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Chapter 8—Facility and Work Designs
Multiple Choice
1. All of the following are common objectives of layout studies EXCEPT to:
a.
minimize delays in materials handling and customer movement.
b.
minimize the number of workstations.
c.
provide for good housekeeping and maintenance.
d.
maintain flexibility.
2. A _____ layout is an arrangement based on the sequence of operations that are performed
during the manufacturing of a good or delivery of a service.
a.
product
b.
process
c.
cellular
d.
fixed-position
3. A _____ layout consists of a functional grouping of equipment or activities that do similar
work.
a.
product
b.
process
c.
cellular
d.
fixed-position
4. A _____ layout is an arrangement based on self-contained groups of equipment needed to
produce a particular set of goods or services.
a.
product
b.
process
c.
cellular
d.
fixed-position
5. The typical layout of facilities in a pizza restaurant would be an example of a _____ layout.
a.
product
b.
process
c.
cellular
d.
fixed-position
6. The production of large goods such as airplanes is best accomplished using a _____ layout.
a.
product
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b.
process
c.
cellular
d.
fixed-position
7. Identify an advantage of product layouts.
a.
Highly flexible
b.
Lower work-in-process inventories
c.
Higher job satisfaction
d.
Easy to add new products
8. Which of the following statements is NOT true about fixed-position layouts?
a.
Work-in-process remains stationary.
b.
They require a high level of planning and control.
c.
The volume of demand is very high.
d.
They are used in the production of heavy machine tools and locomotives.
9. Which of the following statements is NOT true about cellular layout?
a.
Workers concentrate more on moving parts of the machines rather than on production.
b.
Workflow is standardized and centrally located.
c.
It makes additional floor space available for productive uses.
d.
It facilitates the processing of families of parts with similar processing requirements.
10. All of the following are limitations of process layouts EXCEPT:
a.
high material handling costs.
b.
more complicated planning and control systems.
c.
low equipment utilization.
d.
diverse range of products.
11. _____ layout is used for high volumes of demand and setup requirements.
a.
Product
b.
Process
c.
Cellular
d.
Fixed-position
12. _____ classifies parts into families so that cellular layouts can be effectively used.
a.
Ergonomics
b.
Job enlargement
c.
Group technology
d.
Flow-blocking delay
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13. Which of the following is NOT a common reason for facility layout studies?
a.
There is significant change in demand or throughput volume.
b.
A new good or service is introduced to the customer benefit package.
c.
A new material supplier is used.
d.
Different process, equipment and/or technology are installed.
14. The typical layout of facilities in a legal office would be an example of a _____ layout.
a.
product
b.
process
c.
cellular
d.
fixed-position
Problem for #15 to #18
Steve, an operations manager at Krypto InfoTech, must set up an assembly line to assemble a
computer mouse. The precedent network given below is defined with task times in parentheses
and stated in minutes. There are 480 minutes of assembly time per shift and there is one shift.
The forecast (output rate) is 60 units per shift. He decides to use the longest/largest-task-time
rule to assign tasks to workstations.
Worksheet for assembly-line balancing problem
Workstation
Assigned Tasks
Total Time
Idle Time
A
B
C
D
Task 1 (4)
Task 4 (2)
Task 3 (1)
Task 5 (6)
Task 8 (8)
Task 2 (5)
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E
F
Use the previous assembly-line balancing (ALB) information to answer Questions #15 to #18.
15. What is the cycle time?
a. 6 minutes/unit
b. 7 minutes/unit
c. 8 minutes/unit
d. 9 minutes/unit
16. The task assigned to the third workstation (called C) using the longest/largest-task-rule is
_____.
a. task 3
b. task 4
c. task 5
d. task 6
20. _____ occurs whenever one stage completes work and no units from the previous stage are
awaiting processing.
a. Flow-blocking delay
b. Lack-of-work delay
c. Buffer delay
d. Propagation delay
21. An assembly line with 28 activities is to be balanced. The total amount of time required for
all 28 activities is 39 minutes. The line will operate for 450 minutes per day. What must the
cycle time be to achieve an output rate of 400 units/day?
a.
1.39 minutes
b.
11.54 minutes
c.
1.125 minutes
d.
0.89 minutes
22. An assembly line with 28 operations is to be balanced. The total amount of time required for
all 28 operations is 39 minutes. The longest operation takes 2.2 minutes and the shortest takes
0.8 minutes. The line will operate for 450 minutes per day.
1.
Determine the minimum and maximum cycle time.
2.
