Chapter 1

Which of the following is NOT an example of a manual work system? A) A team of assembly workers putting together a piece of machinery using hand tools B) A quality control inspector using a micrometer to measure the diameter of a shaft C) A machinist using a file to round the edges of a rectangular part that has just been milled D) A production line in which the products are moved by mechanized conveyor belts and the workers at some of the stations use power tools to accomplish their processing or assembly tasks

D) A production line in which the products are moved by mechanized conveyor belts and the workers at some of the stations use power tools to accomplish their processing or assembly tasks

Manufacturing support activities include: A) Business functions B) Product design C) Manufacturing control D) All of these

D) All of these

A production order would not be of the form: A) An internal order to purchase raw materials based on forecast of future demand for a proprietary product B) An internal order based on the forecast of future demand for a proprietary product C) A customer order to buy the manufacturer's proprietary products D) An order to manufacture an item to a customer's specifications

A) An internal order to purchase raw materials based on forecast of future demand for a proprietary product

___________ denotes the pervasive use of computer systems to design the products, plan the production, control the operations, and perform information processing functions. A) Computer-integrated manufacturing B) Computer-aided manufacturing C) Computer-aided process planning D) Computer-aided design

A) Computer-integrated manufacturing

Which of the following is not a reason for choosing to use manual labor over automating? A) Improved reliability B) Shorter product life cycle C) Lack of capital D) A task is too difficult to automate

A) Improved reliability

An automation migration strategy is needed because: A) Manual operations are often used to bring a product to market quickly, but it is then desirable to automate gradually B) Manual work cells allow refinements to the product as demand grows C) Manual work cells may be added and removed as demand fluctuates D) All of these

A) Manual operations are often used to bring a product to market quickly, but it is then desirable to automate gradually

The following are all operations that need to be performed by human workers, even in a fully automated operation except: A) Material transportation B) Programming and computer operation C) Plant management D) Equipment maintenance

A) Material transportation

In which manufacturing systems are humans and machines combined to take advantage of their relative strengths? A) Worker-Machine System B) Partially Automated Work System C) Automated Work System D) Manual Work System

A) Worker-Machine System

Which of the following is NOT an example of an automated system? A) Workpieces moving along a conveyor belt to be automatically sorted B) An industrial robot moving pieces between stations where operations are performed by human workers C) An industrial robot sorting parts into packages and sending along a conveyor to the machine for sealing; sealed packages are removed by workers periodically D) An industrial robot moving workpieces into and out of a CNC

B) An industrial robot moving pieces between stations where operations are performed by human workers

The Master Production Schedule includes all of these except: A) The dates on which products are to be delivered to the customer B) Calculations to determine the number of workers needed C) A listing of all the products to be made D) The number of products to be delivered to the customer

B) Calculations to determine the number of workers needed

Capacity Planning is: A) Determining the sequence of individual processing and assembly operations needed to produce the part B) Determining the maximum productive power of the human and equipment resources a firm has available C) Tracking the storage and progression of a workpiece through the factory D) Ensuring that adequate materials are on-hand to produce the product

B) Determining the maximum productive power of the human and equipment resources a firm has available

Process Planning is: A) Ensuring that the quality of the product and its components meets the standards specified in the product design B) Determining the sequence of individual processing and assembly operations needed to produce the part C) Monitoring the progress of the product as it is being processed, assembled, moved, and inspected D) Listing the products to be made, the dates on which they are to be delivered, and in what quantities

B) Determining the sequence of individual processing and assembly operations needed to produce the part

Typical features of _________ automation are high initial investment, high production rates, and inflexibility of the equipment to accommodate product variety. A) Programmable B) Fixed C) Flexible D) Integrated

B) Fixed

Manufacturing control includes all of these except: A) Inventory control B) Process planning C) Shop floor control D) Quality control

B) Process planning

Production Planning includes all of these EXCEPT: A) Materials Requirements Plan B) Quality Assurance Plan C) Capacity Plan D) Master Production Schedule

B) Quality Assurance Plan

Which of the following is not a tool used in a manual work system: A) hammer B) drill C) caliper D) dolly

B) drill

A production line is: A) Does not contact the workpiece B) The same as a manufacturing system C) Contains multiple collections of equipment and workers D) Used for simple processes

C) Contains multiple collections of equipment and workers

Material Requirements Planning involves all of these except: A) Planning for materials B) Ordering raw materials from suppliers C) Determining the number of workers needed to produce the quantity of products requested D) Requisitioning materials from storage

C) Determining the number of workers needed to produce the quantity of products requested

