Question 1

Solving a load-distance problem for a process-oriented layout requires that:

Accepted Answer

Pickup and set-down costs need to be constant from department to department to simplify the calculation of moving loads in a process-oriented layout, ensuring that the focus remains on optimizing the layout for process efficiency rather than varying handling costs.

Question 2

A work cell, 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.

Accepted Answer

While work cells are commonly used in manufacturing, they can also be applied to service settings such as healthcare and transportation.

Question 3

The separate plants that produce seat belts, fuel tanks, and exhaust systems for Toyota are:

Accepted Answer

The production of seat belts, fuel tanks, and exhaust systems for Toyota are examples of focused factories, which specialize in producing a specific type of product. This focus allows for efficient production methods and specialized expertise in the production of these components. Job shops and work cells are more general production methods, while focused work centers are similar to work cells but with a greater focus on specific processes within a factory. Random stocking warehouses are not directly related to production methods.

Question 4

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.

Accepted Answer

The answer of A focused work center is well suited...

Question 5

________ layouts deal with low-volume, high-variety production with like machines and equipment grouped together.

Accepted Answer

The answer of ________ layouts deal with low-volume, high-variety production...

Question 6

A big advantage of a process-oriented layout is:

Accepted Answer

The flexibility in equipment and labor assignments allows for the layout to easily adapt to changes in production needs and ensures efficient usage of resources.

Question 7

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.

Accepted Answer

The answer of An airport is trying to balance where...

Question 8

Which of the following is NOT one of the requirements of cellular production?

Accepted Answer

Adequate volume for high equipment utilization is not a requirement of cellular production. Cellular production focuses on flexibility, efficiency, and minimizing waste, rather than maximizing equipment utilization, which is more aligned with traditional mass production methods.

Question 9

The typical goal used when developing a process-oriented layout strategy is to:

Accepted Answer

The goal of a process-oriented layout strategy is to minimize material handling costs by arranging departments based on the flow of the manufacturing process. This includes minimizing the distance between departments to reduce the amount of time and resources needed to move materials between them. The other options may be secondary goals but are not the primary focus of a process-oriented layout strategy.

Question 10

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?
(b) What is the material handling total of assigning A-1, B-3, C-4, D-2?

Accepted Answer

The answer of Departments A, B, C, and D need...

Question 11

A work cell is required to make 300 computerized diagnostic assemblies (for installation into hybrid automobiles) each day. The cell currently works an eight hour shift, of which 6.5 hours is available for productive work. What is takt time for this cell?

Accepted Answer

Takt time is calculated by dividing the available production time by the required units. Here, 6.5 hours is 23,400 seconds (6.5 * 60 * 60). Dividing 23,400 seconds by 300 units gives a takt time of 78 seconds per unit.

Question 12

The work cell improves layouts by reducing both floor space and direct labor cost.

Accepted Answer

Work cells are designed to group all necessary equipment, materials, and personnel together in one area to optimize workflow and minimize travel time. This can result in a smaller footprint for the production process and potentially reduce the number of workers needed to complete the production process, leading to lower direct labor costs.

Question 13

The disadvantages of process-oriented layout come from:

Accepted Answer

Process-oriented layouts use general-purpose equipment, which can lead to inefficiencies and higher costs due to the need for flexible operations and handling a variety of products.

Question 14

Explain how a load-distance model helps solve problems in process layout.

Accepted Answer

The answer of Explain how a load-distance model helps solve...

Question 15

A ________ is also called a plant within a plant.

Accepted Answer

A focused work center is often referred to as a "plant within a plant" because it is a dedicated area within a larger facility that is organized to focus on a specific set of operations or products, allowing for more efficient and specialized production.

Question 16

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 40 feet, and 1-3 is 60 feet. The matrix of work (trips per day) at the three centers are shown in the following table. Assume 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.
(b) Calculate the total distance traveled in each of these assignments.
(c) Which assignment minimizes distance traveled?

Accepted Answer

The answer of There are three work centers (A, B,...

Question 17

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) among centers is shown below.
  The firm estimates that each trip costs approximately $4. What is the cost of the current assignment?

Accepted Answer

The answer of An insurance claims processing center has six...

Question 18

Which of the following is NOT an advantage of work cells?

Accepted Answer

Work cells aim to increase equipment and machinery utilization by having them dedicated to specific processes within the cell. Therefore, decreased equipment and machinery utilization is not an advantage of work cells.

Question 19

Mathematically, takt time is:

Accepted Answer

Takt time is calculated by dividing the total work time available by the number of units required to meet customer demand. This helps in setting the pace of production to match the rate of customer demand.

Question 20

A process layout problem consists of 3 departments, each of which can be assigned to one of three rooms. The number of different solutions to this problem is ________, although all of them may not have different material handling costs.

Accepted Answer

6In a process layout problem with 3 departments and 3 rooms, each department can be assigned to a different room in a unique way. This is a permutation problem where we are arranging 3 unique items (departments) into 3 unique positions (rooms), which is calculated as 3! (3 factorial), equaling 3*2*1 = 6 different solutions.

Quiz 9: Human Resources, Job Design, and Work Measurement