Operations Management 6th Edition Reid Test Bank

Operations Management 6th Edition
Reid Test Bank

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-6th-edition-reid-test-bank/
Reid & Sanders / Operations Management, 6th edition Test Bank
File: ch10, Chapter 10: Facility Layout
Multiple Choice
1. Which of the following is not a resource that might not be included in deciding a facility
layout?
a) desk
b) work center
c) telephone switch
d) work center
e) person
Ans: c
Section Ref: What is Layout Planning?
Level: Easy
Bloom’s: Comprehension
Learning Objective 1: Define layout planning and explain its importance.
AACSB: Analytic
2. Which of the following may not be a result of a poor layout?

a) wasted time
b) wasted energy
c) confusion
d) poor communication
d) increased flow of information
Ans: e
Level: Easy
AACSB: Analytic
3. Intermittent operations are seen in organizations that produce:

a) a small variety of different products
b) high volumes of a few standard products
c) a large variety of different products
d) a large volume of many standardized products
Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

e) assembly line manufacturing
Ans: c
Level: Easy
Bloom’s: Knowledge
AACSB: Analytic
4. Which of the following is not one of the four basic layout types?
a) product
b) hybrid
c) process
d) fixed position
e) inverted
Ans: e
Section Ref: Types of Layouts
Level: Easy
Learning Objective 2: Identify and describe different types of layouts.
AACSB: Analytic
5. The challenge in process layouts is to arrange resources to maximize __________ and

minimize ___________.
a) movement, effectiveness
b) effectiveness, efficiency
c) efficiency, waste of movement
d) efficiency, effectiveness
e) efficiency, labor cost
Ans: c
Level: Easy
AACSB: Analytic
6. A company with a pure continuous processing system is most likely to use which layout type?
a) inverted
b) product

c) process
d) fixed position
e) hybrid
Ans: b
Level: Easy
AACSB: Analytic
7. Process layouts have

a) less automation
b) more automation
c) fewer employees
d) more cycle time
e) less cycle time
Ans: a
Level: Easy
AACSB: Analytic
8. A job shop is most likely to use which layout type?

a) inverted
b) hybrid
c) process
d) fixed position
e) product
Ans: c
Level: Easy
AACSB: Analytic
9. A hospital is an example of which layout type?

a) inverted
b) hybrid
c) process
d) fixed position
e) product
Ans: c
Level: Easy
AACSB: Analytic
10. A grocery store is most like which of the following layout types?
a) inverted
b) circular
c) process
d) fixed position
e) product
Ans: c
Level: Easy
AACSB: Analytic
11. A university is an example of which layout type?

a) inverted
b) hybrid
c) process
d) fixed position
e) product
Ans: c
Level: Easy
AACSB: Analytic

12. Which of the following is least like a process layout?

a) job shop
b) automobile plant
c) hospital
d) university
e) grocery store
Ans: b
Level: Easy
AACSB: Analytic
13. Which of the following is more like a product layout as compared to a process layout?
a) Resources used are general purpose.
b) Facilities are less capital intensive.
c) Processing rates are slower.
d) Space requirements for inventory storage are lower.
e) Scheduling resources is more challenging.
Ans: d
Level: Easy
AACSB: Analytic
a) Resources used are specialized.
d) Space requirements for inventory storage are higher.
Ans: a
Level: Easy
AACSB: Analytic

b) Facilities are more capital intensive.
Ans: b
Level: Easy
AACSB: Analytic
c) Processing rates are faster.
Ans: c
Level: Easy
AACSB: Analytic
e) Scheduling resources is less challenging.
Ans: e
Level: Easy


AACSB: Analytic
c) Material handling costs are lower.
Ans: c
Level: Easy
AACSB: Analytic
c) Less skilled workers can be used.
Ans: c
Level: Easy
AACSB: Analytic
c) Products cannot be easily added or deleted from the existing product line.
Ans: c

Level: Easy
AACSB: Analytic
21. A company with a pure intermittent processing system is most likely to use which layout
type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product
Ans: c
Level: Easy
AACSB: Analytic
22. A single-line cafeteria is an example of which layout type?

