutA) is possible- but causes serious loss of oversight of the +uality function) cannot be considered seriously in today's high efficiency factories8) is theoretically sound- but several years aay in practiceD) is a ne trend in valueadded activities in arehouses%) none of the aboveAnser! DDiff! *opic! ?arehousing and storage layouts

b(ective! 0,

27) A/#/ stands forA) automated storage and retrieval system) automated storage and recovery system8) automated scan and recogni6e systemD) automated scan and retail system%) none of the aboveAnser! ADiff! *opic! ?arehousing and storage layoutsb(ective! 0,

29) ?hich of the folloing is true of random stockingC

A) =t is a derivation of 8/.) =ts results alays minimi6e handling costs.8)


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20) 8rossdocking isA) seldomly placing an item in storage- it is sent straight from incoming to outbound) using docks for either incoming or outbound shipments8) using a single dock to unload and then load the same truckD) all of the above%) none of the above

Anser! ADiff! *opic! ?arehousing and storage layoutsb(ective! 0,

7;) ?hich one of the folloing is notcommon to repetitive and productoriented layoutsCA) a high rate of output) speciali6ation of labor8) ability to ad(ust to changes in demandD) lo unit costs%) All are common to productoriented layouts.Anser! 8Diff! *opic! #epetitive and productoriented layout

b(ective! 07

71) ?hich of the folloing is notan advantage of ork cellsCA) reduced direct labor cost) decreased use of e+uipment and machinery8) heightened sense of employee participationD) reduced ra material and finished goods inventory%) reduced investment in machinery and e+uipmentAnser! Diff! *opic! ?ork cellsb(ective! 02

7*) alancing a ork cell is done

A) before the ork cell e+uipment is se+uenced) as part of the process of building an efficient ork cell8) before takt time is calculatedD) so that each assembly line orkstation has e4actly the same amount of ork%) to minimi6e the total movement in a process layoutAnser! Diff! *opic! ?ork cellsb(ective! 02

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7,) akt time isA) the total ork time available divided by units re+uired by the consumer) the units re+uired divided by orkers re+uired8) a fictional time increment similar to a therbligD) the same thing as cycle time in a process layout%) an important consideration in balancing an assembly line

Anser! ADiff! *opic! ?ork cellsb(ective! 02

73) A process layout problem consists of 3 departments- each of hich can be assigned toone of four rooms. he number of different solutions to this problem is KKKKKKKKKK- althoughall of them may not have different material handling costs.A) 1) 38) 12D) *3%) unknonAnser! D

Diff! *opic!


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77) ?hich of the folloing is not one of the re+uirements of cellular productionCA) test Fpokayoke) at each station in the cell) ade+uate volume for high e+uipment utili6ation8) a high level of training- fle4ibility- and empoerment of employeesD) being selfcontained- ith its on e+uipment and resources%) identification of families of products- often through the use of group technology codes

Anser! Diff! *opic! ?ork cellsb(ective! 02

79) he assumption of stability of demand is important for (ustifying hich of the folloinglayout typesCA) fi4edposition layout) productoriented layout8) processoriented layoutD) all of the above%) none of the aboveAnser! Diff! *

opic! #epetitive and productoriented layoutb(ective! 07

70) ?hich layout type assumes an ade+uate volume for high e+uipment utili6ationCA) productoriented layout) processoriented layout8) fi4edposition layoutD) retail layout%) arehouse layoutAnser! ADiff! *opic! #epetitive and productoriented layoutb(ective! 07

9;) A productoriented layout ould be most appropriate for hich one of the folloingbusinessesCA) fast food) steelmaking8) insurance salesD) clothing alterations%) a grocery storeAnser! Diff! *opic! #epetitive and productoriented layoutb(ective! 07

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91) he assumptions necessary for a successful product layout include all of the folloingexceptA) ade+uate volume for high e+uipment utili6ation) standardi6ed product8) volatile product demandD) All of the above are appropriate assumptions.

%) Ione of the above is an appropriate assumption.Anser! 8Diff! *opic! #epetitive and productoriented layoutb(ective! 07

9*) ?hich of these layouts is most suitable for processing sugar from sugar beets or sugarcaneCA) processoriented layout) fi4edposition layout8) focused factoryD) productoriented layout%) ork cell layoutAnser! D

Diff! *opic! #epetitive and productoriented layoutb(ective! 07

9,) ?hich of the folloing is trueregarding fabrication linesCA) hey are the same thing as assembly lines.) hey are the same thing as focused factories.8) hey are a special type of processoriented layout.D) alancing their assembly line is more technological than orker oriented.%) Ione of the above is true.Anser! DDiff! *opic! #epetitive and productoriented layoutb(ective! 07

93) he central problem in productoriented layout planning isA) minimi6ing material handling ithin orkstations) minimi6ing labor movement beteen orkstations8) e+uali6ing the space allocated to the different orkstationsD) ma4imi6ing e+uipment utili6ation%) minimi6ing the imbalance in the ork loads among orkstationsAnser! %Diff! *opic! #epetitive and productoriented layoutb(ective! 07

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95) A disadvantageof productoriented layout is thatA) there is a lack of fle4ibility in handling a variety of products or production rates) high volume is re+uired because of the large investment needed to set up the process8) ork stoppage at any one point halts the hole operationD) All of the above are disadvantages of productoriented layouts.%) Ione of the above is a disadvantage of productoriented layouts.

