Operations Management, 12e (Heizer/Render/Munson) Show Section 1 The Strategic Importance of Layout Decisions 1) The objective of layout strategy is to develop an effective and efficient layout that will meet the firm's competitive requirements. 2) Which of the following is NOT one of McDonald's "seven major innovations"?
Answer: A 3) The objective of layout strategy is to:
Answer: B 4) Identify McDonald's seven major innovations. 5) In what specific areas does the layout decision establish a firm's competitive priorities? Section 2 Types of Layout 1) The layout approach that addresses trade-offs between space and material handling is called the fixed-position layout. 2) The ________ layout's main objective is to equalize the task time for each station.
Answer: E 3) A hospital's layout most closely resembles which of the following?
Answer: C 4) What layout strategy deals with low-volume, high-variety production?
Answer: E 5) "A special arrangement of machinery and equipment to focus on production of a single product or group of related products" describes what layout type?
Answer: D 6) A good layout requires determining:
Answer: E 7) Which of the statements below best describes office layout?
Answer: A 8) To develop a good facility layout, what must be
determined? 9) Identify the seven fundamental layout strategies. Describe the use of each one very briefly.
Diff: 3 Section 3 Office Layout 1) Utilization of the total "cube" is the dominant consideration in
office layout. 2) Deloitte & Touche solved the empty desk problem by:
Answer: B 3) In the office relationship chart, which rating reflects the highest importance for two departments' closeness to each other?
Answer: A 4) Which of the following constitutes a major trend influencing office layouts?
Answer: D 5) Workspace can inspire informal and productive encounters if it balances what three physical and social aspects?
Answer: C 6)
A(n) ________ groups workers, their equipment, and spaces/offices to provide for comfort, safety, and movement of information. 7) The ________ uses non-numeric "closeness" ratings to determine which departments should be
located near one another and which departments should be kept farther apart. Section 4 Retail Layout 1) One guideline for a retail layout is to locate high-draw items around the periphery of the store. 2) Category management is the use of computer software to evaluate the profitability of various merchandising plans for hundreds of categories. 3) Servicescape refers to the physical surrounding in which the service is delivered. 4) One guideline for determining the arrangement and space allocation of a retail store is to place high-impulse
and high-margin items in prominent locations. 5) The main goal of retail layout is:
Answer: E 6) Retail layouts are based on the notion that:
Answer: E 7) Slotting fees:
Answer: E 8) Which of the following is NOT a retail layout practice?
Answer: E 9) What is the primary reason why retailers tend to locate high-draw items around the periphery of the store?
Answer: C 10) Which of the following does NOT support the retail layout objective of maximizing customer exposure to products?
Answer: C 11) Ambient conditions; spatial layout and functionality; and signs, symbols, and artifacts are all:
Answer: D 12) A(n) ________ addresses flow, allocates space, and responds to customer behavior. 13) ________ are charges that manufacturers pay to get their products displayed. 14) ________ refers to the physical surroundings in
which a service takes place, and how they affect customers and employees. 15) ________ is the use of computer software to evaluate the profitability of merchandising plans in a retail layout. 16) What design guidelines help retail layouts to maximize customer exposure to products?
Diff: 3 17) Briefly explain what "slotting" is. What ethical issues might arise with regard to slotting? 18) What is a servicescape? How is it related to the retail layout problem? What are the three elements of servicescape for dealing with these human issues? Section 5 Warehouse and Storage Layouts 1) Cross-docking processes items as they are received, rather than placing them in storage. 2) Balancing low-cost storage with low-cost material handling is important in which of the following?
Answer: E 3) Which of the following reduces product handling, inventory, and facility costs, but requires both (1) tight scheduling and (2) accurate inbound product information?
Answer: E 4) The major problem addressed by the warehouse layout strategy is:
Answer: C 5) The concept of customizing in a warehouse layout:
Answer: D 6) ASRS stands for which of the following?
Answer: A 7) Which of the following is TRUE of random stocking?
Answer: E 8) Cross-docking refers to which of the following?
Answer: A 9) ________ avoids placing materials or supplies in storage by
processing them as they are received for shipment. 10) What is cross-docking? What are some of its benefits for manufacturing facilities, distribution centers, and
retailers such as Walmart? Section 6 Fixed-Position Layout 1) The dominant problem associated with the fixed-position layout is that workers are fixed in position, and they cannot be reassigned. 2) The fixed-position layout would be MOST appropriate in which of the following settings?