a) inverted
b) disjointed
c) process
d) fixed position
e) product
Ans: e
Level: Easy
AACSB: Analytic
23. A car wash is an example of which layout type?

a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: e
Level: Easy
AACSB: Analytic
24. A high-volume paper mill is an example of which layout type?

a) inverted
b) circular
c) process
d) fixed position
e) product
Ans: e
Level: Easy
AACSB: Analytic
25. Which of the following is least like a product layout?

a) high-volume paper mill
b) automobile plant
c) hospital
d) single-line cafeteria
e) car wash
Ans: c
Level: Easy
AACSB: Analytic
26. In a product layout facility the manager must decide

a) employees’ salary
b) exactly what tasks will not be performed by every workstation
c) exactly what tasks will be performed by every workstation

d) exactly what vacation schedule must be followed

e) general sequence the work must be performed in
Ans: e
Level: Easy
AACSB: Analytic
27. Which company is widely considered to be the leader of just-in-time production?

a) Ford
b) Timex
c) Gateway
d) Toyota
e) Sony
Ans: d
Level: Easy
AACSB: Analytic
28. A hybrid layout combines

a) fixed and product
b) fixed and process
c) inverted and product
d) services and manufacturing
e) process and product
Ans: e
Level: Easy
AACSB: Analytic
29. A wheat farm is an example of which layout type?

a) inverted

b) hybrid
c) process
d) fixed position
e) product
Ans: d
Level: Easy
AACSB: Analytic
30. Shipbuilding is an example of which layout type?

a) inverted
b) hybrid
c) process
d) fixed position
e) product
Ans: d
Level: Easy
AACSB: Analytic
31. Building construction is an example of which layout type?

a) inverted
b) hybrid
c) process
d) fixed position
e) product
Ans: d
Level: Easy
AACSB: Analytic

32. Bridge construction is an example of which layout type?

a) inverted
b) hybrid
c) process
d) fixed position
e) product
Ans: d
Level: Easy
AACSB: Analytic
33. Which of the following is least like a fixed-position layout?

a) farm
b) shipbuilding
c) bridge construction
d) building construction
e) car wash
Ans: e
Level: Easy
AACSB: Analytic
34. The first step in designing a layout is

a) identifying the facility
b) gathering information
c) selecting the correct layout software package
d) developing a REL chart
e) developing a from-to matrix
Ans: b
Section Ref: Designing Process Layouts
Level: Easy
Learning Objective 3: Describe the steps involved in designing a process layout.
AACSB: Analytic

35. What are the two primary tools used to identify closeness measures during the layout design
process?
a) REL chart and from-to matrix
b) MRP chart and from-to matrix
c) x-bar chart and from-to matrix
d) MRP chart and x-bar chart
e) x-bar chart and REL chart
Ans: a
Level: Easy
AACSB: Analytic
36. According to the textbook, the available space of a facility is best seen by using a
a) photograph
b) detailed floor plan
c) architecture software package
d) block plan
e) overview plan
Ans: d
Level: Easy
AACSB: Analytic
37. Which layout design tool is primarily based on managers’ opinions?

a) x-bar chart
b) REL chart
c) MRP chart
d) from-to matrix
e) Gantt chart
Ans: b
Level: Easy


AACSB: Analytic
38. What is typically used to quantitatively compare the effectiveness of layouts?

a) trial and error
b) process control charts
c) load-distance model
d) mean absolute deviation (MAD)
e) exponential smoothing
Ans: c
Level: Easy
AACSB: Analytic
39. What is the shortest distance between two locations using north-south and east-west
movements called?
a) Euclidean distance
b) triangulated distance
c) rectilinear distance
d) Socratic distance
e) latitude-longitude (LL) distance
Ans: c
Level: Easy
AACSB: Analytic
40. Using a relationship chart to develop acceptable layouts is part of a classic layout technique
called
a) Real layout planning
b) CHART
c) systematic from-to planning
d) systematic layout planning
e) SRP

