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University of Akron MANAGEMENT 6200 Chapter 3 1)A manufacturing process decision affects: A)           the type of workforce needed

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University of Akron

MANAGEMENT 6200

Chapter 3

1)A manufacturing process decision affects:

A)           the type of workforce needed.

B)            the type of equipment needed.

C)            the type of products that can be made. D) All of the above are correct.

 

 

2.            Highly automated batch processes that can reduce the cost of making similar groups of products are:

D)           functional layouts.

E)            flexible manufacturing systems.

F)            make-to-stock.

G)           adjacent processes.

 

3.            The time between completions of successive units on a production line is called: A) cycle time.

B)            takt time.

C)            elapsed time.

D)           work time.

 

4.            An advantage of a production line process is:

a.            the volume of output needed to justify the investment.

b.            the degree of flexibility of the process.

c.             the per unit cost of items produced on the line.

d.            the range of output typically produced on such a process.

 

5.            The manufacturing process used to make a wide variety of highly customized products in quantities as small as one is a:

a.            production line.

b.            continuous flow process. C) job shop.

D) fixed position.

 

 

6.            A sporting apparel manufacturer that produces t-shirts to commemorate significant athletic

 

achievements for proud students and alumni probably uses:

a.            a fixed position layout. B) batch manufacturing.

C)            a continuous flow process.

D)           a production line.

 

7.            The Devon Tower graces the Oklahoma City skyline and is officially the tallest building in the state. The manufacturing process used to produce this jewel is most probably:

a.            a fixed-position layout.

b.            a batch manufacturing process.

c.             a hybrid process.

d.            a job shop.

 

 

8.            Which of these manufacturing processes is most likely dictated by the physical characteristics of the product being produced?

a.            job shop

b.            batch

c.             production line D) continuous flow

 

 

9.            Products that are customized only at the very end of the manufacturing process are known as:

a.            make-to-stock.

b.            assemble-to-order.

c.             make-to-order.

d.            engineer-to-order.

 

10.          Products that use standard components but the final configuration of those components is customer-specific are known as:

a.            make-to-stock.

b.            assemble-to-order. C) make-to-order.

D) engineer-to-order.

 

11.          An assemble-to-order process occurs upstream from:

a.            design.

b.            material sourcing.

c.             fabrication.

d.            assembly/finishing.

 

 

12.          The greater the emphasis on intangible activities, the more management's attention will be directed to:

a.            buildings and property. B) training employees.

C)            truck fleets.

D)           material costs.

 

13.          The point where the customer interfaces directly with the service organization is: A) the front room.

B)            the back room.

C)            onstage.

D)           the floor.

 

14.          A legal service in a corporate acquisition probably scores:

a.            low on customization and high on physical activities.

b.            high on customer contact and low on intangible activities. C) high on customization and high on intangible activities.

D) low on customer contact and low on intangible activities.

 

15.          Champion Cooling has just signed a contract to assemble window air conditioners for another company. The list of tasks, including time requirements and immediate predecessors, follows. Initially, the plan was to make 300 units in an eight hour day but as the summer months approach, Champion Cooling finds themselves far behind in total production. They wish to reconfigure their production line in order to produce maximum output. What should their takt time be?

 

Task       Time (min)          Predecessor

Bolt compressor to base               5              None

Install coils and lines       6              Bolt compressor to base

Install fan motor               7              Install coils and lines

Install switch and thermostat     5              Install fan motor

Charge system and test 10           Install switch and thermostat

Cosmetic detailing           7              Charge system and test

 

a.            5

b.            6

c.             7 D) 10

 

 

 

16.          The process design team at a manufacturer has broken an assembly process into eight basic steps, each with a required time, and predecessor as shown in the table. They work a 7 hour day

 

and want to produce at a rate of 360 units per day. What should their takt time be?

 

Task       Time (sec)           Predecessor

A             45           --

B             50           A

C             40           A

D             55           B, C

E              40           D

F              65           D

G             25           E

H             35           F, G

 

a.            70 seconds

b.            65 seconds

c.             52 seconds

d.            25 seconds

 

17.          Refer to the scenario above. What is the theoretical minimum number of stations?

a.            four B) five

C)            six

D)           seven

 

18.          Refer to the scenario above. Operations managers and process engineers design a line that contains seven stations. What is the percentage of idle time?

