When balancing an assembly line, which of the following is not a way to reduce the longest task time below the required workstation cycle time?
A. Speed up the assembly line transfer mechanism
B. Upgrade the equipment
C. Use a more skilled worker
D. Assign a roaming helper to support the line
E. Split the task between two workstations
answer
A. Speed up the assembly line transfer mechanism
Reason: Because speeding up the assembly line transfer mechanism speeds up the entire workstation cycle, which will decrease the cycle time.
question
The placement of which of the following is not determined by production process organization decisions?
A. Departments
B. Machines
C. Workstations
D. Emergency Exits
E. Workgroups
answer
D. Emergency Exits
Reason: An emergency exit is a part of the safety procedure not the production process
question
Using the assembly-line balancing procedure, which of the following is the required cycle time in minutes per unit if the daily production time is 480 minutes and the required daily output is 50 units?
A. 0.0104
B. 9.6
C. 50
D. 480
answer
B. 9.6
Reason: Cycle Time = (Production time per day/ required output per day)
question
According to Little's Law, which of the following can be used to estimate work-in-process inventory?
A. Set up time/Throughput rate
B. Value added time/Process velocity
C. Process time/Cycle time
D. Throughput rate times flow time
E. Process velocity/Flow time
answer
D. Throughput rate times Flow time
Reason: Simple systems can be analyzed quickly using a principle known as Little's law. Little's law says there is a long-term relationship between the inventory, throughput, and flow time of a production system in steady state. The relationship is: Inventory = Throughput rate × Flow time.
question
Using the assembly-line balancing procedure, which of the following is the required cycle time if the production time in minutes per day is 1440 and the required output per day in units is 2000?
A. 0.72
B. 250
C. 1.388
D. 500
answer
A. 0.72
Reason: Cycle Time = (Production time per day/ required output per day)
question
Which of the following is a basic type of process structure?
A. Workcenter
B. Product Matrix
C. Manual assembly
D. Process Matrix
E. Process flow diagram
answer
A. Workcenter
Reason: there are five basic structures (project, workcenter, manufacturing cell, assembly line, and continuous process).
question
Using the assembly-line balancing procedure, which of the following is the theoretical minimum number of workstations if the task times for the six tasks that make up the job are 4, 6, 7, 2, 6, and 5 minutes, and the cycle time is 10 minutes?
A. 6
B. 5
C. 8
D. 3
answer
D. 3
Reason: Theoretical number of workstations = (sum of task times/cycle time)
question
You have just determined the actual number of workstations that will be used on an assembly line to be 6 using the assembly-line balancing procedure. The cycle time of the line is 5 minutes and the sum of all that tasks required on the line is 25 minutes. Which of the following is the correct value for the resulting line's efficiency?
A. 0.5
B. 0.973
C. None of these
D. 0.833
E. 0.990
answer
D. 0.833
Reason: Efficiency= sum of task times/(actual #of workstation*cycle time)
question
Which of the following basic types of process structures is one which equipment or work processes are arranged according to the progressive steps by which the product is made?
A. Assembly Line
B. Workcenter
C. Manufacturing cell
D. Project
E. Continuous process
answer
A. Assembly line
Reason: An assembly line is where work processes are arranged according to the progressive steps by which the product is made.
question
Which of the following is not considered a major work flow structure?
A. Assembly line
B. Continuous flow
C. Project
D. Work Center
E. Fabrication
answer
E. Fabrication
Reason: there are five basic structures of workflow (project, workcenter, manufacturing cell, assembly line, and continuous process).
question
For an infinite queuing situation, if the arrival rate for loading trucks is 5 trucks per hour, what is the mean time between arrivals?
A. None of these
B. 2.5 hours
C. 5 hours
D. 0.1 hours
E. 0.2 hours
answer
E. 0.2
Reason: Arrival rate = units in per hour
question
Standing in line to buy a ticket for a movie where there are multiple windows to buy tickets is which type of queuing system line structure?
A. Single channel, multiphase
B. Multichannel, multiphase
C. Multichannel, single phase
D. None of these
E. Single channel, single phase
answer
C. Multichannel, single phase
Reason: Single phase because you are only waiting in one line, but multichannel because there is multiple tickets windows
question
Which of the following is not a queue discipline discussed in the textbook?
A. Best customer first
B. Last in, first out
C. Limited needs
D. First come, first serve
E. Shortest processing time
answer
B. Last in, first out
Reason: Common priority rule examples: Reservations first, emergencies first, highest-profit customer first, largest orders first, best customers first, longest waiting time in line, and soonest promised date.
question
There are many applications of poka-yokes in service organizations. Which of the following is one of the three-T's used to classify pika-yokes?
