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Fau man3506 first exam (chapters 1 – 5)
machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other. The processing requirements to make one unit of each product are shown in the table. Weekly product demand for the next planning period has been forecasted as follows: 80E-1000s; 65 S-2000s; 35 P-2000s; and 20 N-1000s. Processing Time (Minutes Per Printer)Model Machine1 Machine 2 Machine 3 Machine 4E-1000 (E) 10 15 15 5S-2000 (S) 10 10 10 10P-2000 (P) 5 10 15 10N-1000 (N) 5 5 5 10In the questions that follow, the traditional method refers to maximizing the contribution margin per unit for each product, and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product.Use the information in Table 7.6. Using the traditional method, in what sequence should products be scheduled for production?a. N, S, E, P b. N, E, P, S c. P, E, N, S d. E, S, P, NQuestion 3In Statistical Process Control, are used to detect defects and determine if the process has deviated from design specifications.a. Flowchartsb. Cause-and-Effect Diagrams c. Process Capability Chartsd. Control ChartsQuestion 4The process that facilitates the placement of orders and identifies, attracts, and builds relationships with external customers is called the:a. customer relationship process.b. new service development process. c. order fulfillment process.d. supplier relationship process.Question 5Scenario 1.1A job consists of three elements. Twenty observations for each element were timed, and the resulting data are shown in the following table. A performance rating has also been assigned for each element, as shown in the table. The job has an allowance of 20% of normal time.Element PerformanceRating (%) Average ElementTime (in minutes)# 1 80 3.6# 2 100 2.5# 3 110 3.1Use the information in Scenario 1.1. What is the normal time for the entire job?a. Greater than or equal to 10.0 minutesb. Less than 10.0 minutes but greater than or equal to 8.5 minutes c. Less than 8.5 minutes but greater than or equal to 7.0 minutes d. Less than 7.0 minutesQuestion 6Table 1.3Act. I.P N. Time C. Time N. COST ($000s) C. COST ($000s) Av. Crash wks C. Cost/wkA – 4 2 8 14 B A 3 2 9 11 C A 4 4 10 10 D B,C 5 3 10 15 E C 4 1 11 14 F D,E 1 1 6 6 * Act.: ActivityI.P. : Immediate PredecessorN. Time : Normal TimeC. Time: Crash TimeN. Cost: Normal Cost ($000s) C. Cost: Crash Cost ($000s)Av. Crash wks: Available Weeks of CrashingC. Cost/wk: Crashing cost per weekWhich activity should be crashed first for the project shown in Table 1.3?a. A b. B c. C d. DQuestion 7You are interested in buying a laptop computer. Your list of considerations include the computer’s speed in processing data, its weight, screen size, and price. You consider a number of different models, and narrow your list based on speed and monitor screen size, then finally select a model to buy based on its weight and price. In this decision, weight and price are examples of:a. order qualifiers.b. the voice of the supplier. c. order winners.d. the voice of the customer.Question 8Input measures to planning long-term capacity include such metrics as:a. the number of customers served per hour.b. the number of trucks produced per day. c. the number of machine hours available. d. the number of bills processed in a week.Selected Answer: c. [None Given] Question 9Regardless of how departments like Accounting, Engineering, Finance, and Marketing function in an organization, they are all linked together through:a. management. b. processes.c. customers.d. stakeholders.Question 10 When considering the plan-do-study-act cycle for problem solving, data are collected to measure process improvements in the step.a. plan b. do c. study d. actQuestion 11 The upper and lower specifications for a service are 10 min. and 8 min., respectively. Theprocess average is 9 min. and the process capability ratio is 1.33. What is the process standard deviation?a. 0.1 b. 0.15 c. 0.20d. 0.25Selected Answer: d. [None Given]Question 12 2.5 out of 2.5 pointsActivity slack is defined as:a. latest start time minus earliest start time. b. earliest start time minus latest start time.c. earliest finish time minus latest finish time.d. latest finish time minus earliest start time.Question 13 2.5 out of 2.5 pointsA company desires to set up a line to produce 60 units per hour. The work elements and their precedence relationships are shown in Table 7.12.Use the information in Table 7.12. What is the highest efficiency line balance possible?a. Less than 93%b. More than 93% but less than or equal to 95% c. More than 95% but less than or equal to 97% d. More than 97%Table 7.12 Work Time Immediate Page 6 of 17Element (sec) Predecessor(s) Question 16The second step in Theory of Constraints application, “exploit the bottleneck(s),” means that:a. the analyst should create a schedule that maximizes the throughput of the bottlenecks.b. the analyst should repeat the analysis process to look for other bottlenecks.c. the analyst should consider increasing