Ans: d
Level: Easy
AACSB: Analytic
41. Which type of movement is most like rectilinear?

a) driving cross-country on an interstate highway
b) flying an airplane
c) climbing a mountain
d) driving in New York City
e) riding a roller coaster
Ans: d
Level: Easy
AACSB: Analytic
42. How many different layout solutions are possible with 7 departments?
a) 7
b) 720
c) 28
d) 7000
e) 5040
Ans: e
Level: Easy
AACSB: Analytic
43. How many different layout solutions are possible with 7 departments?
a) 7!
b) 6!
c) 7!  1
d) (1!)(2!)(3!)(4!)(5!)(6!)(7!)

e) 8!
Ans: a
Level: Easy
AACSB: Analytic
44. What are two of the most popular facility layout software packages?
a) CONWIP and CRAFT
b) ALDEP and CRAFT
c) CONWIP and MRP
d) ALDEP and MRP
e) ALDEP and CONWIP
Ans: b
Level: Easy
AACSB: Analytic
45. Which popular facility layout software package works from an REL chart?
a) CONWIP
b) MRP
c) ALDEP
d) LAYOUT
e) CRAFT
Ans: c
Level: Easy
AACSB: Analytic
46. Which popular facility layout software package uses a from-to matrix?
a) CONWIP
b) MRP

c) ALDEP
d) LAYOUT
e) CRAFT
Ans: e
Level: Easy
AACSB: Analytic
47. When developing a detailed layout, what tools would be used?

a) MS Excel
b) MULTISTORY
c) CRAFT++
d) 3-D models and CAD software
e) Architecture Software
Ans: d
Level: Easy
AACSB: Analytic
48. Warehouse layouts have the key characteristics of process layouts except
a) number of loads is not a design consideration
b) location isn’t a major consideration
c) there is movement between the storage areas
d) from trips are the only consideration
e) there is no movement between the storage areas
Ans: e
Section Ref: Special Cases of Process Layout
Level: Easy
Learning Objective 4: Describe the two special cases of process layout.
AACSB: Analytic

49. For the general warehouse layout problem, which department should be located furthest from
the dock?
a) least trips needed
b) most area needed
c) highest ratio of trips needed to area needed
d) smallest ratio of area needed to trips needed
e) smallest ratio of trips needed to area needed
Ans: e
Level: Easy
AACSB: Analytic
50. Approximately how much of the U.S. workforce works in an office environment?
a) 10%
b) 25%
c) 50%
d) 75%
e) 90%
Ans: c
Level: Easy
AACSB: Analytic
51. Studies mentioned in the textbook have shown that workers that are in close proximity to
each other are more likely to ______________________.
a) catch a cold
b) date each other
c) get on each other’s nerves
d) have greater understanding, tolerance, and trust for one another
e) play practical jokes on each other
Ans: d
Level: Easy

AACSB: Analytic
52. On which key trade-off does the textbook focus concerning office layouts?
a) cost vs. comfort
b) pictures vs. windows
c) cubes vs. doors
d) network printers vs. individual printers
e) proximity vs. privacy
Ans: e
Level: Easy
AACSB: Analytic
53. One important consideration in designing any layout is

a) consistency
b) flexibility
c) equitability
d) uniformity
e) tenure
Ans: b
Level: Easy
AACSB: Analytic
54. What is the term for the number of units we wish to produce over a specific period of time?
a) job flow
b) output rate
c) cycle time
d) output flow
e) flow time
Ans: b
Section Ref: Designing Product Layouts

Level: Easy
Learning Objective 5: Describe the steps involved in designing a product layout.
AACSB: Analytic
55. What is the term for the maximum amount of time each workstation has to complete its
assigned task?
a) output rate
b) task time
c) station time
d) cycle time
e) output time
Ans: d
Level: Easy
AACSB: Analytic
56. What term tells us how frequently a product is completed?

a) output rate
b) task time
c) station time
d) cycle time
e) output time
Ans: d
Level: Easy
AACSB: Analytic
57. Which of the following statements is not true?

a) The bottleneck determines the lowest possible cycle time.
b) It might be possible to split a bottleneck task into two smaller non-bottleneck tasks.
c) A production process always has at least one bottleneck.
d) A bottleneck task is the longest task in a process.
e) A perfectly balanced line has no bottlenecks.