Answer: D 3) For which of the following operations would a fixed-position layout be MOST appropriate?
Answer: C 4) Because problems with fixed-position layouts are so difficult to solve well onsite, operations managers:
Answer: D
Answer: C 6) The project remains in one place and workers and equipment come to that one work area in a(n) ________ layout. 7)
The techniques for addressing the fixed-position layout are complicated by what three factors? What is an alternative strategy to address these? An alternative strategy is to complete as much of
the project as possible offsite. Section 7 Process-Oriented Layout 1) A process-oriented layout is the traditional way to support a product differentiation strategy. 3) Process-oriented layouts typically have low levels of work-in-process inventory. 4) The most
common tactic to arrange departments in a process-oriented layout is to minimize material handling costs. 5) Which type of layout features departments or other functional groupings in which similar activities are performed?
Answer: A 6) One of the major advantages of process-oriented layouts is:
Answer: C
Answer: B 8) Which of the following is NOT an information requirement for solving a load-distance problem to design a process layout?
Answer: D 9) The major problem addressed by the process-oriented layout strategy is:
Answer: D
Answer: D 11) A big advantage of a process-oriented layout is:
Answer: A 12) The disadvantages of process-oriented layout come from:
Answer: E 13) The typical goal used when developing a process-oriented layout strategy is to:
Answer: B
Answer: D 15) Solving a load-distance problem for a process-oriented layout requires that:
Answer: A 16) ________ layouts deal with low-volume, high-variety production with like machines and equipment grouped together. 17) Explain how a load-distance model helps solve problems in process layout. 18) Departments A, B, C, and D need to be assigned to four rooms 1, 2, 3, and 4. These rooms are arranged in a row, in that order, with 20 meters between each. The departmental work flows are contained in the table below. (a) What is the material handling total of assigning A-1, B-2, C-3, D-4?
Answer: (b) The material handling total of A-1, B-3, C-4, D-2 is 5400 (which is also the optimal solution). Details:
1-2 (A-D): 20 × 20 + 20 × 10 = 600; 1-3 (A-B): 40 × 30 + 40 × 5 = 1400; 1-4 (A-C): 60 × 5 + 60 × 0 = 300; 2-3 (B-D): 20 × 20 + 20 × 5 = 500; 2-4 (C-D):40 × 40 + 40 × 0 = 1600; and 3-4 (B-C): 20 × 40 + 20 × 10 = 1000. These six elements sum to 5400. 19) There are three work centers (A, B, and C) behind the financial aid counter at a nearby university. They can each fit into any of three office spaces (1, 2, and 3) off the corridor behind the desk. There is no student contact in these areas, only workers. The distance 1-2 is 20 feet, 2-3 is 30 feet, and 1-3 is 50 feet. The matrix of work (trips per day) at the three centers are shown in the following table. Remember that each trip must be a round-trip (from 1 to 2 and back, for example).
(a) How many possible assignments are there? List them.
Diff: 3 20) An insurance claims processing center has six work centers, any of which can be placed into any of six physical departmental locations. Call the centers 1, 2, 3, 4, 5, and 6, and the departments A, B, C, D, E, and F. The current set of assignments is A-3, B-1, C-6, D-2, E-4, and F-5. The (symmetric) matrix of departmental distances, in meters is shown below.
The matrix of work flow (estimated trips per day) is among centers is shown below.
The firm estimates that each trip costs approximately $4. What is the cost of the current assignment? 21) An airport is trying to balance where to place the three subgroups (local (A), regional (B), and national (C)) for an airline. The distance between terminals and the number of trips that travelers make between subgroups for flight connections per day are listed. Find the assignment that minimizes the distance travelers must walk.
Answer: There are 6 possible assignments and the distance traveled for each scenario is 110(Distance A-B) + 195(Distance C-B) + 180(Distance A-C) = total distance. Section 8 Work Cells 1) The work cell layout, a special arrangement of machinery and personnel to focus on the production of a single product or group of related products, is for manufacturing applications and has no relevance to services. 2) The work cell improves layouts by reducing both floor space and direct labor cost. 3) A focused work center is well suited to the production of a
large family of products requiring similar processing, even if their demands are not very stable. 4) Which of the following is NOT an advantage of work cells?
