MS350 Chapter 6

A map showing the flow of materials through a manufacturing system is known as a __________ process map.

make-to-stock

The __________ relationship identifies the restrictions imposed by product design and process technologies.

precedence

The calculated theoretical number of workstations should be ____________.

rounded up to the next highest integer.

In a project layout, a high degree of __________ is common.

task ordering

True or false: The longest required task time often defines the shortest possible workstation cycle time for production.

True

Which process layout is best used for manufacturing liquids?

continuous

In a _________ layout, machines are grouped according to type or function and parts travel to the appropriate location for processing.

workcenter

A computer manufacturer offers 3 types of hard disk drives, 2 types of monitors, 4 types of batteries, and 5 choices of operating systems. How many total combinations are possible using these choices?

120

_________________ is used to avoid expensive shut downs by operating 24 hours a day.

Continuous process

Inventory turn

Cost of goods sold/Average inventory

Which statement is true regarding differences between service and manufacturing organizations?

Manufacturing organization must plan and hold inventory.

A manufacturing cell is generally made up of ___________ machines.

dissimilar

A __________ line layout can increase operator access and improve workstation time.

flexible

The time between successive units coming off the end of an assembly line is referred to as

workstation cycle time

When parts are moved on a conveyor that passes a series of workstations in a uniform time interval, this is called the ___________________.

workstation cycle time

Standardization on the product-process matrix refers to

variations in the product

Workcenters are often focused on

one type of operation

The efficiency of an assembly-line balance must always be less than or equal to ______%

100

Which of the following statements about inventory measures is TRUE? 1. Days-of-supply measures how long (on average) a firm's inventory can support sales. 2. Inventory turn compares cost of goods sold to average inventory. 3. Total average inventory is the best measure of inventory. 4. Inventory turn and days-of-supply are unrelated measures.

1, 2

Which of the following statements about inventory measures is true 1. Days-of-supply measures how long (on avg) a firm's inventory can support sales 2. Inventory turn compares cost of goods sold to average inventory 3. Inventory turn and days-of-supply are unrelated measures. 4. Total average inventory is the best measure of inventory.

1, 2

Identify the true statements about assembly-line and continuous process layouts. 1. In an assembly line, a product goes through a progressive set of steps. 2. In a continuous process, a product moves continuously through the process. 3. Often, the item being produced in a continuous process is a liquid or chemical that actually flows through the system. 4. In an assembly line, the stations are completely independent of each other.

1, 2, 3

Which are characteristics of a continuous process line? 1. May operate 24 hours a day. 2. Shutdowns can be expensive. 3. Highly automated machinery is used. 4. Product is moved from one workstation to the next workstation in a sequence of events.

1, 2, 3

Rank the production process layouts from lowest- to highest-volume (top to bottom). Workcenter project manufacturing cell assembly line

1. Project 2. Workcenter 3. Manufacturing cell 4. Assembly line

Last year a firm had an average inventory of $1,500,000 and the cost of goods sold was $3,750,000. What was the days-of-supply last year?

146

Which of the following is NOT true about a workcenter layout? 1. A workcenter layout can produce a wide variety of products. 2. A workcenter layout is commonly used for systems with high production volumes. 3. In a workcenter layout, machines with similar functions are grouped together. 4. A workcenter layout is also called a job shop.

2

Last year a firm had an average inventory of $1,500,000 and the cost of goods sold was $3,750,000. What was the inventory turn?

2.5

An assembly line must produce 1,000 units in an 8 hour day. Assuming the line operates continuously, what is the required workstation cycle time?

28.8 seconds/unit Reason: 8 hr * 60 min * 60 sec = 28,800 28,800 / 1,000 = 28.8 seconds/unit

Which of the following is NOT a step in the process of developing a manufacturing cell? 1. Physically regroup machines into cells. 2. Identify dominant flow patterns for each family. 3. Determine which machines perform the same process. 4. Group parts into families that follow a common sequence of steps.

3

Which of the following is not a step in the process to balance an assembly line? 1. Determine the required workstation cycle time. 2. Calculate the efficiency of the balance. 3. Determine the theoretical number of workstations. 4. Randomly assign tasks to workstations.

4

Which of the following is not a way to reduce the required time for a task? 1. Work overtime 2. Product redesign 3. Share the task among several workstations 4. Use a less skilled worker

4

If the sum of all task times is 100 seconds and the required cycle time is 21 seconds, what is the theoretical minimum number of workstations?

5 (100/21) = 4.76

For an assembly-line system with 6 workstations, the cycle time is 27 seconds and the sum of task times is 120 seconds. What is the efficiency of this balance?

74.1% 120 / (6*27) = 0.741

Days-of-Supply

Average Inventory/Cost of goods sold x 365

True or false: The total work at a workstation is equal to the sum of all tasks to complete a product.

False

The long-term relationship between inventory, throughput, and time flow is mathematically related to using _____________

Little's Law

_____________ techniques are typically used to manage production processes that follow a project layout structure.

Project Management

Total average value of inventory

Sum of raw material, work-in-process, and finished goods inventory

inventory measures

Total average value of inventory Inventory turn Days-of-Supply

True or False: Manufacturing processes are used to make tangible goods.

True

True or False: Typically, there is a trade-off where quicker response to customer demand comes at the expense of greater inventory investment.

True

Which of the following is an example of a product made with a project layout? a refrigerator a car a computer a house

a house

Workcenters with large amounts of interdepartmental traffic are often placed near exits. adjacent to each other. far away from each other. in areas where few machines are located.

adjacent to each other

A flexible line layout may improve assembly-line balance by

allowing work sharing among employees

An ________________ arranges processes according to the sequence of steps by which the product is manufactured.

assembly line

Which common layout format refers to the progressive build of a product?

assembly line

Which layout moves product from workstation to workstation at a controlled rate?

assembly line

Which of the following type of work flow is appropriate when production volume is high?

assembly line

Which the following describes the layout for items produced through a fixed sequence of workstations?

assembly line

Which of the following products would use a project layout?

bridge

With which of the following goods would a continuous process be used? Cars chemicals houses computers

chemicals

Lead time can vary based on ______________ and __________

customization of the product being produced the location of the manufacturing facility

Customer order decoupling points

determine lead times and can impact inventory investments

The required workstation cycle time is determined by

dividing the production time per day by the required output per day.

The practice of achieving high levels of customer service with a minimal inventory investment is known as

lean manufacturing

Which layout format groups machines to work on products that have similar processing requirements?

manufacturing cell

Which layout format groups machines to work on products that have similar processing requirements? Workcenter manufacturing cell assembly line project layout

manufacturing cell

a _________ _________ layout uses dedicated areas for production of similar products

manufacturing cell

When attempting to balance an assembly-line, the amount of idle time across workstations should be _________________.

minimized

If inventory turn is known, days-of-supply is calculated by

multiplying the inverse of inventory turn by 365 days.

In an assemble-to-order system, the total number of unique combinations possible is calculated by

multiplying the number of options for each choice together

On an assembly-line, the order in which tasks must be performed is called the __________.

precedence relationship

The _____ - _____ matrix shows when different production process types are used in relation to product volume and standardization.

product-process

To determine the required workstation cycle time, an analyst needs to know the _______ _______ per day and the required ______________ per day (in units).

production time output

In which production system does the product remain in one place while resources (such as workers or equipment) travel to the product when needed?

project layout

A production process map is built by

tracking the flow of material through the system

Which of the following is one of the dimensions depicted on a product-process matrix?

volume

In a _____ layout, machines are grouped according to type or function and parts travel to the appropriate location for processing

workcenter