A. Task
B. Talent
C. Trust
D. Time
E. Teamwork
answer
A. Task
Reason/Example: Task, Treatment, Tangible
Task: Fix a Car, Treatment: was the the servos manager courteous, Tangible environment: was the waiting line clean and comfortable
question
Buying a ticket for a college football game where there are multiple windows to buy the ticket at features which type of queuing system line structure?
A. Single channel, multiphase
B. Multichannel, multiphase
C. Multichannel, single phase
D. None of these
E. Single channel, single phase
answer
C. Multichannel, single phase
Reason: Single phase because you are only waiting in one line, but multichannel because there is multiple tickets windows
question
Which of the following is a suggestion for managing queues that is mentioned in the textbook?
A. Tell people in the queue that each will be served as soon as possible
B. Put up a serpentine lane to keep people from jumping ahead in line
C. Use humor to defuse a potentially irritating situation
D. Assure customers that the wait is fair and inform them of the queue discipline
E. Segment the customers
answer
E. Segment the customers
Reason: Useful suggestions for managing are the following:
• Segment the customers.
• Train your servers to be friendly.
• Inform your customers of what to expect.
• Try to divert the customer's attention when waiting.
• Encourage customers to come during slack periods.
question
Which of the following is a suggestion for managing queues presented in the textbook?
A. Tell customers that the line should encourage them to come during slack periods
B. Use humor to defuse a potentially irritating situation
C. Periodically close the service channel to temporarily disperse the line
D. Train your servers to be friendly
E. Give each customer a number
answer
D. Train your servers to be friendly
Reason: Useful suggestions for managing are the following:
• Segment the customers.
• Train your servers to be friendly.
• Inform your customers of what to expect.
• Try to divert the customer's attention when waiting.
• Encourage customers to come during slack periods.
question
In the service-system design matrix, a face-to-face total customization service encounter is expected to have which of the following?
A. Low sales opportunity
B. Low production efficiency
C. Low degree of customer/server contact
D. None of these
E. High production efficiency
answer
B. Low production efficiency
Reason: Just seems right
question
Which of the following is a characteristic that can be used to guide the design of service systems?
A. Quality work means quality service
B. Services are all similar
C. Services cannot be inventoried
D. Services businesses are inherently entrepreneurial
E. Even service businesses have internal services
answer
C. Services cannot be inventories
Reason: In designing service organizations we must remember one distinctive characteristic of services: We cannot inventory services.
question
Which of the following is an input to the master production schedule?
A. None of these
B. Exception reports
C. Bill of Materials File (BOM)
D. Inventory records file
E. Planned-order schedules
answer
A. None of the above
question
In an MRP program, the program accesses the status segment of an inventory record according to specific periods called which of the following?
A. Cubed time units
B. Time lines
C. Time modules
D. Time buckets
E. BOM units
answer
D. Time buckets
question
Which of the following is the net requirement using an MRP program if the gross requirement is 1,000 and the inventory on hand is 500?
A. 950
B. 350
C. 400
D. 500
C. 1,000
answer
D. 500
question
Which of the following is considered a primary report in an MRP system?
A. Planning Report
B. Inventory accuracy report
C. Peg report
D. Aggregate production plan report
E. Planned order schedule
answer
E. Planned order schedule
question
One of the main purposes of a MRP system is which of the following?
A. Decrease layers of management
B. Track inventory levels
C. Upgrade manufacturing's professionalism
D. Develop schedules specifying when each component should be ordered or produced.
E. Create productive capacity
answer
D. Develop schedules specifying when each component should be ordered or produced.
question
Which of the following is an input file necessary to run an MRP system?
A. Personnel files
B. Exception report
C. Planned order schedule
D. Computer-aided design files
E. Inventory records file
answer
E. Inventory records file
question
Which of the following is an input to the master production schedule (MPS)?
A. Inventory records file
B. Planned order schedules
C. The aggregate plan
D. The bill of materials
E. The exception report
answer
C. The aggregate plan
question
MRP systems seek to achieve which of the following?
A. Minimize lot sizes
B. Determine the number of dependent demand items needed
C. Relieve capacity bottlenecks
D. Provide a yardstick for future improvements.
E. Improve on JIT methods
answer
B. Determine the number of dependent demand items needed
question
We would expect to see which of the following in an MRP system's inventory status file?
A. Computer errors
B. Labor Efficiency
C. End items produced
D. Late/early delivery records
E. Scrap parts
answer
E. Scrap Parts
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