Ans: e
Level: Easy
AACSB: Analytic
58. What is the longest task in a process called?

a) obstruction
b) bottleneck
c) blockade
d) hindrance
e) constrainer
Ans: b
Level: Easy
AACSB: Analytic
59. The bottleneck determines ________________.
a) which station has the minimum cycle time

b) the minimum cycle time of the whole process
c) the maximum cycle time of the whole process
d) the point at which a product layout converts to a process layout
e) which station has the maximum output rate
Ans: b
Level: Easy
AACSB: Analytic
60. Assigning tasks to workstations is known as __________________.
a) offsetting the line

b) harmonizing the line

c) stabilizing the line
d) balancing the line
e) counterbalancing the line
Ans: d
Level: Easy
AACSB: Analytic
61. The theoretical minimum number of stations is the number of workstations that would be
needed if:
a) all stations were balanced.
b) all task times were the same.
c) the line was 100% efficient.
d) every task had a separate station.
e) the company had no absenteeism.
Ans: c
Level: Easy
AACSB: Analytic
62. When line balancing, which rule does the textbook suggest for assigning tasks to
workstations?
a) shortest task time
b) first come first served
c) fewest predecessors
d) longest task time
e) most successors
Ans: d
Level: Easy
AACSB: Analytic

63. Which production line shapes are particularly useful for the sharing of resources?
a) S and U
b) L and O
c) O and S
d) L and S
e) O and U
Ans: e
Level: Easy
AACSB: Analytic
64. What is the amount by which the efficiency of a production line falls short of 100%?
a) balance delay
b) efficiency deficiency
c) efficiency delay
d) balance shortfall
e) percentage deficiency
Ans: a
Level: Easy
AACSB: Analytic
65. What is the term for a system in which the product being worked on is physically attached to
the line and automatically moved to the next station when the cycle time has elapsed?
a) cyclical line
b) paced line
c) autoline
d) continuous line
e) constrained line
Ans: b
Level: Easy

AACSB: Analytic
66. Group technology creates groupings of products primarily based on what?

a) product cost
b) raw materials requirements
c) similar processing requirements
d) operating characteristics
e) market segmentation
Ans: c
Section Ref: Group Technology (Cell) Layouts
Level: Easy
Learning Objective 6: Explain the meaning of group technology (cell) layouts.
AACSB: Analytic
67. The items listed below are stored in a one-dock warehouse. Which of them should be stored
at the very back (furthest away from the dock)?
Item Trips Area Needed (blocks)
A 300 60
B 220 3
C 72 1
D 60 10
E 24 3
a) A
b) B
c) C
d) D
e) E
Ans: a
Solution: See pages 357-358 (Trip ratio = trips/area needed: A = 300/60 = 5; B= 220/3 = 73.3; C
= 72/1 = 72; D = 60/10 = 6; E = 24/3 = 8: A lowest trip ratio store furthest from dock)
Level: Medium
Bloom’s: Application
AACSB: Reflective Thinking

68. Consider a production line that has a station with two machines, and each unit produced at
the station needs to be processed by both of the machines. (A unit cannot be worked on by both
machines simultaneously.) Each machine has a production capacity of 4 units per hour. What is
the lowest possible cycle time of the station?
a) 4 minutes per unit
b) 8 minutes per unit
c) 7.5 minutes per unit
d) 30 minutes per unit
e) 15 minutes per unit
Ans: e
Solution: 60 min/hr / 4 units/hr = 15 min per unit
Level: Medium
69. Which of the following is true?