Anser! DDiff! *opic! #epetitive and productoriented layoutb(ective! 07

92) he main advantage of a productoriented layout is typicallyA) lo ra material cost) employability of highly skilled labor8) high fle4ibilityD) lo capital cost%) lo variable cost per unitAnser! %Diff! *opic! #epetitive and productoriented layout

b(ective! 07

97) =n a productoriented layout- the process of deciding ho to assign tasks to orkstationsis referred to asA) station balancing) process balancing8) task allocationD) line balancing%) ork allocationAnser! DDiff! *opic! #epetitive and productoriented layoutb(ective! 07

99) =n assembly line balancing- the theoretical minimum number of orkstations isA) the ratio of the sum of all task times to cycle time) alays Fhen a fraction) rounded upard to the ne4t larger integer value8) not alays possible to reach hen tasks are actually assigned to stationsD) all of the above%) none of the aboveAnser! DDiff! *opic! #epetitive and productoriented layoutb(ective! 07

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90) =n assembly line balancing- cycle time Fthe ratio of available production time toscheduled production) is theA) minimum time that a product is alloed at each orkstation) ma4imum time that a product is alloed at each orkstation8) optimum time that a product is alloed at each orkstationD) desired cycle time that a product is alloed at each orkstation

%) all of the aboveAnser! Diff! *opic! #epetitive and productoriented layoutb(ective! 07

0;) A production line is to be designed to make 5;; %lMore dolls per day. %ach doll re+uires11 activities totaling 12 minutes of ork. he factory operates 75; minutes per day. here+uired cycle time for this assembly line isA) onehalf minute) one and onehalf minutes8) to minutesD) 5-5;; minutes%) cannot be determined from the information given

Anser! Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

01) A production line is to be designed for a (ob ith four tasks. he task times are *.3minutes- 1.3 minutes- ;.0 minutes- and 1.7 minutes. he ma4imum cycle time is KKKKKKKKKKand the minimum cycle time is KKKKKKKKKK minutes.A) 1.9> 1.3) 1.2> ;.08) 2.3> *.3D) *.3> ;.0%) none of theseAnser! 8Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

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0*) 8ycle time is computed asA) desired output divided by the daily operating time) daily operating time divided by the product of desired output and the sum of (ob times8) the product of desired output and the sum of (ob times divided by daily operating timeD) daily operating time divided by the scheduled output%) 1.;; minus station time

Anser! DDiff! *opic! #epetitive and productoriented layoutb(ective! 07

0,) Daily capacity of a product layout is determined byA) operating time divided by cycle time) cycle time divided by operating time8) operating time divided by total task timeD) total task time divided by cycle time%) cycle time divided by total task timeAnser! ADiff! *opic! #epetitive and productoriented layout

b(ective! 07

03) our hundred and eighty minutes of production time are available per day. /cheduledproduction is 1*; units per day. ?hat is the re+uired cycle timeCA) 3 minutes) 5 minutes8) 2 minutesD) 7 minutes%) 9 minutesAnser! ADiff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

05) A production line is to be designed for a product hose completion re+uires *1 minutesof ork. he factory orks 3;; minutes per day. 8an an assembly line ith five orkstationsmake 1;; units per dayCA) yes- ith e4actly 1;; minutes to spare) no- but four orkstations ould be sufficient8) no- it ill fall short even ith a perfectly balanced lineD) yes- but the line's efficiency is very lo%) cannot be determined from the information givenAnser! 8Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /kills

b(ective! 07

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02) our hundred and eighty minutes of production time are available per day. he schedulecalls for the production of 9; units per day. %ach unit of the product re+uires ,; minutes ofork. ?hat is the theoretical minimum number of orkstationsCA) *) ,8) 3

D) 5%) 2Anser! DDiff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

07) ?hich of the folloing is not a heuristic rule for assigning tasks to orkstations in aproduct layoutCA) longest tasks first) in order of most number of folloing tasks8) median tasks firstD) shortest tasks first

%) in accordance ith positional eightAnser! 8Diff! *opic! #epetitive and productoriented layoutb(ective! 07

09) =f a layout problem is solved by use of "heuristics-" this means thatA) there as no other ay to solve the problem) no computer softare as available8) the problem has only a fe alternatives to evaluateD) no optimum solution e4ists%) a "satisfactory" solution is acceptableAnser! %Diff! *opic! #epetitive and productoriented layoutb(ective! 07

00) ?hich of the folloing is a common heuristic for assembly line balancingCA) debits near the indos- credits near the door) manufacturers locate near materials- retailers locate near customers8) earliest due date firstD) ranked positional eight%) none of the aboveAnser! DDiff! *opic! #epetitive and productoriented layoutb(ective! 07

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1;;) An assembly line consists of *1 tasks grouped into 5 orkstations. he sum of the *1task times is 95 minutes. 8ycle time for the line is *; minutes. he efficiency of this line isA) 3.* percent) 17 percent8) 95 percentD) 1;; percent

%) none of the aboveAnser! 8Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

1;1) An assembly line consists of 159 tasks grouped into ,* orkstations. he sum of alltask times is 1;5 minutes. 8ycle time for the line is 3 minutes. he efficiency of this line isappro4imatelyA) 9 percent) *1 percent8) 9* percentD) 1;; percent

%) none of the aboveAnser! 8Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

1;*) McDonald's "Made for You" kitchen system represents a KKKKKKKKKK use of layoutdecisions.Anser! strategicDiff! 1opic! &lobal company profileb(ective! 05

1;,) KKKKKKKKKK layouts deal ith lovolume- highvariety production ith like machines ande+uipment grouped togetherAnser!


