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Exam 9: Layout Strategies

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Question 31

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The main goal of retail layout is

A) minimizing material handling cost.
B) maximizing high-margin sales.
C) minimizing storage costs.
D) minimizing space required.
E) maximizing profitability per square foot of floor space.

F) A) and B)
G) A) and D)

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Question 32

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A(n) ________ is a special product-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility.

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Question 33

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Currently there are 5 tasks that need to be performed. These tasks, ABCDE, have required times of 2 minutes, 5 minutes, 4 minutes, 3 minutes, and 10 minutes respectively. The assembly line needs to produce 50 units per day to meet demand and can work for up to 7.5 hours each day. A. What is the required cycle time? B. What is the theoretical minimum # of workstations?

The assumptions necessary for a successful product layout include all of the following except

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

Heuristics are problem-solving procedures that mathematically optimize the solution.

The minimum number of workstations depends upon the set of task times and the precedence chart, but not the number of units scheduled.

Cross-docking processes items as they are received, rather than placing them in storage; this helps explain why "warehouses" are now called "distribution centers."

One disadvantage of process-oriented layouts arises from

A fabrication line and an assembly line are both types of repetitive and product-focused layout, but only the fabrication line utilizes workstations.

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 $\begin{array} { | c | c | c | c | c | c | c | } \hline & \mathbf { 1 } & \mathbf { 2 } & \mathbf { 3 } & \mathbf { 4 } & \mathbf { 5 } & \mathbf { 6 } \\\hline \mathbf { 1 } & - - & 5 & 30 & 20 & 15 & 20 \\\hline \mathbf { 2 } & & - - & 40 & 15 & 10 & 10 \\\hline \mathbf { 3 } & & & - - & 50 & 20 & 5 \\\hline \mathbf { 4 } & & & & - - & 10 & 35 \\\hline \mathbf { 5 } & & & & & - - & 5 \\\hline \mathbf { 6 } & & & & & & - - \\\hline\end{array}$ The matrix of work flow (estimated trips per day) is among centers $\begin{array} { | l | c | c | c | c | c | c | } \hline & \boldsymbol { A } & \mathbf { B } & \mathbf { C } & \mathbf { D } & \mathbf { E } & \mathbf { F } \\\hline \mathrm { A } & - - & 15 & 20 & 0 & 30 & 0 \\\hline \mathrm { B } & 20 & - - & 50 & 0 & 160 & 10 \\\hline \mathrm { C } & 0 & 50 & - - & 30 & 0 & 30 \\\hline \mathrm { D } & 30 & 60 & 20 & - - & 70 & 0 \\\hline \mathrm { E } & 40 & 0 & 0 & 10 & - - & 60 \\\hline \mathrm { F } & 0 & 0 & 30 & 20 & 50 & - - \\\hline\end{array}$ The firm estimates that each trip costs approximately $4. a. What is the cost of the current assignment? b. Use trial-and-error to find one improved assignment. c. What is that assignment, and what is its cost?

McDonald's "Made by You" kitchen system represents a ________ use of layout decisions.

A manufacturing work cell has a takt time of 7 minutes and is staffed by 10 workers. If the work cell delivers 68 units each day find A. The total operation time B. The amount of time worked during the day for all 10 workers combined C. If the plant is open for only 8 hours per day, can the staff meet demand?

If the schedule calls for the production of 120 units per day and 480 minutes of production time are available per day, the maximum cycle time would be 4 minutes.

A(n) ________ addresses flow, allocates space, and responds to customer behavior.

Identify the four requirements for cellular production.

________ is that element of balancing a work cell that superficially resembles cycle time.

A manufacturing work cell has a takt time of 5 minutes and is staffed by 7 workers. If the work cell delivers 61 units each day find A. The total operation time B. The amount of time worked during the day for all 10 workers combined C. If the plant is open for only 5 hours per day, can the staff meet demand?

Product-oriented layouts tend to have high levels of work-in-process inventories.

Develop a solution for the following line balancing problem, allowing a cycle time of 5 minutes. a. Draw the precedence diagram for the set of tasks. b. Calculate the theoretical minimum number of workstations. c. Balance this line using the longest task time heuristic. d. What tasks are assigned to which stations? e. Does the solution have the minimum number of stations? Explain. f. How much idle time is there, summed over all workstations? g. What is the efficiency of this line? $\begin{array} { | c | c | c | } \hline \text { Work Task } & \begin{array} { c } \text { Task Time } \\\text { (seconds) }\end{array} & \begin{array} { c } \text { Immediate } \\\text { Predecessor(s) }\end{array} \\\hline \text { A } & 70 & - \\\hline \text { B } & 60 & \mathrm {~A} \\\hline \text { C } & 120 & \mathrm {~B} \\\hline \text { D } & 60 & - \\\hline \text { E } & 240 & \mathrm { C } , \mathrm { D } \\\hline \text { F } & 100 & \mathrm {~A} \\\hline \text { G } & 190 & \mathrm { E } , \mathrm { F } \\\hline\end{array}$