a) A line with a lower cycle time has greater output than one with a higher cycle time.
b) A line with a higher cycle time has greater output than one with a lower cycle time.
c) Cycle time is unrelated to output rate.
d) A line must be arranged such that capacity grows with each successive station.
e) Cycle time cannot be greater than the task time of the bottleneck.
Ans: a
Level: Easy
AACSB: Analytic
at the very back (furthest away from the dock)?
“Star Trek” videos 2000 5
Ballet videos 5 1
Tom Cruise videos 200 2
“The Simpsons” videos 1000 2
Operations Management videos 500 1
a) “Star Trek” videos
b) ballet videos

c) Tom Cruise videos

d) “The Simpsons” videos
e) operations management videos
Ans: b
Solution: Trips / Area Needed; lowest number should be furthest away from dock.
“Star Trek” videos 2000 5 400
Ballet videos 5 1 5
Tom Cruise videos 200 2 100
“The Simpsons” videos 1000 2 500
Operations Management videos 500 1 500
Level: Medium
at the very front (closest to the dock)?
A 300 60
B 220 3
C 74 1
D 60 10
E 24 3
a) A
b) B
c) C
d) D
e) E
Ans: c
Solution: Trips / Area Needed = highest number should be closest to dock
Area Needed
Item Trips
(blocks)
A 300 60 5
B 220 3 73.33333
C 74 1 74
D 60 10 6
E 24 3 8
Level: Medium


at the very front (closest to the dock)?
“Star Trek” videos 2000 5
Ballet videos 5 1
Tom Cruise videos 200 2
“The Simpsons” videos 1000 2
Operations Management videos 500 3
a) “Star Trek” videos
b) ballet videos
c) Tom Cruise videos
d) “The Simpsons” videos
e) operations management videos
Ans: d
Solution: Highest number should be closest to the dock
“Star Trek” videos 2000 5 400
Ballet videos 5 1 5
Tom Cruise videos 200 2 100
“The Simpsons” videos 1000 2 500
Operations Management
500 3
videos 166.6667

Level: Medium
73. Which of the following production line shapes is least likely to be found in a factory?
a) N
b) S
c) U
d) O
e) L
Ans: a
Level: Easy

AACSB: Analytic
74. What is Wal-Mart’s primary consideration for its store layout decision regarding the number
and size of aisles in its stores?
a) predictability
b) comfort
c) ease of navigation through the store
d) customer exposure to merchandise
e) inventory control
Ans: d
Level: Easy
AACSB: Analytic
75. The company’s __________ dictates type of layout the company will have.
a) location
b) process
c) union agreements
d) HR policies
e) market share
Ans: b
Section Ref: Facility Layout Within OM: How it all Fits Together
Level: Easy
AACSB: Analytic
76. The step, when Designing a Product Layout, whose goal is to design a product layout that
can produce the desired number of units with the least amount of work centers and a balance of
workload.
a) Compute efficiency, idle time & balance delay
b) Determine cycle time
c) Determine output rate
d) Assign tasks to workstations

e) Identify tasks & immediate predecessors
Ans: c
Level: Easy
AACSB: Analytic
True/False
77. An assembly line is an example of an intermittent processing system.
Ans: False
Level: Easy
AACSB: Analytic
78. A process layout is seen in companies with continuous processing systems.
Ans: False
Level: Easy
AACSB: Analytic
79. A hospital is an example of process layout.
Ans: True
Level: Easy
AACSB: Analytic

80. As compared to a process layout, a product layout generally requires less skilled workers.
Ans: True
Level: Easy
AACSB: Analytic
81. In general, scheduling resources is less challenging under a process layout than it would be
under a product layout.
Ans: False
Level: Easy
AACSB: Analytic
82. At Wal-Mart, to maximize customer comfort and enjoyment, layouts are designed with a
limited number of aisles, each of which is very wide, rather than with multiple but narrow aisles.
Ans: False
Level: Easy
AACSB: Analytic
83. In product layouts, the material moves continuously and uniformly through a series of
workstations until the product is completed.
Ans: True
Level: Easy
AACSB: Analytic