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1;5) AFn) KKKKKKKKKK groups orkers- their e+uipment- and spacesHoffices to provide forcomfort- safety- and movement of information.Anser! office layoutDiff! *opic! ffice layoutb(ective! 01

1;2) he KKKKKKKKKK is a nonnumeric method for determining hich departments are locatednear one another- and hich departments are kept farther apart.Anser! office relationship chart or relationship chartDiff! *opic! ffice layoutb(ective! 01

1;7) AFn) KKKKKKKKKK addresses flo- allocates space- and responds to customer behavior.Anser! retail layoutDiff! *opic! #etail layoutb(ective! 0*

1;9) KKKKKKKKKK are fees manufacturers pay to get their products displayed.

Anser! /lotting feesDiff! *opic! #etail layoutb(ective! 0*

1;0) KKKKKKKKKK refers to the physical surroundings in hich a service takes place- and hothey affect customers and employees.Anser! /ervicescapeDiff! *opic! #etail layoutb(ective! 0*

11;) KKKKKKKKKK avoids placing materials or supplies in storage by processing them as theyare received for shipment.Anser! 8rossdockingDiff! *opic! ?arehousing and storage layoutsb(ective! 0,

111) he pro(ect remains in one place and orkers and e+uipment come to that one orkarea in a KKKKKKKKKK layout.Anser! fi4edpositionDiff! *opic! #etail layoutb(ective! 0*

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11*) KKKKKKKKKK is the use of computer softare to evaluate the profitability ofmerchandising plans in a retail layout.Anser! 8ategory managementDiff! *opic! #etail layoutAA8/! $se of =b(ective! 0*

11,) KKKKKKKKKK is that element of balancing a ork cell that superficially resembles cycletime.Anser! akt timeDiff! *opic! ?ork cellsb(ective! 02

113) AFn) KKKKKKKKKK line is a machinepaced productoriented facility for buildingcomponents.Anser! fabricationDiff! *opic! #epetitive and productoriented layoutb(ective! 07

115) KKKKKKKKKK is the ma4imum time that the product is available at each orkstation.Anser! 8ycle timeDiff! *opic! #epetitive and productoriented layoutb(ective! 07

112) =dentify McDonald's "seven ma(or innovationsAnser! he seven ma(or innovations are indoor seating- drivethrough indos- breakfast

menus- play areas- the "Made for You" kitchen system- the selfservice kiosk- and the *1stcentury look.Diff! *opic! &lobal company profile

b(ective! no

117) =n hat specific areas does the layout decision establish a firm's competitive prioritiesCAnser! ayout decisions establish a firm's competitive priorities in the folloing areas!processes- fle4ibility- cost- capacity- and +uality of ork life.Diff! *opic! he strategic importance of layout decisionsb(ective! no

119) o develop a good facility layout- hat must be determinedCAnser! You need to consider the folloing to determine a good layout! selection ofmaterial handling e+uipment- capacity and space re+uirements- environment andaesthetics- flos of information- and cost of moving beteen various ork areas.Diff! *

opic! ypes of layoutb(ective! no

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110) =dentify the seven fundamental layout strategies. Describe the use of each one verybriefly.Anser! 1. ffice layout!


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1*3) %4plain ho a loaddistance model helps solve problems in process layout.Anser! he problem in process layout is to hold don material movement and materialhandling. he loaddistance model calculates these movements from department todepartment- and can find that set of departmental space assignments that minimi6e theaggregate material handling cost. his is an optimal layout for a process layout- given thepattern of loads and distances.Diff! *opic! F*) a high level of training- fle4ibility- and empoerment of employees>F,) being selfcontained- ith its on e+uipment and resources> and F3) test Fpokayoke) ateach station in the cell.Diff! *opic!


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1*9) 8onsider the five ideas for determining the overall arrangement of most retail stores.Bo are these ideas implemented Fa) in a supermarket- and Fb) in a fine department storeCF *. using prominent locations for highimpulse and highmarginitems> ,. distributing hat are knon in the trade as "poer items" to both sides of an aisle-

and dispersing them to increase the vieing of other items> 3. using end aisle locationsbecause they have a very high e4posure rate> 5. conveying the image of the store by carefulselection in the positioning of the leadoff department. /upermarkets make more use ofaisles- here ideas , and 3 are featured. Department stores are meandering- so there's lessuse of endcaps. oth types of retail seem to follo ideas 1 and 5. =dea * seems to beimplemented ith impulse items near the checkouts for both retail types. he supermarket'sstraight lines convey its strategy of lo cost> the department store's display areas convey itsfocus on image- brosing- etc.Diff! ,opic! #etail layoutAA8/! #eflective hinkingb(ective! 0*

1*0) riefly e4plain hat "slotting" is. ?hy is slotting considered a "controversial" practiceC

?hat ethical issues might arise ith regard to slottingCAnser! /lotting is the practice of manufacturers paying for retail shelf space. =t iscontroversial because some managers approve of the practice- but others do not. %thicalissues involved ith slotting are F1) such payments might be considered bribery- F*) suchpayments cost consumers more- and F,) such payments may interfere ith efficient andprofitable use of retail space.Diff! ,opic! #etail layoutAA8/! %thical #easoningb(ective! 0*

1,;) ?hat is a servicescapeC Bo is it related to the retail layout problemC ?hat are thethree elements of servicescape for dealing ith these human issuesCAnser! /ervicescape describes the physical surroundings in hich a service takes place.#ather than design a retail space strictly for profitability- managers must consider ho thesurroundingsLthe layoutLhave a humanistic effect on customers and employees. he threeelements are ambient conditions- spatial layoutHfunctionality- and signs- symbols- andartifacts.Diff! *opic! #etail layoutb(ective! 0*