capacity of the bottleneck.d. the analyst should schedule non-bottleneck resources to support the bottleneck.Question 17In an assembly operation at a furniture factory, six employees assembled an average of 450 custom cabinet drawers per 5-day week. What is the labor productivity of this operation?a. 90 chairs per worker per day b. 20 chairs per worker per day c. 15 chairs per worker per day d. 75 chairs per worker per dayQuestion 18Front offices typically emphasize:a. low cost operations and on-time delivery. b. top quality and customization.c. on-time delivery and standardization. d. top quality and low cost operationsQuestion 19Manufacturing processes usually have:a. physical, durable output.b. high levels of customer contact.c. output that cannot be inventoried. d. low levels of capital intensity.Question 20Regarding control charts, a type I error refers to concluding that the process is:a. in control when it is not in control. b. incapable when it is capable.c. out of control when it is in control. d. capable when it is not capable.Question 21Table 7.6Burdell Industries makes four different models of computer printers: the E-1000, the S-2000, the P-2000 and the N-1000. The E-1000 sells for $200 andhas $40 in parts and $40 in labor; the S-2000 sells for $150 and requires $30 in parts and $30 in labor; the P-2000 sells for $100 and has $20 in parts and $20 in labor; and the N-1000 sells for $75 but requires only $10 of parts and $10 of labor. Fixed overhead is estimated at $5,000 per week. The manufacture of each printer requires four machines, Machines #1, 2, 3 and 4. Each of the machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other. The processing requirements to make one unit of each product are shown in the table. Weekly product demand for the next planning period has been forecasted as follows: 80 E-1000s; 65 S-2000s; 35 P-2000s; and 20 N-1000s. Processing Time (Minutes Per Printer)Model Machine1 Machine 2 Machine 3 Machine 4E-1000 (E) 10 15 15 5S-2000 (S) 10 10 10 10P-2000 (P) 5 10 15 10N-1000 (N) 5 5 5 10In the questions that follow, the traditional method refers to maximizing the contribution margin per unit for each product, and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product.Use the information in Table 7.6. Using the bottleneck method, in what sequence should products be scheduled for production?a. N, S, E, P b. N, E, P, S c. P, E, N, S d. E, S, P, N Question 22A manufacturer that produces standard products in large volumes is likely to be using a(n):a. make-to-stock strategy. b. make-to-order strategy.c. assemble-to-order strategy. d. engineer-to-order strategy. Question 23Which one of the following statements about flexible automation is best?a. Investment cost is lower when a transfer machine handles many operations.b. Chemical processing plants and oil refineries mainly utilize programmable automation. c. It is an automatic process that can be reprogrammed to handle various products.d. It achieves top efficiency; accommodating new products is difficult and costly.Question 24Which statement regarding learning rates is best?a.A more complicated process offers more room for improvement.b.A simpler process has a more pronounced learning rate.c. Typically, the effect of each capital addition on the learning curve is significant.d.Regardless of output volume, the estimate for the time required to produce the first unit is less important than the estimate of the learning rate. Question 25You are given the following information about an activity A:i) Normal time = 9 weeks ii) Crash time = 7 weeks iii) Normal cost = $20,000 iv) Crash cost = $30,000What will it cost to complete activity A in 8 weeks?a. Less than or equal to $24,000b. Greater than $24,000 but less than or equal to $27,000 c. Greater than $27,000 but less than or equal to $30,000 d. Greater than $30,000Question 26Which one of the following statements concerning capacity cushions is best?a. Large capacity cushions are used more often when future demand is level and known.b. Small capacity cushions are used extensively in capital intensive firms.c. Capacity cushions are used primarily in manufacturing organizations, not in service organizations.d. Small cushions are used in organizations where the products and services produced often change. Question 27 Historically, the average diameter of the holes drilled has been 0.25 cm and the average range has been 0.1 cm. Determine the central line and upper and lower control limits for an x and an R-chart, assuming samples of size 8 will be taken. Use Table 5.1. what is the value of UCL for x bar chart?a. Less than or equal to 0.100b. Greater than 0.100 but less than or equal to 0.200 c. Greater than 0.200 but less than or equal to 0.300 d. Greater than 0.300Question 28 2.5 out of 2.5 pointsHistorically, the average proportion of defective bars has been 0.015. Samples will be of 100 bars each. Construct a p-chart using . Suppose a sample had 0.07 defectives. What would you do?a. Nothing; it is just random