Answer: B 5) Balancing a work cell is done:
Answer: B 6) Mathematically, takt time is:
Answer: A 7) Which of the following is NOT one of the requirements of cellular production?
Answer: B 8) A(n) ________ is a special product-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility. 9) ________ is the pace (frequency) of production necessary (time per
unit) to meet customer orders. 10) "Having a focused work center is like having a plant within a plant." Discuss. Include in your discussion what conditions make focused work centers appropriate. 11) Why do work cells increase the utilization of equipment and machinery? 12) What are the advantages of focused factories? 13) Identify the four requirements for cellular production. 14) A work cell is required to make 200 computerized diagnostic assemblies (for installation into hybrid automobiles) each day. The cell currently works an eight hour shift, of which seven hours is available for productive work. What is takt time for this cell? 15) A work cell is scheduled to build 120 digital light processor (DLP) assemblies each week. These assemblies are later installed into home theater projection systems. The work cell has 7.5 hours of productive work each day, six
days per week. What is takt time for this cell? 17) A work cell is required to make 140 computerized diagnostic assemblies (for installation into hybrid automobiles) each day. The cell currently works an
eight hour shift, of which seven hours is available for productive work. These assemblies require five operations. Standard times for these operations are: Operation A, 3.0 minutes, B, 1.8 minutes, C, 2.4 minutes, D, 2.5 minutes, and E, 1.4 minutes. 18) Brandon's computer shop has hired a consultant to help apply operations management techniques to increase profits. Currently the shop sells most of its
computers to a high-end customized online retailer and sales are steady at 250 per month. A single work cell produces the computers. To produce the computer, three operations are required. First the parts must be assembled, next software must be installed, and finally the computer must be safely packed and labeled for shipping. These operations take 2 hours, 5 hours, and 1 hour respectively. If there are 6 available work hours each day and the shop operates 20 days per month find: 19) A manufacturing work cell has a takt time of 7 minutes. Exactly 10 workers are required. Suppose that the work cell delivers 68 units each day. Section 9 Repetitive and Product-Oriented Layout 1) A fabrication line and an assembly line are both types of repetitive and product-focused layout, but only the fabrication line utilizes workstations. 2) The biggest advantage of a product layout is its flexibility to handle a varied product mix. 3) The minimum number of workstations depends upon the set of task times and the precedence chart, but not the number
of units scheduled. 4) A product requires 24 separate tasks, and the sum of those task times is 14 minutes. If the cycle time is 2 minutes, then at least 12 workstations will be needed. 5) If the schedule calls for the production of 120 units per day and 480 minutes of production time are available per day, the cycle time would be 4
minutes. 6) Product-oriented layouts tend to have high levels of work-in-process inventories. 7) One drawback of a product-oriented layout is that work stoppage at any one point ties up the whole operation. 8)
Cycle time is the maximum time that the product is allowed at each workstation. 9) Heuristics are problem-solving procedures that mathematically optimize the solution. 10) Which one of the following is NOT common to repetitive and product-oriented layouts?
Answer: C 11) A product-oriented layout would be MOST appropriate for which one of the following businesses?
Answer: B 12) The assumptions necessary for a successful product-oriented layout include all EXCEPT which of the following?
Answer: C 13) Which of the following is TRUE regarding fabrication lines?
Answer: D 14) The central problem in product-oriented layout planning is:
Answer: E 15) Which of the following is a disadvantage of product-oriented layout?
Answer: E 16) Which of the following is one of the main advantages of a product-oriented layout?
Answer: E 17) In a product-oriented layout, what is the process of deciding how to assign tasks to workstations?
Answer: D 18) In assembly-line balancing, the theoretical minimum number of workstations is:
Answer: D 19) In assembly-line balancing, cycle time (the ratio of available production time to scheduled production) is the:
Answer: B 20) A production line is to be designed to make 500 El-More dolls per day. Each doll requires 11 activities totaling 16 minutes of work. The factory operates 750 minutes per day. What is the required cycle time for this assembly line?
