Operations Management Ch 10- Facility Layout
Steps of designing process layouts?
1. Gather information 2. Develop alternative block plans 3. Develop a detailed layout
When developing a detailed layout, what tools would be used? - MS Excel - MULTISTORY - CRAFT++ - 3-D models and CAD software - Architecture Software
3-D models and CAD software
Which of the following statements is not true? - A perfectly balanced line has no bottlenecks. - It might be possible to split a bottleneck task into two smaller non-bottleneck tasks. - A production process always has at least one bottleneck. - A bottleneck task is the longest task in a process. - The bottleneck determines the lowest possible cycle time.
A perfectly balanced line has no bottlenecks.
Which popular facility layout software package uses a from-to matrix? - CONWIP - MRP - ALDEP - LAYOUT - CRAFT
CRAFT
Describe Hybrid layouts
Combine aspects of both process and product layouts
Describe Product layouts
Designed to produce a specific product efficiently
What tools are available to facilitate developing a detailed layout in step 3 of designing process layouts?
Drawings 3-D models CAD software
What considerations need to be made when developing a detailed layout in step 3 of designing process layouts?
Exact sizes/shapes of departments and work centers including aisles and stairways
What type of layout are Dams?
Fixed-position
What type of layout are aircraft manufacturing sites?
Fixed-position
What type of layout are bridges?
Fixed-position
What type of layout are construction sites?
Fixed-position
What type of layout are shipbuilding sites?
Fixed-position
What type of layout requires all resources to be brought to the site?
Fixed-position
Describe Process layouts
Group similar resources together based on similar processes/functions
Type of layout: group technology or cell layouts
Hybrid
What type of layout are grocery stores?
Hybrid
What type of layout are retail stores?
Hybrid
What type of layout is Winnebago?
Hybrid
How do hybrid layouts combine process and product layouts?
Identify parts of process layout operation that can be standardized and produce them in a product layout format
Type of layout: Facilities are less capital intensive
Process
Type of layout: Facilities are more labor intensive
Process
Type of layout: Material handling costs are higher
Process
Type of layout: Processing rates are slower
Process
Type of layout: Resources have greater flexibility
Process
Type of layout: Scheduling resources & work flow is more complex
Process
Type of layout: Space requirements are higher
Process
Type of layout: resources used are general purpose
Process
What type of layout is a Department store?
Process
What type of layout is a Metalworking shop?
Process
What type of layout is a University?
Process
What type of layout is a hospital?
Process
What type of layout is a tool and die manuf.?
Process
What type of layout is walmart?
Process
Which layout is able to produce a large number of different products?
Process
What are the 4 basic layout types?
Process layouts Product layouts Hybrid layouts Fixed-Position layouts
Which of the following is more like a product layout as compared to a process layout? - Resources used are general purpose. - Facilities are less capital intensive. - Processing rates are faster. - Space requirements for inventory storage are higher. - Scheduling resources is more challenging.
Processing rates are faster.
Type of layout: Facilities are capital intensive
Product
Type of layout: Flexibility is low relative to the market
Product
Type of layout: Material handling costs are lower
Product
Type of layout: Processing rates are faster
Product
Type of layout: Resources are specialized?
Product
Type of layout: Space requirements for inventory storage are lower
Product
What type of layout are assembly lines?
Product
What type of layout are cafeterias?
Product
What type of layout is See's Candies?
Product
What type of layout is Toyota?
Product
What type of layout is a car wash?
Product
Which layout is able to produce a small number of products efficiently?
Product
Describe Fixed-Position layouts
Product is too large to move (e.g. a building)
What are the two primary tools used to identify closeness measures during the layout design process? - REL chart and from-to matrix - MRP chart and from-to matrix - x-bar chart and from-to matrix - MRP chart and x-bar chart - x-bar chart and REL chart
REL chart and from-to matrix
What is the shortest distance between two locations using north-south and east-west movements called? - Euclidean distance - Triangulated distance - Rectilinear distance - Socratic distance - Latitude-longitude (LL) distance
Rectilinear distance
What is a challenge with fixed-position layout?
Scheduling of crews and resources
Which of the following is more like a product layout as compared to a process layout? - Resources used are general purpose. - Facilities are less capital intensive. - Processing rates are slower. - Space requirements for inventory storage are higher. - Scheduling resources is less challenging.
Scheduling resources is less challenging.
What do hybrid layouts maintain from product layouts?
Some of the efficiencies
What do hybrid layouts maintain from process layouts?
Some of the flexibility
What information needs to be gathered in step 1 of designing process layouts?
Space needed Space available Identify closeness measures (From-to matrix, REL, SLP)
Which of the following is more like a product layout as compared to a process layout? - Resources used are general purpose. - Facilities are less capital intensive. - Processing rates are slower. - Space requirements for inventory storage are lower. - Scheduling resources is more challenging.
Space requirements for inventory storage are lower.
Using a relationship chart to develop acceptable layouts is part of a classic layout technique called - Real layout planning - CHART - Systematic from-to planning - Systematic layout planning - SRP
Systematic layout planning
How are alternative block plans developed in step 2 of designing process layouts?
Using trial-and-error or decision support tools (load-distance model, ALDEP, CRAFT)
When are fixed-position layouts used?
When product is large, difficult/impossible to move
Process layout problems can become very complex because - managers are involved. - all resources will be moved. - all resources relationships are considered. - it requires complex software solutions. - it is a frequent activity.
all resources relationships are considered.
Which of the following is least like a process layout? - job shop - automobile plant - hospital - university - grocery store
automobile plant
According to the textbook, the available space of a facility is best seen by using a - photograph - detailed floor plan - architecture software package - block plan - overview plan
block plan
Which of the following is not a challenge for fixed-position layouts? - scheduling work crews - scheduling material deliveries - scheduling inspections - coordinating equipment - calculating load-distance factors
calculating load-distance factors
Which of the following is least like a fixed-position layout? - farm - shipbuilding - bridge construction - building construction - car wash
car wash
What is the term for the maximum amount of time each workstation has to complete its assigned task? - output rate - task time - station time - cycle time - output time
cycle time
Building construction is an example of which layout type? - inverted - hybrid - process - fixed position - product
fixed position
In a product layout facility the manager must decide - employees' salary - exactly what tasks will not be performed by every workstation - exactly what tasks will be performed by every workstation - exactly what vacation schedule must be followed - general sequence the work must be performed in
general sequence the work must be performed in
Which of the following is not one of the four basic layout types? - inverted - hybrid - process - fixed position - product
inverted
A job shop is most likely to use which layout type? - inverted - hybrid - process - fixed position - product
process
A car wash is an example of which layout type? - inverted - hybrid - process - fixed position - product
product
A company with a pure continuous processing system is most likely to use which layout type? - inverted - hybrid - process - fixed position - product
product
A high-volume paper mill is an example of which layout type? - inverted - circular - process - fixed position - product
product
For the general warehouse layout problem, which department should be located furthest from the dock? - least trips needed - most area needed - highest ratio of trips needed to area needed - smallest ratio of area needed to trips needed - smallest ratio of trips needed to area needed
smallest ratio of trips needed to area needed
Warehouse layouts have the key characteristics of process layouts except - number of loads is not a design consideration - location isn't a major consideration - there is movement between the storage areas - from trips are the only consideration - there is no movement between the storage areas
there is no movement between the storage areas