A __________ automation system is capable of producing a variety of parts or products with virtually no time lost for changeovers from one design to the next. A) Integrated B) Programmable C) Flexible D) Fixed

C) Flexible

These are all manufacturing support functions except: A) Manufacturing planning B) Manufacturing control C) Inventory control D) Business functions

C) Inventory control

A manufacturer's product design sector would NOT include: A) Research and development B) Prototyping C) Market analysis D) Design engineering

C) Market analysis

Which of the following would not traditionally be a tool used in a worker-machine system? A) Mill B) Industrial robot C) Metal Brake D) Lathe

C) Metal Brake

Inventory control: A) Uses statistical approaches like Six Sigma B) Is unaffected by the master production schedule C) Must strike a balance between inventory on-hand and carrying costs D) Is not concerned with work-in-progress inventory

C) Must strike a balance between inventory on-hand and carrying costs

In _____________ automation, the production equipment is designed with the capability to change the sequence of operations to accommodate different product configurations. A) Fixed B) Integrated C) Programmable D) Flexible

C) Programmable

Which of the following is NOT an example of a worker-machine system? A) A machinist operating an engine lathe to fabricate a part for a product B) A fitter and an industrial robot working together in an arc-welding work cell C) A crew of workers operating a rolling mill that converts hot steel slabs into flat plates D) A material handling worker using a dolly to move cartons in a warehouse

D) A material handling worker using a dolly to move cartons in a warehouse

Manufacturing control is concerned with: A) Controlling the physical operations in the factory to implement the manufacturing plans. B) Monitoring the progress of the product as it is being processes. C) Deciding the right quantities of materials to keep on hand for a given product. D) All of these

D) All of these

Quality control: A) Should only occur after a product has been produced B) Is not concerned with raw materials for a product C) Requires humans to perform inspection operations D) Includes data collection and problem solving approaches to identify issues with the process

D) Includes data collection and problem solving approaches to identify issues with the process

Manufacturing planning includes all of these EXCEPT: A) Capacity planning B) Process planning C) Master scheduling D) Product design

D) Product design

Manufacturing supports systems are used to accomplish all of the following tasks except: A) Design the process and equipment B) Plan and control the production orders C) Satisfy product quality requirements D) Program automated robots

D) Program automated robots

Manufacturing Business Functions do NOT include: A) Order entry B) Sales forecasting C) Sales and marketing D) Quality control

D) Quality control

Automated operations are used to combat labor shortages in underdeveloped nations.

False

Automating a manufacturing operation invariably reduces production rate and labor productivity.

False

Fully-automated processes do not require human workers to be present at all times to monitor the process for anomalies.

False

Humans are better at storing large amounts of data and retrieving it from memory reliably

False

Humans are better than machines at making routine decisions quickly

False

In order for a system to be fully automated, it can have no worker-intervention whatsoever.

False

Manual work systems involve powered tools.

False

Manufacturing planning sends documentation and information to product design.

False

Manufacturing support systems control the product's progress through the factory but never come in contact with it.

False

Manufacturing support systems do not contact or add value to the product.

False

Manufacturing systems have no human intervention.

False

Modern production systems do not contain human workers.

False

Shop floor control and inventory control are completely different operations.

False

The USA Principle only applies to automation projects.

False

The master production schedule may include production quantities that exceed the manpower of the factory but not that of the equipment, because human labor can be quickly added and subtracted while machinery cannot.

False

The quantity of work-in-progress inventory at a given time has no effect on the bottom line of the manufacturer.

False

Worker-machine systems are defined by the use of non-automated power tools.

False

A manufacturing system is a logical grouping of equipment and workers which accomplishes processing or assembly operations.

True

A semi-automated machine operates without worker intervention for a portion of the cycle but requires worker intervention for the remainder of the cycle.

True

Automated elements of the production system can be separated into two categories: automation of the manufacturing systems in the factory and computerization of the manufacturing support systems.

True

Automation can be used to improve worker safety and improve working conditions.

True

Even in fully-automated systems, human workers are still needed to perform adjustments, routine maintenance, and attend to emergencies.

True

High investment in automation is economically justifiable due to increasing labor costs.

True

Humans are better at developing new solutions to problems than machines.

True

In order for a system to be fully automated, it must be able to operate for more than one cycle without worker intervention.

True

Manufacturing systems come into direct contact with the product.

True

Quality control is the only manufacturing support system that makes physical contact with the product.

True

Reducing worker fatigue improves product quality.

True

The manufacturing support systems are the people and procedures by which a company manages its production operations.

True

The master production schedule is a direct result of production planning.

True

The plant layout is considered to be a part of the facilities.

True