1,1) ?hat is crossdockingC ?hy is it appropriate for some forms of arehouse layoutCAnser! 8rossdocking avoids placing materials or supplies in storage by processing themas they are received for shipment. =t avoids storing the product- saves space and receivingtime- and speeds up shipment to the ultimate destination.Diff! *

opic! ?arehousing and storage layoutsb(ective! 0,

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1,*) ?hat are the to basic types of product layoutsC %4plain ho they are alike- and hothey are different.Anser! he to types are fabrication lines and assembly lines. abrication lines buildcomponents on a series of machines- hile assembly lines put the fabricated parts togetherat a series of orkstations. abrication lines tend to be machine paced and re+uiremechanical changes to facilitate balance- hile assembly lines tend to be paced by ork

tasks assigned to individuals or to orkstations and are therefore balanced by moving tasksfrom one individual to another.

Diff! ,opic! #epetitive and productoriented layoutb(ective! 07

1,,) %4plain hat the purpose of assembly line balancing is. Describe briefly ho it is done.%4plain ho assembly line balancing supports the needs of product layout.Anser! Assembly line balancing attempts to put e+ual amounts of ork into each of theorkstations that assemble a product. he techni+ue begins ith a task list and precedencechart> to this is added demand data- from hich cycle time can be computed. his is thespeed at hich the line must move. hen the theoretical number of stations is calculated.%ach re+uired task is then assigned into one orkstation. his approach holds don the

amount of idle time in a product layout- and leads to higher utili6ation of the plant- and tohigher volume of output.Diff! ,opic! #epetitive and productoriented layoutb(ective! 07

1,3) Define the folloing terms that occur in assembly line balancing! cycle time- minimumnumber of orkstations- and efficiency.Anser! 8ycle time is the ratio of alloed ork time to units scheduled. he theoreticalminimum number of orkstations in an assembly line is determined by dividing the totaltaskduration time for the product by the cycle time. he efficiency of a line balance isdetermined by dividing the total task time assigned by the product of the number oforkstations times the cycle time.Diff! *opic! #epetitive and productoriented layoutb(ective! 07

1,5) ?hat is the role of heuristics in solving layout problemsC


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1,2) Assembly line balancing has (ust been used to solve a product layout problem. osolutions look especially attractive to the plant managers. oth solutions make the sameoutput per day- and both have the same number of orkstations. he managers ere goingto break the tie by looking at line efficiency- but discovered that both lines had the sameefficiency as ell. /hould they have been surprised at thisC %4plain.Anser! Io- they should not be surprised. %fficiency is the ratio of actual ork needed per

unit to time available. ?ork needed is clearly the same in both cases as the product is thesame. ?ork available is also the same- since both lines have the same number of stationsand the same cycle time. nce cycle time and number of stations are knon- so isefficiency- no matter hat tasks are assigned to hat stations ithin that frameork.Diff! ,opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

1,7) ?hat are the advantages and disadvantages of product layoutsCAnser! he advantages of a product layout are! he lo variable cost per unit usually associated ith highvolume- standardi6ed products o material handling costs #educed orkinprocess inventories

%asier training and supervision #apid throughput

he disadvantages are! he high volume re+uired because of the large investment needed to establish theprocess hat ork stoppage at any point halts the hole operation A lack of fle4ibility hen handling a variety of products or production ratesDiff! *opic! #epetitive and productoriented layoutb(ective! 07

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1,9) Develop a solution for the folloing line balancing problem- alloing a cycle time of 5minutes.a. Dra the precedence diagram for the set of tasks.b. 8alculate the theoretical minimum number of orkstations.c. alance this line using the longest task time heuristic.d. ?hat tasks are assigned to hich stationsC

e. Does the solution have the minimum number of stationsC %4plain.f. Bo much idle time is there- summed over all orkstationsCg. ?hat is the efficiency of this lineC

?ork askask imeFseconds)

ask


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Anser! he theoretical minimum number of orkstations is ,. alance places AD instation 1- 8 in station *- % in station ,- and & in station 3. he solution uses four stations- notthree. he


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1,0) An assembly line has been designed to make batterypoered beverage mi4ers. askdetails are shon in the table belo!

/tation ask Assignedask imeFminutes)

1 1 ,.;

* ,> 3 1.5> *.;, *> 5> 2 1.5> 1.5> 1.;3 7 ,.;5 9 *.52 0> 1;> 11 *.;> 1.;> 1.;

a. ?hat is the assigned cycle time Fin minutes)Cb. ?hat is the ma4imum output rate of this line in mi4ers per hourCc. ?hat is the total idle time per cycleCd. ?hat is the assembly line's efficiencyCAnser! 8ycle time is 3.; minutes Fgoverned by stations , and 2). Ma4imum output is 2;H3Q 15.; units per hour. =dle time is 1.; R ;.5 R ;.; R 1.; R 1.5 R ; Q 3.; minutes. %fficiencyis *;.;H*3.; Q 9,.,N.

Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

13;) Departments A- - 8- and D need to be assigned to four rooms 1- *- ,- and 3. heserooms are arranged in a ro- in that order- ith *; meters beteen each. he departmentalork flos are contained in the table belo.

a. ?hat is the material handling total of assigning A1- *- 8,- D3Cb. ?hat is the material handling total of assigning A1- ,- 83- D*C

lo Matri4Dept. A Dept. Dept. 8 Dept. D

Dept. A ; ,; 5 *;Dept. 5 ; 3; *;Dept. 8 ; 1; ; 3;Dept. D 1; 5 ; ;

Anser! Fa)he material handling total of A1- *- 8,- D3 is 55;;. Details! 1* FA)!*;4,;R*;45Q7;;> 1, FA8)! 3;45R3;4;Q*;;> 13 FAD)! 2;4*;R2;41;Q19;;> *, F8)!*;43;R*;41;Q1;;;> *3 FD)! 3;4*;R3;45Q1;;;> and ,3 F8D)! *;43;R*;4;Q9;;. hesum of these si4 elements is 5-5;;.Fb) he material handling total of A1- ,- 83- D* is 53;;- hich is also the optimalsolution. Details! 1* FAD)! *;4*;R*;41;Q2;;> 1, FA)! 3;4,;R3;45Q13;;> 13 FA8)!2;45R2;4;Q,;;> *, FD)! *;4*;R*;45Q5;;> *3 F8D)!3;43;R3;4;Q12;;> and ,3 F8)!

*;43;R*;41;Q1;;;. hese si4 elements sum to 53;;.Diff! *opic!


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lo able A 8 Di4edroom

A ; 5 9 , ; ; 7 28 ; * ; 0

D 5 1* 3 ;

Distanceable #oom 1 #oom * #oom , #oom 3#oom 1 ; ,; 2; 9;#oom * ,; ; ,; 5;#oom , 2; ,; ; *;#oom 3 9; 5; *; ;

Anser! he si4 elements of movement in the original solution are 1* FD)!24,;R1*4,;Q53;> 1, F8)! 742;R*42;Q53;> 13 FA)! 549;R;49;Q3;;> *, F8D)!04,;R34,;Q,0;> *3 FAD)! ,45;R545;Q3;;> and ,3 FA8)! 94*;R;4*;Q12;. he sum ofthese si4 elements is *3,;. his solution is not necessarily optimal because the pairise

comparison techni+ue does not inspect all possible solutions. Another possible solution is A3- 1- 8*- and D,- hich has a total movement of *7;;. he optimal assignment ofdepartments to rooms is A1- 3- 8*- and D,- hich has a total movement of *,*;. 8 isthus put farther from and closer to A- hich helps reduce movement.Diff! *opic!


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13*) 8yclone Appliances has developed a ne %uropeanstyle convection oven that ill bemade on an assembly line. he schedule re+uires 9; ovens in an 9hour day. he assemblyincludes seven tasks. he table belo indicates the performance time and the se+uencere+uirements for each task.

ask

15 H 2 Q *.5 or , orkstations. Fc) he precedencediagram appears belo.


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13,) An electronics manufacturer makes remote control devices for interactivecableGsystems. he folloing assembly tasks must be performed on each device.

ask Description


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Anser! he sum of the task times is 3.;5 minutes. he cycle time for *;; units output is2;;H*;; Q, minutes. he theoretical minimum number of stations is 3.;5H, Q 1.,5 or *.oth solutions use to stations and have 27.5N efficiency.

/tation askime

Fminutes)

ime leftFminutes

)#eady tasksFPfolloers)

AF2)-%F,)-F,)

1 A ;.5 *.5%F,)-F,)-F5

)

;.7 1.9%F,)-F,)-8F3

)

8 ;.3 1.3.%F,)-F,)-DF,

)% ;., 1.1 F,)-DF,) ;.* ;.0 DF,)-&F*)D ;., ;.2 &F*)-BF*)& ;.,5 ;.*5 BF*)

* B ;.3 *.2 =F1)

= ;.2 *. @F;)@ ;., 1.7

/ummary /tatistics8ycle time , minutes

ime allocated Fcycle time OP) 2 minutesHcycle

ime needed Fsum of tasktimes) 3.;5 minutesHunit=dle time Fallocatedneeded) 1.05 minutesHcycle%fficiencyFneededHallocated)

27.5N

alance Delay F1efficiency)

,*.5

NMin Ftheoretical) P ofstations *

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/tation askime

Fminutes)

ime leftFminutes

) #eady tasksA-%-

1 A ;.5 *.5 %-- ;.7 1.9 %--88 ;.3 1.3. %--D% ;., 1.1 -DD ;., ;.0 .BB ;.3 ;.3 ;.* ;.* &

* & ;.,5 *.25 == ;.2 *.;5 @

@ ;., 1.75/ummary /tatistics8ycle time , minutes

ime allocated Fcycle time O

P) 2 minutesHcycleime needed Fsum of tasktimes) 3.;5 minutesHunit=dle time Fallocatedneeded) 1.05 minutesHcycle%fficiencyFneededHallocated)

27.5N

alance Delay F1efficiency),*..5

NMin Ftheoretical) P ofstations *

Diff! *opic! #epetitive and productoriented layout

AA8/! Analytic /killsb(ective! 07

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133) A company is designing a product layout for a ne product. =t plans to use thisproduction line eight hours a day in order to meet a schedule of 3;; units per day. he tasksnecessary to produce this product are detailed in the table belo.

ask hat is the ma4imumCc. ?hat is the re+uired cycle time Fin seconds) in order to meet the scheduleCd. ?hat is the theoretical minimum number of orkstations needed to meet thescheduleC

e. alance this line using longest processing time.f. ?hat is the efficiency of the balance obtained in part eC

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Anser! he netork diagram appears belo. Minimum cycle time is 7; seconds Fthelongest task time)> ma4imum cycle time is *,3 seconds Fsum of the task times). #e+uiredcycle time is 39;H3;; Q 1.* minutes or 7* seconds Fhich is barely feasible). he theoreticalminimum number of stations re+uired is at least *,3H7* Q ,.*5 or 3.