variation. b. Look for assignable causes.c. Change z to 2 and take another sample. d. Change z to 4 and continue sampling.Question 29 2.5 out of 2.5 pointsA welder can weld 2 angle irons together in 2 minutes. Over the course of an entire year she willassemble 1,000 units, each of which requires 3 such welds (i.e., welding two angle irons together is one step, and three such steps are needed per unit). If she is paid $25 an hour, how much is her annual welding labor cost?a. $1,000 b. $1,250c. $2,500 d. $3,000Question 30 2.5 out of 2.5 pointsTable 6.3The North Bend Manufacturing Company is producing two types of products, A and B. Demand forecasts for next year and other production-related information are provided in the following table: Product A Product B Demand forecast (units/year) 4,000 12,000 Batch size (units/batch) 80 150 Standard processing time(hr/unit)Standard setup time(hr/batch) 2.5 218 24Both products A and B are produced at the same operation called MASAC27A.Use the information in Table 6.3 to help answer this question. Currently, the company has 12 MASAC27A machines, and financial constraints prevent any expansion for the next year. Which one of the following alternatives will allow next year’s demand to be fully covered?a. Do nothing.b. Increase the capacity cushion to 30 percent.c. Increase the batch size of product B to 300 units. d. Decrease the capacity cushion by 1 percent.Question 31A company is interested in monitoring the number of scratches on Plexiglass panels. The appropriate control chart to use would be:a. an x chart. b. a p-chart. c. a c-chart.d. an R-chart.Question 32Precedence Table to accompany Table 1:Activity Immediate PredecessorA – B A C A D BE B, C F C G D, E, F Table 1.1ACTIVITY ACTIVITY EARLIEST EARLIEST LATEST LATEST SLACK TIME START FINISH START FINISHA 2 0 0 2 0B 1 2 3 3 4 1C 3 2 5 2 5 0D 7 3 10 4 11E 3 5 8 11 3F 5 11 5 11 0G 4 11 15 11 15 0Using the information in Table 1 and Table 1.1, which one of the following is the critical path?a. a. ABDG b. b. ABEG c. c. ACEG d. d. ACFGQuestion 33 2.5 out of 2.5 pointsA company is interested in monitoring the variability in the weight of the fertilizer bags it produces. An appropriate control chart would be:a. an x chart. b. a p-chart.c. a c-chart.d. an R-chart.Question 34The earliest start time for an activity is equal to the:a. smallest earliest finish time of all of its immediate predecessors. b. largest earliest finish time of all of its immediate predecessors.c. smallest late start time of any of its immediate predecessors. d. largest late finish time of all of its immediate predecessors.Question 35The three sigma limits for a process whose distribution conforms to the normal distribution include:a. about 50% of the observed values, in the long run. b. about 68% of the observed values, in the long run. c. about 95% of the observed values in the long run. d. about 99% of the observed values in the long run. Question 36A manufacturing plant is capable of producing 10 tons of product per day when run three shifts with no breakdowns and plenty of raw materials. Over the past week, the plant has produced an average of 7.3 tons per day since the third shift has devoted much of their time to preventive maintenance. What is the capacity of the plant?a. 10 tons/dayb. 7.3 tons/day c. 73%d. 137%Question 37A wait-and-see capacity strategy does all of the following EXCEPT:a. lag behind demand.b. minimize the chance of lost sales due to insufficient capacity.c. meet capacity shortfalls with overtime, temporary workers, subcontracting, and stockouts.d. reduce the risk of overexpansion based on overly optimistic demand forecasts. Question 38A Kanban system is an important mechanism for lean system management.Which one of the following statements regarding the operation of aKanban system is TRUE?a. A typical Kanban used in the JIT system includes information such as item number, unit price, competitor’s product name, and its price.b. A Kanban can be used to set the order quantity but not the inventory level.c. A Kanban and a container move as a pair once production begins at the fabrication process.d. An empty container can be exchanged for a full container at the storage location even though no Kanban is on the full container.Question 39 The focus for a process improvement exercise should be on balancing:a. flow.b. capacity. c. workload. d. time.Question 40Table 1.2:Activity Immediate Predecessor (s) Most Optimistic Time (Wks) Most Likely Time (Wks) Most Pessimistic Time (Wks)A — 1 2 3B A 2 4 12 C A 1 2 3 D B 6 7 8 E B,C 10 12 14 F D 2 3 4 G E,F 1 5 15 H A 2 5 14 Using Table 1.2, if the expected times for activities A, G, and H increased by 2, 3, and 4 weeks, respectively, by how many weeks would the project’s earliest expected time of completion increase?a. Fewer than or equal to 2 weeksb. Greater than 2 weeks but fewer than or equal to 4 weeks c. Greater than 4 weeks but fewer than or equal to 6 weeks d. Greater than 6 weeks
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