84. Load-distance calculations are very concerned with the direction of the move.
Ans: False
Level: Easy
AACSB: Analytic
85. Maximizing worker proximity minimizes privacy issues.
Ans: False
Level: Easy
AACSB: Analytic
86. In a fixed position layout, resources are fixed in various locations and the products move
from one resource location to the next.
Ans: False
Level: Easy
AACSB: Analytic
87. A predecessor can be worked in parallel with a successor.
Ans: False
Level: Easy
AACSB: Analytic

88. Managers use a from-to matrix for facility layout design to identify both the number of trips
and the direction of those trips.
Ans: False
Level: Easy
AACSB: Analytic
89. Typically, an REL chart is more subjective than a from-to matrix.
Ans: True
Level: Easy
AACSB: Analytic
90. An REL chart can contain ratings of both desirability of closeness and undesirability of
closeness.
Ans: True
Level: Easy
AACSB: Analytic
91. The shortest distance between two locations is called rectilinear distance.
Ans: False
Level: Easy
AACSB: Analytic

92. When possible, managers should purchase and use CRAFT because it gives an optimal
solution to the facility layout problem.
Ans: False
Level: Easy
AACSB: Analytic
93. A heuristic solution always provides the best possible answer.
Ans: False
Level: Easy
AACSB: Analytic
94. For the general warehouse layout problem, the department with the highest ratio of trips to
areas needed should be located closest to the dock.
Ans: True
Level: Easy
AACSB: Analytic
95. The cycle time of a production line is based on the workstation with the highest potential
output rate.
Ans: False
Level: Easy
AACSB: Analytic

96. If a process has a “faster” cycle time, then its cycle time has decreased.
Ans: True
Level: Easy
AACSB: Analytic
97. As the cycle time of a process decreases, its output also decreases.
Ans: False
Level: Easy
AACSB: Analytic
98. The theoretical minimum number of stations results in the production of daily requirements
when no inefficiency exists.
Ans: True
Level: Easy
AACSB: Analytic
99. Group Technology has the advantage of bringing the efficiencies of a process layout to a
product layout environment.
Ans: False
Level: Easy
AACSB: Analytic

100. A product layout can look like an S-curve.
Ans: True
Level: Easy
AACSB: Analytic
101. Marketing is not highly affected by layout planning.
Ans: False
Section Ref: Facility Layout Across the Organization
Level: Easy
AACSB: Analytic
Short Answer
102. What are the two broad categories of operating systems?
Ans: intermittent processing systems and continuous processing systems

Level: Easy
AACSB: Analytic
103. What are the four basic layout types?
Ans: process, product, fixed position, and hybrid

Level: Easy

AACSB: Analytic
104. How does material move in a product layout?
Ans: continuously and uniformly through a series of workstations until the product is completed
Level: Easy
AACSB: Analytic
105. What is another name for cell layout?
Ans: group technology

Level: Easy
AACSB: Analytic
106. What is the term for a layout in which the product cannot be moved due to its size, and all
the resources have to come to the production site?
Ans: fixed-position layout

Level: Easy
AACSB: Analytic
107. What are the three steps in designing process layouts?
Ans: (1) gather information, (2) develop a block plan or schematic of the layout, (3) develop a
detailed layout
Level: Easy

AACSB: Analytic
108. What is a table that gives the number of trips or units of product moved between any pair of
departments called?
Ans: from-to matrix

Level: Easy
AACSB: Analytic
109. What is a table that reflects opinions of managers with regard to the importance of having
any two departments close together called?
Ans: REL chart

Level: Easy
AACSB: Analytic
110. What is the maximum amount of time that each workstation has to complete its assigned
task called?
Ans: cycle time

Level: Easy
AACSB: Analytic
111. Compare the minimum versus maximum cycle time of a process.