/tation askime

Fseconds)

ime leftFseconds

)#eadytasksA-8-D

1 A 5;. **. 8-D-D **. ;. 8-

* ,2. ,2. 8-%8 *2. 1;. %

, % 7;. *. 3 ,;. 3*./ummary /tatistics8ycle time 7* seconds

ime allocated Fcycle time OP) *99 secondsHcycle

ime needed Fsum of tasktimes) *,3 secondsHunit

=dle time Fallocatedneeded) 53secondsHcycle%fficiencyFneededHallocated)

91.*5N

alance Delay F1efficiency)19.75

NMin Ftheoretical) P ofstations 3


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135) You have been asked to balance a flo shop assembly operation to achieve an outputrate of 9; units per eighthour day. ask times and precedence relationships are shon inthe table belo.

ask


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Anser! he precedence diagram appears belo. he desired cycle time for 9; units is 2minutes. he theoretical minimum number of stations is 1;.1 H 2 Q 1.29 or *.

/tation askimeFminutes)

ime leftFminutes

)#eady tasksFPfolloers)

AF3)-F3)-DF1)-%F

*)1 A 1.3 3.2 F3)-DF1)-%F*)

;.9 ,.9 DF1)-%F*)-8F,)8 ;.3 ,.3 DF1)-%F*)-F*)% ;.3 ,. DF1)-F*) *.1 ;.0 DF1)-&F1)

* D 1.9 3.* &F1)& *. *.* BF;)B 1.* 1.

/ummary /tatistics8ycle time 2 minutes

ime allocated Fcycletime O P) 1*

minutesHcycle

ime neededFsum oftask times) 1;.1 minutesHunit=dle time Fallocatedneeded) 1.0;;;;1

minutesHcycle

%fficiencyFneededHallocated)

93.12222N


15.9,,,3N

Min Ftheoretical) P ofstations *


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132) A firm operates a flo shop building kitchen cabinetry for recreational vehicles. hema(or activities of this process are listed belo.

askDurationFhours)


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Anser!

/tation ask ime Fhours)ime left

Fhours)#eady tasksFPfolloers)

AF2)-F3)1 A 3. 3. F3)-8F3)-DF*)

8 *. *. F3)-DF*)* 2. *. DF*)-%F*)-F*), D 2. *. %F*)-F*)3 % ,. 5. F*)

,. *. &F1)5 & 5. ,. BF;)

B 1. *./ummary /tatistics8ycle time 9 hours

ime allocated Fcycletime O P) 3; hoursHcycle

ime needed Fsum oftask times) ,; hoursHunit=dle time Fallocatedneeded) 1; hoursHcycle%fficiencyFneededHallocated) 75Nalance Delay F1efficiency) *5NMin Ftheoretical) P ofstations 3

Fb) he cycle time is 12;H*;Q9 hours> Fc) his line re+uires at least ,;H9Q,.75 or 3 stations>Fd) A and 8 are in /tation 1> is in /tation *> D is in /tation ,> % and occupy /tation 3> and& and B are in /tation 5. Fe) %fficiency is ,;H3;Q.75 or 75 percent.Diff! *

opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

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137) here are three ork centers FA- - and 8) behind the financial aid counter at a nearbyuniversity. hey can each fit into any of three office spaces F1- *- and ,) off the corridorbehind the desk. here is no student contact in these areas- only orkers. he distance 1*is *; feet- *, is ,; feet- and 1, is 5; feet. he matri4 of ork Ftrips per day) at the threecenters is in the folloing table. #emember that each trip must be a roundtrip Ffrom 1 to *and back- for e4ample).

A 8A *; ; 35 *58 2; ;

a. Bo many possible assignments are thereC ist them.b. 8alculate the total distance traveled in each of these assignments.c. ?hich assignment minimi6es distance traveledCAnser! Fa) here are ,S Q 2 assignments- listed in the table belo. Fb) he cost- in feet- ofeach assignment appears in the table belo. Fc) he loest cost assignment is A*- 1- 8,.

A 8 8ost

1 * , 1;-1;;1 , * 1;-3;;* 1 , 9-7;;* , 1 9-9;;, 1 * 11-1;;, * 1 1;-0;;

Diff! ,opic!


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139) Bemotech- =nc.- a biomedical technology and research laboratory- produces a standardblood filtering device on an assembly line basis. /i4 basic tasks are performed along anassembly line. he time to perform each task and the tasks that must immediately precedeeach task are in the table belo. enty pumps per 35;minute day must be produced bythe assembly line.

ask


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Anser! Fa) he appropriate diagram appears belo. Fb)he absolute minimum cycle time is17.1; minutes Fthe longest operation). he absolute ma4imum cycle time is 3*.9; minutesFthe sum of all task times). Fc) he theoretical minimum number of stations is 3*.9H**.5 Q1.0; or *- but the actual number of stations needed is ,. Fd) he re+uired cycle time is35;H*; Q **.5 minutes. Fe) he balanced line appears belo. Ff) he line's efficiency is only2,N. Fg) here is idle time at all stations> removing the smallest amount of idle time F5.3

minutes) from all stations reduces the cycle time from **.5 minutes to 17.1 minutes. heefficiency of the line rises to 9, percent.