Answer: B 21) A production line is to be designed for a job with four tasks. The task times are 2.4 minutes, 1.4 minutes, 0.9 minutes, and 1.7 minutes. After line balancing, the largest possible assigned cycle time is ________ minutes, and the smallest possible assigned cycle time is ________ minutes.
Answer: C 22) Cycle time is computed as:
Answer: D 23) Four hundred and eighty minutes of production time are available per day. Scheduled production is 120 units per day. What is the required cycle time?
Answer: A 24) A production line is to be designed for a product whose completion requires 21 minutes of work. The factory works 400 minutes per day. Can an assembly line with five workstations make 100 units per day?
Answer: C 25) Four hundred and eighty minutes of production time are available per day. The schedule calls for the production of 80 units per day. Each unit of the product requires 30 minutes of work. What is the theoretical minimum number of workstations?
Answer: D 26) Which of the following is NOT a heuristic rule for assigning tasks to workstations in a product layout?
Answer: C 27) If a layout problem is solved by use of heuristics, this means that:
Answer: E 28) Which of the following is a common heuristic for assembly line balancing?
Answer: D 29) An assembly line consists of 21 tasks grouped into 5 workstations. The sum of the 21 task times is 85 minutes. The largest assigned cycle time is 20 minutes. What is the efficiency of this line?
Answer: C 30) An assembly line consists of 158 tasks grouped into 32 workstations. The sum of all task times is 105 minutes. The largest assigned cycle time is 4 minutes. What is the efficiency of this line?
Answer: C 31) A(n) ________ line is a machine-paced product-oriented facility for building components. 32) ________ is the
maximum time that the product is allowed at each workstation. 33) Explain what the purpose of assembly-line balancing is. Describe briefly how it is done. 34) Identify the formulas for the following terms that occur in assembly line balancing: (1) cycle time, (2) minimum number of workstations, and (3) efficiency. 35) Identify the five common layout heuristics used to assign tasks to workstations in assembly-line balancing. 36) Assembly line balancing has just been used to solve a product layout problem. Two solutions look especially attractive to the plant managers. Both solutions make the same output per day, and both have the same number of workstations. The managers were going to break the tie by looking at line efficiency, but discovered that both lines had the same
efficiency as well. Should they have been surprised at this? Explain. 37) What are the advantages and disadvantages of product-oriented layouts?
The disadvantages are:
Diff: 3 38) Develop a solution for the following line balancing problem, allowing a cycle time of 5 minutes.
Answer: The theoretical minimum number of workstations is 3. Balance places ABDF in station 1, C in station 2, E in station 3, and G in station 4. The solution uses four stations, not three. The POM for Windows solution is shown below. Idle time is distributed 10, 180, 60, and 110 per station. There are 360 seconds of idle time in the system. Efficiency is 70.0%.
Diff: 3 39) An assembly line has been designed to make battery-powered beverage mixers. Task details are shown in the table below:
Answer: Cycle time is 4.0 minutes (governed by stations 3 and 6). Maximum output is 60/4 = 15.0 units per hour. Idle time is 1.0 + 0.5 + 0.0 + 1.0 + 1.5 + 0 = 4.0 minutes. Efficiency is 20.0/24.0 = 83.3%. 40) Cyclone Appliances has developed a new European-style convection oven that will be made on an assembly line. The schedule requires 80 ovens in an 8-hour day. The assembly includes seven tasks. The table below indicates the performance time and the sequence requirements for each task.
(a) What is the cycle time for this assembly operation? Diff: 2 41) An electronics manufacturer makes remote control devices for interactive-cable-TV systems. The following assembly tasks must be performed on each device.
Answer: The sum of the task times is 4.05 minutes. The cycle time for 200 units output is 600/200 = 3 minutes. The theoretical minimum number of stations is 4.05/3 = 1.35 or 2. Both solutions use two stations and have 67.5% efficiency—no preference. Most Following Tasks Station 1: A, B, C, E, F, D, G; idle time = 0.25 Station 1: A, B, C, E, D, H, F; idle time = 0.20
Answer: The network diagram appears below. Minimum cycle time is 70 seconds (the longest task time); maximum cycle time is 234 seconds (sum of the task times). Required cycle time is 480/400 = 1.2 minutes or 72 seconds (which is barely feasible). The theoretical minimum number of stations required is at least 234/72 = 3.25 or 4.