A) 21.9%

B) 14.3%

C) 25.6%

D) 17.8%

 

 

19.          Refer to the scenario above. The manager assigns tasks to workstations and breaks ties using a longest operation heuristic. That is, if two or three tasks could be assigned to a given station, the manager assigns the longest task first and then fills in the remaining time at the workstation as completely as possible. Using this approach, what task(s) would be assigned at the fourth station?

a.            N, P B) M

C)            N, O

D)           O, P

 

20.          Refer to the scenario above. What task(s) should be assigned at the third workstation?

a.            B and E

 

b.            D

c.             C, E, and G D) F

 

 

21.          Refer to the scenario above. Without using more than one worker per station, what is the maximum output achievable in the 7.5 hour work day?

a.            1000 units

b.            1800 units

c.             1258 units D) 415 units

 

22.          Refer to the scenario above. The process design team realizes that the potential spike in demand for this device requires increased output. They elect to add a seventh worker to their production team at the first station. What is the net effect of adding this worker?

a.            Nothing—the output rate does not change.

b.            The output rate increases by 20%.

c.             The output rate increases by 10%.

d.            The output rate increases by 5%.

 

23.          Refer to the scenario above. What is the takt time?

a.            53.3 seconds B) 67.5 seconds

C)            75.8 seconds

D)           90 seconds

 

 

24.          Refer to the scenario above. The process engineer calculates the takt time and examines the task times indicated in the table. He decides to use the minimum cycle time instead and have the workers leave early each day once they have built 400 units. How much earlier would the workers leave?

a.            12 minutes and 53.3 seconds

b.            14 minutes and 20 seconds C) 16 minutes and 40 seconds

D) 18 minutes and 15 seconds

 

 

 

 

25.          Refer to the scenario above. What is the theoretical minimum number of stations that will be used if the line is balanced using the appropriate takt time?

 

a.            3

b.            4 C) 5

D) 6

 

26.          Refer to the scenario above. How many workers must be added to increase the output rate to one unit per minute?

a.            1

b.            2 C) 3

D) 4

 

27.          The table depicts a production line that has been balanced with a takt time of 2 minutes. What is the percent idle time of this balance?

 

Workstation       1              2              3              4              5              6

Task       A, B        C             D, E, F    G, H       I               J, K, L

Time (min)          1, 1         1.8          1, 0.5, 0.4             0.9, 0.8  1.8          0.5, 0.5, 0.6

 

a.            5% B) 10% C) 15%

D) Cannot be determined from the information provided.

 

28.          The table depicts a production line that has been balanced with a takt time of 2 minutes. What is the efficiency of this balance?

 

Workstation       1              2              3              4              5              6

Task       A, B        C             D, E, F    G, H       I               J, K, L

Time (min)          1, 1         1.8          1, 0.5, 0.4             0.9, 0.8  1.8          0.5, 0.5, 0.6

 

A) 82.5%

B) 85%

C) 87.5%

D) 90%

 

 

 

 

 

29.          The table depicts an production line that has been balanced with a takt time of 2 minutes. Where would you add a worker if you wanted to increase the output rate while keeping six work

 

stations?

 

Workstation       1              2              3              4              5              6

Task       A, B        C             D, E, F    G, H       I               J, K, L

Time (min)          1, 1         1.8          1, 0.5, 0.4             0.9, 0.8  1.8          0.5, 0.5, 0.6

 

a.            station 1

b.            station 2

c.             station 3

d.            station 6

 

30.          The table depicts a production line that has been balanced with a takt time of 2 minutes. If you could hire another six workers, which of these systems would result in the highest output rate?

 

Workstation       1              2              3              4              5              6

Task       A, B        C             D, E, F    G, H       I               J, K, L

Time (min)          1, 1         1.8          1, 0.5, 0.4             0.9, 0.8  1.8          0.5, 0.5, 0.6

 

a.            simply duplicating the existing line so you had two lines doing exactly the same thing

b.            assigning one worker to each activity and creating a single twelve station production line

c.             keeping the existing balance and assigning three workers to stations 1, two workers to station 2, two workers to station 3, one worker to station 4, two workers to station 5, and two workers to station 6

d.            you would be indifferent between alternatives a and b

 

31.          Refer to the scenario above. Balance the line according to the longest operation rule. What is the assignment for station 2?

a.            B, C, F

b.            E, H, F

c.             C,   D D) D, G

 

32.          Refer to the scenario above. Balance the line according to the longest operation rule. What is the efficiency of your line balance?

A) 85.66%

B) 90.28%

C) 88.14%

D) 83.88%

 

 

33.          Refer to the scenario above. What is the theoretical minimum number of stations needed?

a.            3

 

b.            4

c.             5

d.            6

 

34.          These three tables show the floor layout of 5 departments in an office building, the average number of daily trips between each pair of offices, and the distance between each pair of offices. What is the total cost of this layout if there is a $0.50 per foot transportation cost?

 

A) $460.00

B) $2300.00 C) $3037.50 D) $4785.50

 

 

 

35.          The majority of the total operating budget for most organizations is:

a.            engineering costs.

b.            advertising costs. C) supply chain costs.

D) equipment maintenance costs.