/tation askime

Fminutes)

ime leftFminutes

)

#eadytasks

FPfolloers)

AF3)-8F,)1 A 5.3 17.1 8F,)-F,)

8 1.5 15.2 F,) ,.* 1*..3 DF*)D *.9 0.2 %F1)

* % 17.1 5.3 F;), 1*..9 0.7/ummary /tatistics8ycle time **.5 minutes

ime allocated Fcycletime O P) 27.5 minutesHcycle

ime needed Fsum of

task times) 3*.9 minutesHunit=dle time Fallocatedneeded) *3.7 minutesHcycle%fficiencyFneededHallocated)

2,.3;731N


,2.50*50N

Min Ftheoretical) P ofstations *

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/tation askime

Fminutes)

ime leftFminutes

)#eadytasks

1 A 5.3 11.7 8F,)-F,)8 1.5 1;.* F,)

,.* 7. DF*)D *.9 3.* %F1)

* % 17.1 ;. F;), 1*.9 3.,/ummary /tatistics8ycle time 17.1 minutes

ime allocated Fcycletime O P) 51., minutesHcycle

ime needed Fsum oftask times) 3*.9 minutesHunit=dle time Fallocatedneeded) 9.5;;;;3 minutesHcycle%fficiency

FneededHallocated)

9,.3,;70

Nalance Delay F1efficiency)

12.520*1N

Min Ftheoretical) P ofstations *Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

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130) A firm is planning to set up an assembly line to assemble 3; units per hour- and 57minutes per hour are productive. he time to perform each task and the tasks hichprecede each task are!

ask


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Anser! Fa) he appropriate diagram appears belo. Fb) 8ycle time is 57H3; Q 1.3*5minutes. Fc) he theoretical minimum number of stations re+uired is 2.;*H1.3*5 Q 3.** or 5.Fd) he balanced line appears in the softare output panel belo. Fe) he line's efficiency is2.;* H 9.55 Q 7;.3N

/tation askime

Fminutes)

ime leftFminutes

)#eadytasks

A1 A ;.20 ;.7,5

;.55 ;.195 8-D-%-* 1.1 ;.,*5 8-D-%, 8 ;.0* ;.5;5 D-%3 % ;.7 ;.7*5 D

D ;.50 ;.1,5 &5 & ;.75 ;.275 B

B ;.3, ;.*35 =2 = ;.*0 1.1,5/ummary /tatistics8ycle time 1.3*5 minutes

ime allocated Fcycletime O P) 9.530000 minutesHcycle

ime needed Fsum oftask times) 2.;* minutesHunit=dle time Fallocatedneeded) *.5*0000 minutesHcycle%fficiencyFneededHallocated) 7;.3;0,2Nalance Delay F1efficiency) *0.50;23NMin Ftheoretical) P ofstations 5

Diff! ,opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

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15;) An insurance claims processing center has si4 ork centers- any of hich can beplaced into any of si4 physical departmental locations. 8all the centers 1- *- ,- 3- 5- and 2-and the departments A- - 8- D- %- and . he current set of assignments is A,- 1- 82- D*- %3- and 5.

he Fsymmetric) matri4 of departmental distances- in meters is

1 2 3 4 !

1 5 ,; *; 15 *;2 3; 15 1; 1;3 5; *; 54 1; ,5 5!

he matri4 of ork flo Festimated trips per day) is among centers

A " C # $ %

& 15 *; ; ,; ;

" *; 5; ; 12; 1;C ; 5; ,; ; ,;# ,; 2; *; 7; ;$ 3; ; ; 1; 2;% ; ; ,; *; 5;

he firm estimates that each trip costs appro4imately E3.a. ?hat is the cost of the current assignmentCb. $se trialanderror to find one improved assignment.c. ?hat is that assignment- and hat is its costCAnser! Fa) he current assignment costs 13-;;; meters- or E52-;;;. Fb-c) he optimalsolution is 1;-35; meters- or E31-9;;- ith A,- 5- 83- D1- %2- and *. /tudents mayfind improved solutions other than the optimal solution.

Diff! ,opic!


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151) An assembly line ith 11 tasks is to be balanced. he longest task is *.3 minutes- theshortest task is ;.3 minutes- and the sum of the task times is 19 minutes. he line illoperate for 2;; minutes per day.a. Determine the minimum and ma4imum cycle times.b. ?hat range of output is theoretically possible for the lineCc. ?hat is the minimum number of stations needed if the ma4imum output rate is to be

soughtCd. ?hat cycle time ill provide an output rate of *;; units per dayCAnser! Minimum cycle time is *.3 minutes. Ma4imum cycle time is 19 minutes. Ma4imumoutput is 2;;H*.3 Q *5;> minimum output is 2;;H19 Q ,,.,. or ma4imum output- 19H*.3 Q7.5 or 9 stations ill be needed. o produce *;; units per day re+uires a ,minute cycletime.Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

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15*) A facility is trying to set up an assembly line- and has identified the various tasks- andtheir relationship to each other- as shon in the folloing table. hey ish to produce 2;;units per day- orking to 9hour shifts.

ask


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Anser! Fa) he precedence diagram appears belo. Fb) #e+uired cycle time is 02 seconds.Fc) *.35 or , orkstations are needed. Fd) he computer output places tasks A8D instation 1- % in station *- and &B in station ,. Fe) %fficiency is about 9* percent.

/tation ask

ime

Fseconds)

ime leftFseconds

)

#eady

tasksA--8-D

1 ,;. 22. A-8-D8 *5. 31. A-DA *;. *1. D-%D 1;. 11. %-

* % 55. 31. -& ,;. 11. &

, & *5. 71. BB 3;. ,1.