What is the output rate if the cycle time is set at 2.2 minutes?
a.
min cycle time = 0.8; max cycle time = 39; output rate = 204.5
b.
min cycle time = 2.2; max cycle time = 39; output rate = 204.5
c.
min cycle time = 2.2; max cycle time = 31.2; output rate = 562.5
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d.
min cycle time = 0.8; max cycle time = 2.2; output rate = 562.5
Problem for Questions #23 to #25
23. Use the information in Table 1. The company is planning to operate 2 shifts per day, 8 hours
per shift. If the desired output rate of the line is 480 units per day, what is the cycle time?
a. 60 seconds
b. 120 seconds
c. 180 seconds
d. 240 seconds
24. Use the information in Table 1. Total idle time is _____ seconds using the longest-task-time
rule.
a. 10
b. 15
c. 30
d. 25
25. Use the information in Table 1. What is the efficiency using the longest-task-time rule?
a. Less than 85%
b. More than 85% but less than 91%
c. More than 91% but less than 93%
d. More than 93% but less than 95%
Problem for Questions #26 to #28
Assembly-Line Balancing Problem—Table 1 below
The Florida Appliance Company is installing an assembly line to produce
vacuum cleaners, and Patrick, as an operations manager, is responsible for
balancing the line. The work elements to be performed are listed, along with
their items and immediate predecessors.
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Consider the following assembly line information for manufacturing the latest cell phone in
Table 2. The firm wants to produce 80 cell phones per hour.
Table 2
Task
Time (in minutes)
Predecessors
A
0.5
none
B
0.4
A
C
0.6
A
D
0.2
B, C
E
0.3
B
F
0.7
E, D
G
0.4
F, C
26. The cycle time is _____ seconds.
a. 45
b. 60
c. 75
d. 100
27. Using the longest-task-time rule, the efficiency of an assembly-line balance is _____.
a. Less than 65%
b. more than 65% but less than 75%
c. more than 75% but less than 85%
d. more than 85% but less than 95%
28. Is this a good assembly-line balancing solution? Explain. What do you recommend?
ANS:
A
C
G
29. An assembly line with 28 activities is to be balanced. The total amount of time required for
all 28 activities is 39 minutes. The longest activity is 2.2 minutes and the shortest is 0.8 minutes.
The line will operate for 450 minutes per day. What is the assembly-line efficiency with 11
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stations and a product produced every 5 minutes?
a. Less than 65%
b. More than 65% but less than 75%
c. More than 75% but less than 85%
d. More than 85% but less than 95%
Problems for Questions #30 & #31
The eleven tasks necessary to assemble an MP3 player along with their time (in seconds) and
immediate predecessor(s) is given below:
Task
Time (in seconds)
Predecessors
A
40
none
B
15
none
C
35
none
D
12
A, B
E
27
B, C
F
29
D
G
60
D, E
H
30
E
I
14
F, G
J
22
G, H
K
43
I, J
Total
327
The company wants to produce 600 units in a 9-hour day.
30. The cycle time is _____ seconds.
a. 45
b. 54
c. 63
d. 71
31. The minimum number of workstations required is _____.
a. 5
b. 6
c. 7
d. 8
Problem for Questions #32 & #33
An assembly line with 28 activities is to be balanced. The total amount of time required for all
28 activities is 88 minutes. The longest activity is 2.2 minutes and the shortest is 0.8 minutes.
The line will operate for 450 minutes per day. Using a cycle time of 60 seconds, determine an
assembly-line balance by selecting the longest-processing-time task available. Compute the total
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idle time and assembly-line efficiency.
32. The total idle time is _____ seconds.
a. less than or equal to 20
b. more than 20 but less than or equal to 30
c. more than 30 but less than or equal to 40
d. more than 40 but less than or equal to 50
33. Using the longest-task-time rule, the efficiency of the assembly-line balance is _____.
a. less than 65%
b. more than 65% but less than 75%
c. more than 75% but less than 85%
d. more than 85% but less than 95%
34. A line-balancing solution has been developed for the assembly line for fertilizer spreaders at
Green Grass, Inc. The desired output rate of 30 spreaders per hour will be achieved. The sum of
times for all tasks performed on the line is 1200 seconds for each spreader assembled. Which of
the following statements is TRUE?
a.
The cycle time is 30 seconds per spreader.
b.
The theoretical minimum number of workstations is 10.
c.
If the solution calls for 12 stations, the efficiency is 90%.
d.
If the solution calls for 11 stations, the efficiency is 80%.
35. An assembly line with 28 activities is to be balanced. The total amount of time required for
all 28 activities is 39 minutes. The line will operate for 300 minutes per day. What must the
cycle time be to achieve an output rate of 250 units/day?
a.