Diff: 3 43) You have been asked to balance a flow shop assembly operation to achieve an output rate of 80 units per eight-hour day. Task times and precedence relationships are shown in the table below.
Answer: The precedence diagram appears below. The desired cycle time for 80 units is 6 minutes. The theoretical minimum number of stations is 10.1/6 = 1.68 or 2.
Diff: 3 44) A firm operates a flow shop building kitchen cabinetry for recreational vehicles. The major activities of this process are listed below.
160 hours per month)?
Answer:
(b) The cycle time is 160/20 = 8 hours; (c) This line requires at least 30/8 = 3.75 or 4 stations; (d) A and C are in Station 1; B is in Station 2; D is in Station 3; E and F occupy Station 4; and G and H are in Station 5. (e) Efficiency is 30/40 = .75 or 75 percent. 45) Hemo-tech, Inc., a biomedical technology and research laboratory, produces a standard blood filtering device on an assembly-line basis. Six basic tasks are performed along the assembly line. The time to perform each task and the tasks that must immediately precede each task are in the table below. Twenty pumps per 450-minute day must be produced by the assembly line.
(a) Draw the network diagram of the precedence relationships.
Diff: 3 46) A firm is planning to set up an assembly line to assemble 40 units per hour, and 57 minutes per hour are productive. The time to perform each task and the tasks that precede each task are contained in the following table.
(a) Draw a network diagram of precedence relationships.
Diff: 3 47) An assembly line with 11 tasks is to be balanced. The longest task is 2.4 minutes, the shortest task is 0.4 minutes, and the sum of the
task times is 18 minutes. The line will operate for 600 minutes per day. 48) A facility is trying to set up an assembly line, and has identified the various tasks, and their relationship to each other, as shown in the following table. Managers wish to produce 600 units per day, working two 8-hour shifts.
(a) Draw a network diagram of precedence relationships.
Diff: 3 49) A company is trying to balance production between 3 workstations on an assembly line. Currently there are 5 tasks that need to be
performed. These tasks, ABCDE, have required times of 2 minutes, 4 minutes, 1 minutes, 3 minutes, and 10 minutes, respectively. The assembly line needs to produce 40 units per day to meet demand and can work for up to 8 hours each day. ---------------------------------- OPERATIONS MANAGEMENT - 2017 - COLLECTION FREE DOWNLOAD EBOOKS Operations Management, 2015, 12th Edition, William J. Stevenson - Free Download Link Operations Management: Sustainability and Supply Chain Management, 12th Edition, Jay Heizer, Barry Render, Chuck Munson, 2017 Free Online Course Materials 4. Full List of Videos Case Studies - Link 5. All articles about Operations Management http://top20mba.com/mba-cases/94-mba-operation-management 2017 Updates 6. QUIZ, Multiple choice questions and answers 7. CASE STUDY GUIDES 8. Video Case study guides All Free downloads - LINK FREE DOWNLOADS: 1. Operations Management: Sustainability and SCM, 12th Edition, Jay Heizer, 2017 2. Operations Management, Sustainability and SCM, 11th Ed, 2014, Jay Heizer 3. Principles of Operations Management: Sustainability and SCM, 10th Ed, Jay Heizer, 2017 Free Download Link Free Download Link 6.
Operations Research: An Introduction, 10th Edition, Hamdy A. Taha, 2017 8. Hotel Operations Management, 3rd Edition, David K. Hayes, 2017Ebooks – Free Download Links Videos – Youtube channel links Good Luck and Success, Enjoy Your Study ! What is a common goal in designing process layouts?We have mentioned that the objective in designing process layouts is to place resources close together based on the need for proximity. This need could stem from the number of trips that are made between these resources or from other factors, such as sharing of information and communication.
Which of the following is an advantage of a product layout quizlet?The main advantage of the product layout is flexibility and the main disadvantage is efficiency.
Which of the following is a key advantage of a productTrue (Repetitive and product-oriented layout, moderate)
The biggest advantage of a product layout is its flexibility to handle a varied product mix.
What are some other external factors which might influence process layout design?What are some external factors which might influence process layout design? - Ability to design a safe environment for employees and customers. - Size and location of restrooms. - Noise levels at the various locations.
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