Ans: The minimum cycle time is equal to the bottleneck, or longest, task. The maximum cycle
time is equal to the sum of the task times in the whole process. The minimum and maximum
cycle times are important as they establish the range of output for the production line.
Level: Medium
Bloom’s: Analysis
AACSB: Analytic
112. Describe what group technology is.
Ans: Group technology is the process of creating groupings of products based on similar
processing requirements.
Level: Easy
AACSB: Analytic
113. Discuss why facility layout is important to a supply chain
Ans: Arranging layouts for efficient delivery of materials to move directly to the production line
is important. Arranging the facility layout to be linked to inbound and outbound shipments can
greatly enhance the smooth flow of products throughout the supply chain.
Section Ref: The Supply Chain Link
Level: Easy
AACSB: Analytic
114. Explain the difference between paced and un-paced lines.
Ans: Paced lines use an automatic enforced cycle time. Un-paced lines have more autonomy
And the product may be removed off the assembly line.
Level: Medium
Bloom’s: Analysis
AACSB: Analytic

Problems
115. Consider the following layout of departments.

A B C
D F E
Compute the ld score given the following from-to matrix.
Trips Between Departments
Department A B C D E F
A  12 45 3 14 29
B  16 72 5 42
C  30 20 90
D  10 4
E  12
F 
Ans: 743
Level: Medium
116. Consider the following two layouts of departments.

Layout 1 Layout 2
D E C C D B
A B A E
Compute the ld score for each and choose the best, given the following from-to matrix.
Trips Between Departments
Department A B C D E
A  18 8 3 4
B  16 22 5
C  50 20
D  90
E 
Ans: layout 1 = 344, layout 2 = 316, layout 2 is better

Level: Medium

117. A firm has four departments to locate in the following space.
Department A has a daily average of 20, 10, and 60 trips to Departments B, C, and D,
respectively; Department B has a daily average of 25 and 30 trips to Departments C and D,
respectively; and Department C has a daily average of 50 trips to Department D. While there are
24 different layout combinations, only three are effectively different (in terms of distances
between departments). Calculate the ld score for the three different combinations and choose the
best.
Ans: A diagonal from B = 265, A diagonal from C = 235, A diagonal from D = 280, best layout
is A diagonal from C
Level: Medium
118. The items listed below are stored in a one-dock warehouse. Rank them in order from
closest to the dock to furthest away.
A 200 5
B 100 4
C 78 3
D 60 2
E 35 1
Ans: A-E-D-C-B
Level: Medium
119. The items listed below are stored in a one-dock warehouse. Rank them in order from
closest to the dock to furthest away.
Golf balls 300 1

Basketballs 420 3
Ballet shoes 10 1
Aerobics tapes 20 1
Volleyballs 360 3
Ans: golf balls-basketballs-volleyballs-aerobics tapes-ballet shoes

Level: Medium
120. If a production line produces 800 units per 8-hour workday, what is the cycle time in
minutes?
Ans: 0.6 minutes

Level: Medium
121. Suppose that assembly of a product involves three different tasks taking 10 seconds, 20
seconds, and 30 seconds, respectively. What is the maximum possible output per hour of the
system?
Ans: 120
Level: Medium
122. Maxine’s cookie factory bottleneck is the oven. It takes 45 seconds to cook a batch of 144
cookies. What is the maximum number of cookies that Maxine can produce every hour?
Ans: 11,520
Level: Medium


123. Maxine has identified the following process times and desired output. What is the
theoretical minimum number of work stations?
mix dough 90 sec desired output 30 batches/hour
shape cookie 50 sec
cook 45 sec
cool 75 sec
Ans: 3
Level: Medium
124. Suppose that assembly of a product involves four different tasks taking 40 seconds, 20
seconds, 30 seconds, and 80 seconds, respectively. What is the theoretical minimum number of
stations?
Ans: 3
Level: Medium
125. Suppose that an assembly line consists of two stations. Station 1 involves three tasks,
taking 40 seconds, 20 seconds, and 30 seconds, respectively. Station 2 involves one task that
takes 80 seconds. Compute the efficiency and balance delay of the assembly line.
Ans: efficiency = 94.4%, balance delay = 5.6%

Level: Medium

126. The following table provides tasks on an assembly line, along with their predecessors and
task times.
Immediate
Task Predecessor Time (seconds)
A None 45
B None 30
C A, B 48
D B 20
E C 10
F D, E 20
G E 40
If desired output is 75 units per hour, compute (a) the associated cycle time, (b) the assignment
of tasks to stations using the longest task time rule, and (c) the efficiency of your solution.
Ans: (a) = 48 seconds

(b) = Workstation Eligible Selected Time Idle
1 A, B A 45 3
2 B B 30 18
3 C, D C 48 0
4 D, E D 20 28
E E 10 18
5 F, G G 40 8
6 G F 20 28
(c) = 73.96%
Level: Medium
Short Answer
127. Managers' opinions about the importance of paired departments being near each other are
recorded in ________________.
Ans: REL charts.

