1. An 80,000 seat stadium was created with what kind of facility layout? 2. Designing a process layout focuses on determining what?

Transcription

1 1. An 80,000 seat stadium was created with what kind of facility layout? 2. Designing a process layout focuses on determining what? 3. Name two disadvantages of a product layout. 4. The grouping of processes needed to perform the similar work for families of products is known as what type of layout? 5. What closeness rating reflects indifference to the nearness or lack of nearness of two particular departments within a facility layout? 6. Two assembly lines build the exact same product. One assembly line has 15 workstations and the other has 20 workstations. Which assembly line builds that product faster? Chapter Six Process and Facility Selection Minute Answer Questions #1 to 12 PDF A1M060-01

2 7. Two assembly lines build the exact same product. One assembly line has a cycle time of 30 seconds and the other a cycle time of 90 seconds. Which assembly line has more workstations? 8. Which would be expected to be less expensive to the customer, a product that resulted from a make-to-stock process or the same product from an assemble-to order process? 9. Which would be expected to offer greater variety to the customer, a product that resulted from a make-to-stock process or the same product from an assemble-to order process? 10. Would reducing the cycle time of a product layout speed up its production or slow it down? 11. Project management is most likely to be associated with production within which of the four layout types? 12. Process layouts are often designed according to what objective? Chapter Six Process and Facility Selection Minute Answer Questions #1 to 12 PDF A1M060-01

3 A production line is to be designed to assemble a product. The assembly of this product requires three tasks, one of which requires 0.3 minutes to complete, one of which requires 1.4 minutes to complete, and one of which requires 0.7 minutes to complete. What is the minimum possible cycle time of this assembly line? A production line is to be designed to assemble a product. The assembly of this product requires three tasks, one of which requires 0.3 minutes to complete, one of which requires 1.4 minutes to complete, and one of which requires 0.7 minutes to complete. If this production line has three workstations and a cycle time of 1.5 minutes, what is its efficiency? Chapter Six Process and Facility Selection Quick Start Questions #13 to 14 PDF A1Q601-01

4 A production line must produce 1,500 units every 4 hours of operating time. What is its cycle time in seconds? A production line must produce 900 units every 10 hours of operating time. What is its cycle time in minutes? If a production line has a cycle time of 90 seconds, how much can it produce in 8 hours? Chapter Six Process and Facility Selection Quick Start Questions #15 to 17 PDF A1Q601-02

5 An assembly line must create one finished product every 90 seconds. The sum of the task times required to create a product is 295 seconds. What is the theoretical minimum number of workstations for this assembly line? An assembly line must create one finished product every 90 seconds. The sum of the task times required to create a product is 295 seconds. If one design for this assembly line uses four workstations, what is its efficiency? What is the balance delay of an assembly line that is 65% efficient? Chapter Six Process and Facility Selection Quick Start Questions #18 to 20 PDF A1Q601-03

6 A food court has a row of four locations available for food vendors. The food court manager must decide which of four food vendors should be assigned which locations. Technically, any food vendor could be assigned any one of the four locations. The four food vendors who wish to rent locations are: Pops are Us, Taco Madness, Ice Cream Scream, and Mega Pretzel. Theoretically, how many different possible layouts does the developer have available to consider? Chapter Six Process and Facility Selection Ramp-up Question #21 PDF A1R602-01

7 You are standing outside Thompkin Bus Manufacturing Company, watching one finished school bus roll off their assembly line every 15 minutes. An employee, taking a break nearby, proudly states: We build 40 of those buses every day, Monday through Friday. Based on what you see and have been told, how many hours a day does the Tompkin Bus Manufacturing Company operate? Chapter Six Process and Facility Selection Ramp-up Question #22 PDF A1R601-01

8 An average of 50 customers travel between departments A and B each day. Unfortunately, department C is located between departments A and B, and no customers travel between department C and departments A and B. What is the load-distance score of this three-department layout? Chapter Six Process and Facility Selection Ramp-up Question #23 PDF A1R602-02

9 An assembly line must create one finished product every 2 minutes. The sum of the task times required to create a product is 200 seconds. What is the theoretical minimum number of workstations for this assembly line? Chapter Six Process and Facility Selection Ramp-up Question #24 PDF A1R601-02

10 Two different companies produce and sell a certain product to customers. Each of the two companies starts with the same raw materials and creates the product through three stages of processing. But each of the two companies uses a different strategy to create the product, shown in the process flow diagrams of each company s operations below. In each diagram, the triangles represent inventory stocks, while the squares represent processing. a. From which company is purchasing the product likely to be less expensive? b. From which company is the customer likely to wait longer before receiving the product? c. Which company appears to be practicing delayed differentiation? d. Which company has adopted a make-to-stock process for production? Chapter Six Process and Facility Selection Scenario Question #25 PDF A1F060-01

11 It takes a total of 400 seconds for one technician, working alone, to assemble one AirRules smartphone. However, AirRules manufactures its smartphones with 20 technicians staffing a 20-station assembly line, producing one smartphone every 30 seconds. Based on this information, a. How many hours must AirRules operate its assembly line to create 1,200 smartphones daily? b. What is the theoretical minimum number of workstations for an assembly line supporting the AirRules smartphone production described here? c. How efficient is the AirRules smartphone assembly line? Chapter Six Process and Facility Selection Scenario Question #26 PDF A1F601-01

12 Digital Eye must design an assembly line to produce a new line of slim digital cameras. Assembling a single camera requires the completion of nine distinct tasks, and information about each of these tasks is provided below: Task Immediate Predecessors Task Duration (sec.) Task Immediate Predecessors A none 10 B A 30 C A 25 D B 18 E B 5 F B 17 G D,E 37 H C,F 30 I H 12 Task Duration (Seconds) This assembly line operates 8 hours a day to produce 576 digital cameras daily. Digital Eye uses the LPT rule to create the design. a. What is the cycle time of Digital Eye s assembly line, in seconds? Chapter Six Process and Facility Selection Scenario Question #27 PDF A1F601-02