1.39 minutes
b.
11.2 minutes
c.
1.2 minutes
d.
0.89 minutes
36. Which of the following statements is NOT true about assembly lines?
a.
They are low cost.
b.
They are a type of cellular layout.
c.
They make goods and services affordable to mass markets.
d.
They are important in service operations.
37. _____ occurs when a work center completes a unit but cannot release it because the in-
process storage at the next stage is full.
a.
Lack-of-work delay
b.
Propagation delay
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c.
Flow-blocking delay
d.
Overload delay
38. For a given cycle time in line balancing, assembly-line efficiency can be increased by _____.
a.
speeding the assembly line
b.
slowing the assembly line
c.
decreasing the number of workstations
d.
increasing the number of workstations
Problem for Questions #39
The eleven tasks defined in Table 1 given below are necessary to assemble an MP3 player along
with their time (in seconds) and flow diagram,
Table 1
TASK
TIME (in seconds)
A
40
B
15
C
35
D
12
E
27
F
29
G
60
H
30
I
14
J
22
K
43
TOTAL:
327
39. Refer to Table 1. Using this data and a cycle time of 60 seconds, determine an assembly-line
balance by using the longest-task-time rule.
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a) Station 1: A, B
Station 2: C, D
Station 3: E, F
Station 4: G, H
Station 5: J, I, K
40. In designing _____ layouts, one is concerned with the arrangement of departments or work
centers relative to each other.
a.
product
b.
cellular
c.
process
d.
fixed-position
41. Which of the following is NOT an objective of ergonomics?
a.
To increase speed and accuracy
b.
To reduce fatigue
c.
To improve customer interaction
d.
To increase the cost of doing the job
42. _____ is vertical expansion of job duties to give a worker more responsibility.
a.
Job enlargement
b.
Job rotation
c.
Job enrichment
d.
Job design
43. A(n) _____ team performs entire jobs rather than specialized, assembly-line work.
a.
virtual
b.
self-managed
c.
natural work
d.
ergonomic
44. The determination of specific job tasks and responsibilities is called _____.
a.
job design
b.
ergonomics
c.
job enlargement
d.
job enrichment
d) Station 1: A, B
Station 2: C, D
Station 3: E, F
Station 4: G
Station 5: H, J
Station 6: I, K
b) Station 1: A, B
Station 2: C, D
Station 3: E, F
Station 4: G, H
Station 5: J
Station 6: I, K
c) Station 1: A, B
Station 2: C, E
Station 3: D, F
Station 4: G
Station 5: H, I
Station 6: J, K
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45. _____ is the horizontal expansion of a job to give a worker more variety—although not
necessarily more responsibility.
a.
Job design
b.
Ergonomics
c.
Job enlargement
d.
Job enrichment
46. In a _____ team, members communicate by computer, take turns as leaders, and join and
leave the team as necessary.
a.
self-managed
b.
virtual
c.
natural work
d.
cross-functional
True/False Questions
1. Changes in goods and services for a firm’s customer benefit package do not impact facility
layouts.
2. Facility layout is not only concerned with the arrangement of physical facilities, but also the
material handling capabilities within the facility.
3. In a product layout, a breakdown of one piece of equipment will not cause the entire process
to shut down.
4. Product layouts are less flexible than process layouts.
5. Process layouts generally require less investment in equipment than product layouts because
the equipment is less specialized.
6. Services such as legal and medical specialties employ cellular layouts.
7. Cellular layouts are designed according to the functional characteristics of equipment much in
the same fashion as process layouts.
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8. The volume of demand in product layout is low, while it is high in process layout.
9. Workers in cellular layouts generally have greater responsibilities than those who work in
product or process layouts.
10. A fixed-position layout is based on the sequence of operations that is performed during the
manufacturing of a good or delivery of a service.
11. The predominant layout type used in hospitals is the fixed-position layout.
12. The facility layout in a library would most likely be a process layout.
13. In a product layout, flow-blocking delay occurs whenever one stage completes work and no
units from the previous stage are awaiting processing.
14. Flow-blocking and lack-of-work delays can be reduced by assigning an appropriate level of
capacity at each workstation.
15. An assembly line is a type of product layout.
16. The objective of assembly-line balancing is to group tasks among workstations so that the
amount of work assigned to each workstation is highly variable, thus maximizing flexibility.
17. In a perfectly balanced assembly line, no bottlenecks exist.
18. Cycle time in assembly-line balancing is the maximum amount of time it takes to process a
part at some workstation along the line.