Level: Easy
AACSB: Analytic

128. The number of trips or products moved between pairs of departments is recorded in a
____________________.
Ans: from-to matrix

Level: Easy
AACSB: Analytic
129. The _____________ distance between two locations on north-south and east-west axes is
used in the _____________ model.
Ans: rectilinear, load-distance

Level: Easy
AACSB: Analytic
130. The load-distance model tells us which departments should be closest to each other by
_________.
Ans: minimizing the distance large numbers of products move.

Level: Easy
AACSB: Analytic
131. While traditional walls and doors provide privacy, they reduce _____________ and
opportunities for ______________.
Ans: proximity, team work

Level: Easy


AACSB: Analytic
132. Cycle time assumes that each workstation has ____________ time to work on a product.
Ans: the same

Level: Easy
AACSB: Analytic
133. Since there are 3600 seconds per hour, a process that is expected to produce 40 units per
hour has a cycle time of _________________.
Ans: 90 seconds / unit

Level: Medium
134. Bottlenecks determines determine maximum output because it __________________.
Ans: has the minimum cycle time.

Level: Easy
AACSB: Analytic
135. What is the formula for the theoretical minimum number of work stations?
Ans: ∑t/NC
Level: Easy

AACSB: Analytic
136. What is the formula efficiency?
Ans: Efficiency(%) = ∑t/NC(100)

Level: Easy
AACSB: Analytic
137. A single-model line is __________ to produce only __________ version of a product.
Ans: designed, one

Level: Easy
AACSB: Analytic
138. Facility layout decisions are _________ with a number of other ____________.
Ans: linked, operations decisions.

Section Ref: Facility Layout Within OM: How it All Fits Together
Level: Easy
AACSB: Analytic

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File: ch10, Chapter 10: Facility Layout

2. Which of the following may not be a result of a poor layout?

3. Intermittent operations are seen in organizations that produce:

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

e) assembly line manufacturing

5. The challenge in process layouts is to arrange resources to maximize __________ and

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

7. Process layouts have

8. A job shop is most likely to use which layout type?

9. A hospital is an example of which layout type?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

11. A university is an example of which layout type?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

12. Which of the following is least like a process layout?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

Learning Objective 2: Identify and describe different types of layouts.

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

22. A single-line cafeteria is an example of which layout type?

23. A car wash is an example of which layout type?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

24. A high-volume paper mill is an example of which layout type?

25. Which of the following is least like a product layout?

26. In a product layout facility the manager must decide

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

d) exactly what vacation schedule must be followed

27. Which company is widely considered to be the leader of just-in-time production?

28. A hybrid layout combines

29. A wheat farm is an example of which layout type?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

30. Shipbuilding is an example of which layout type?

31. Building construction is an example of which layout type?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

32. Bridge construction is an example of which layout type?

33. Which of the following is least like a fixed-position layout?

34. The first step in designing a layout is

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

37. Which layout design tool is primarily based on managers’ opinions?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

Learning Objective 3: Describe the steps involved in designing a process layout.

38. What is typically used to quantitatively compare the effectiveness of layouts?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

41. Which type of movement is most like rectilinear?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

47. When developing a detailed layout, what tools would be used?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

53. One important consideration in designing any layout is

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

56. What term tells us how frequently a product is completed?

57. Which of the following statements is not true?

Copyright ©2016 John Wiley & Sons, Inc. TB 10-1

58. What is the longest task in a process called?

59. The bottleneck determines ________________.

a) which station has the minimum cycle time

60. Assigning tasks to workstations is known as __________________.

a) offsetting the line