13 b. How many workstations are required by this design and what tasks are done at which workstation? Station Time Remaining Eligible Tasks Eligible Tasks will Fit Assigned Chapter Six Process and Facility Selection Scenario Question #27 PDF A1F601-02

14 c. Which workstation enjoys the maximum idle time? How efficient is this design? What is the balance delay? d. How does the actual number of workstations required by this design compare to its theoretical minimum number of workstations? Chapter Six Process and Facility Selection Scenario Question #27 PDF A1F601-02

15 An industrial food processor needs to design a product layout for a new product, mint chocolate chip sandwiches. The company plans to use this new production line 8 hours a day to meet projected demand of 1,440 cases per day. The following table describes the tasks involved in the production of a mint chocolate chip sandwich. Task Immediate Predecessors Task Duration (sec.) Task Immediate Predecessors A none 4 B A 14 C B 20 D B 12 E C,D 6 F E 8 Task Duration (Seconds) a. Design this layout using the LPT decision rule and then repeat the design process using the SPT rule. What are the differences between the two designs? Which design is more efficient? Chapter Six Process and Facility Selection Scenario Question #28 PDF A1F601-03

16 b. Suppose the food processor decides to implement the design created with the LPT rule. You have been hired to manage the production of mint chocolate chip sandwiches and you have just learned there may be two errors in the data originally used during the design process. In particular, you discover that both task A and task C will probably require 3 seconds more to complete than originally planned. Which of these two mistakes in the duration data is the most troubling to you, and why? Chapter Six Process and Facility Selection Scenario Question #28 PDF A1F601-03

17 LPT Station Time Remaining Eligible Tasks Eligible Tasks will Fit Assigned Chapter Six Process and Facility Selection Scenario Question #28 PDF A1F601-03

18 SPT Station Time Remaining Eligible Tasks Eligible Tasks will Fit Assigned Chapter Six Process and Facility Selection Scenario Question #28 PDF A1F601-03

19 Consider the following diagram of a fast-food restaurant drive-through with three stops for each car following the path described by arrows in the diagram below. The time required to complete the work at each of these workstations is also listed here: a. What is the maximum rate at which this restaurant can successfully serve arriving cars with this product layout? Chapter Six Process and Facility Selection Scenario Question #29 PDF A1F601-04

20 b. An average of 15 cars arrive each hour at the restaurant drive-through. What does this imply about the efficiency of this layout? c. The employee who works at the first window, where the car s payment is processed, has just left the restaurant due to a family emergency. To keep operating, the restaurant has closed the first window and the employee at the second window is now doing the work required at both windows, processing payments and assembling and providing the meal to each of the cars. Now, due to this change, what is the maximum rate at which this restaurant can successfully serve arriving cars? Chapter Six Process and Facility Selection Scenario Question #29 PDF A1F601-04

21 Palms Coast Hospital is designing a new building and has determined the closeness ratings between the eight departments that must be located on the ground floor of that structure. These ratings are as follows: a. Palms Coast considers it absolutely necessary that Admitting be located next to what? b. What departments should the Emergency Room not be next to? c. Palms Coast is considering a ground floor layout in which the main elevators are next to the pharmacy. Which other departments would be more important neighbors to the main elevators? Chapter Six Process and Facility Selection Scenario Question #30 PDF A1F602-01

22 Linlithi Medical provides on-site health screenings for other organizations, and has been hired by the City of Baltimore to conduct the annual health screening of all 250 of Baltimore s bus drivers. The annual health screening for a bus driver consists of the following tasks: Task Name Description Task Description Immediate Time Required Name Predecessor A Vision test none 5 minutes B Hearing test none 7 minutes C Blood pressure none 3 minutes test D Lung function none 10 minutes test E Draw blood C 4 minutes sample F Pulse stress test B,D,E 8 minutes G Doctor s consultation A,F 10 minutes Linlithi Medical has arranged to screen all 250 drivers during one 5-day week. Thus, Linlithi must complete 50 health screenings during each of the 10-hour days. To perform the health screenings efficiently, Linlithi Medical will set up its operation as a product layout, in which the drivers move from station to station until all the tasks of their individual health screening are completed. Please use line balancing to design the most appropriate layout for Linlithi, using the LPT rule to choose among tasks when assigning each task to a particular workstation. a. What is the cycle time of Linlithi Medical s layout for the Baltimore city bus driver screenings? Chapter Six Process and Facility Selection Scenario Question #31 PDF A1F601-05

23 b. What is the theoretical minimum number of workstations that Linlithi Medical might have to staff to support this cycle time? c. At which station will task D, the lung function test, be completed? d. At which workstation will task F, the pulse stress test, be completed? Station Time Remaining Eligible Tasks Eligible Tasks will Fit Assigned Chapter Six Process and Facility Selection Scenario Question #31 PDF A1F601-05

24 2 nd Edition Consider the following four Departments (A, B, C and D) in this facility layout diagram: An average of 25 customers travel between Departments A and C each day, and an average of 10 customers travel between Department C and Department D each day. There is no other customer traffic between any other pairs of departments. a. What is the load-distance score of the department layout above? Chapter Six Process and Facility Selection Scenario Question #32 PDF A2F602-02

25 2 nd Edition b. Some employees have suggested that this facility layout be changed: Departments C and D should switch places in the layout, although A and B should stay in the same places. If this suggestion were implemented, would the load distance score improve, and if so, by how much? c. Where is the best location(s) for Department B? Chapter Six Process and Facility Selection Scenario Question #32 PDF A2F602-02