/ummary /tatistics8ycle time 02 seconds

ime allocated Fcycletime O P) *99 secondsHcycle

ime needed Fsum oftask times) *,5 secondsHunit=dle time Fallocatedneeded) 5, secondsHcycle%fficiencyFneededHallocated) 91.507**Nalance Delay F1efficiency) 19.3;*79NMin Ftheoretical) P ofstations ,


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15,) A ork cell is re+uired to make *;; computeri6ed diagnostic assemblies Fforinstallation into hybrid automobiles) each day. he cell currently orks an eight hour shift- ofhich seven hours is available for productive ork. ?hat is takt time for this cellCAnser! akt time Q 3*; minutes H *;; units re+uired Q *.1 minutesDiff! *opic! ?ork cellsAA8/! Analytic /kills

b(ective! 02

153) A ork cell is scheduled to build 1*; digital light processor FD


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152) A ork cell is re+uired to make 13; computeri6ed diagnostic assemblies Fforinstallation into hybrid automobiles) each day. he cell currently orks an eight hour shift- ofhich seven hours is available for productive ork. hese assemblies re+uire fiveoperations. /tandard times for these operations are! peration A- ,.; minutes- - 1.9minutes- 8- *.3 minutes- D- *.5 minutes- and %- 1.3 minutes. ?hat is takt time for this cellCBo many orkers ill be needed to achieve this scheduleC $se the grid belo to construct

a ork balance chart for this cell.

Anser! akt time Q 3*; H 13; Q , minutesHunit. otal operation time Q ,.; R 1.9 R *.3 R

*.5 R 1.3 Q 11.1 minutes. A minimum of four orkers are re+uired F11.1 H , Q ,.7)- but tobalance at , min.Hunit re+uires five. he balance chart appears belo.

Diff! *opic! ?ork cellsAA8/! Analytic /killsb(ective! 02

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157) An airport is trying to balance here to place three airlines. he distance beteenterminals and the number of trips that travelers make beteen airlines per day are listed.ind the assignment that minimi6es the distance travelers must alk.

Airline A 8rips to A 2; 9;

rips to 5; 1*;rips to 8 1;; 75 erminal 1 * ,Distance to erminal1 3;;; 5;;;Distance to erminal* 3;;; 2;;;Distance to erminal, 5;;; 2;;;

Anser! here are 2 possible assignments and the distance traveled for each scenario is11;FDistance A)R105FDistance 8) R 19;FDistance A8)Qtotal distanceAF1)F*)8F,)Q11;F3;;;)R105F2;;;)R19;F5;;;)Q*51;T

AF1)F,)8F*)Q11;F5;;;)R105F2;;;)R19;F3;;;)Q*33;TAF*)F1)8F,)Q11;F3;;;)R105F5;;;)R19;F2;;;)Q*305TAF*)F,)8F1)Q11;F2;;;)R105F5;;;)R19;F3;;;)Q*,55TAF,)F*)8F1)Q11;F2;;;)R105F3;;;)R19;F5;;;)Q*,3;TAF,)F1)8F*)Q11;F5;;;)R105F3;;;)R19;F2;;;)Q*31;TAirline A should be assigned terminal ,- Airline terminal * and Airline 8 terminal 1 tominimi6e the distance travelers must go.Diff! *opic!


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150) A manufacturing ork cell has a takt time of 7 minutes and is staffed by 1; orkers. =fthe ork cell delivers 29 units each day findA. he total operation time. he amount of time orked during the day for all 1; orkers combined8. =f the plant is open for only 9 hours per day- can the staff meet demandCAnser! otal operation time Q ?orkers re+uired O akt time Q 1;F7 minutes) Q 7; minutes

ime orked Q akt time O $nits Delivered O P orkers Q 7minutesOF29)O1; Q372; minutesQ 70.,, hours1; orkers O 9hoursHday Q 9; hours per day are available. rom only 70.,, are re+uired-so the orkers can meet demand.Diff! *opic! ?ork cellsAA8/! Analytic /killsb(ective! 02

12;) A company is trying to balance production beteen , orkstations on an assemblyline. 8urrently there are 5 tasks that need to be performed. hese tasks- A8D%- havere+uired times of * minutes- 3 minutes- 1 minutes- , minutes- and 1; minutes respectively.

he assembly line needs to produce 3; units per day to meet demand and can ork for upto 9 hours each day.

A. ?hat is the re+uired cycle timeC. ?hat is the theoretical minimum P of orkstationsC8. Assign the tasks according to shortest task time.D. =s there a better ay to divide the ork than in


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121) An assembly line is assigned as follos. /tation A task A- - and 8. /tation task D./tation 8 task % and . he task times are 7- ,- *- 0- 3- and 5 minutes respective to A- - 8-D- %- and . FAssume that there is no precedence relationships beteen the tasks- ie theycan be accomplished in any order)A. 8alculate the efficiency.. ?hat ould the assignment of tasks to stations be using shortest processing time

Fassuming the current ma4imum station time remains the cycle time)CAnser! %fficiencyQ /um of task time H FP /tations O ongest /tation duration) QF7R,R*R0R3R5)HF,O1*)Q 9,.,N/tation A ould be assigned task 8 for a total of * minutes- task for a total of 5 minutes-

ask % for a total of 0 minutes. ask cannot be assigned because the total ould be 13minutes hich is greater than the 1* ma4imum. herefore /tation ould be assigned task for a total of 5 minutes and task A for a total of 1* minutes. inally station 8 ould beassigned task D for a total of 0 minutes.Diff! *opic! #epetitive and productoriented layoutAA8/! Analytic /killsb(ective! 07

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BSOP 209 Ch 9 Test Bank