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Managing Supply Chain and Operations, (Foster et al.) Chapter 3 Product and Process Design and Mapping Learning Objective 3-1 1) The selection and implementation of methods for producing products is known as product design. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 2) A job shop is used is used for producing highly standardized products in large volumes. Answer: FALSE Difficulty: Easy Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 3) Continuous-flow processes are capital-intensive usually requiring very specialized technologies. Answer: TRUE Difficulty: Easy Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 4) Product design is the A) act of creating new products. B) selection and implementation of methods for producing products. C) means of making something that is of value to a customer. D) none of the above. Answer: A Difficulty: Easy Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 5) Process design is A) the act of creating new products. B) designing the structure of the supply chain. C) the selection and implementation of methods for producing products. D) transporting products from manufacturer to customer. Answer: C Difficulty: Easy Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge

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6) An advantage of a production line process is A) the ability to produce highly customized products. B) the high degree of flexibility of the process. C) the low per unit cost of items produced on the line. D) the range of output typically produced on such a process. Answer: C Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 7) The type of processing system which is used for highly standardized products is A) continuous flow. B) job shop. C) batch. D) project. Answer: A Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 8) In which type of process are you likely to see, at most, only minor variations in the type of product or service being produced? A) Assembly line B) Job shop C) Batch D) Project Answer: A Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 9) The process which requires high worker skill levels and worker training requirements is A) Assembly line B) Job shop C) Batch D) Continuous Answer: B Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge

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10) The process which is the least labor intensive is A) Assembly line B) Job shop C) Batch D) Continuous Answer: D Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 11) Comparing various process options and their relationship to volume and variety can be accomplished using A) breakeven analysis. B) product-process matrix. C) net present value. D) payoff matrix analysis. Answer: B Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge Use the information below to answer the following question(s). A small automotive parts manufacture is evaluating opening a new manufacturing plant for assembly of its battery chargers line. The location being considered has a monthly fixed cost of $42,000 and a variable cost of $3 per charger. Chargers sell for $ 7 each. 12) What is the break-even point in units per month? A) 10,500 B) 11,000 C) 9,000 D) 12,700 Answer: A Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Analytical Thinking

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13) The other option (in addition to the option of opening a new manufacturing plant) being considered is subcontracting the work to an external vendor. This option has a monthly fixed cost of $6,000 and a variable cost of $5 per charger. Chargers continue to sell for $7 each. What is the break-even point for the subcontracting option in units per month? A) 6,000 B) 3,000 C) 10,000 D) 7,500 Answer: B Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Analytical Thinking 14) Which option should be chosen if the expected demand is 5,000 units per month? A) New manufacturing plant B) Subcontracting C) Either of the two options D) None of the two options Answer: B Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Reflective Thinking 15) The selection and implementation of methods for producing products is known as ________. Answer: process design Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 16) The act of creating new products is known as ________. Answer: product design Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 17) The process which is most capital-intensive and often requires very specialized technology is ________. Answer: continuous-flow Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 18) The process which is used to produce a variety of products in low volumes is ________. Answer: job shop Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 4 Copyright © 2016 Pearson Education, Inc.

19) The tool used to compare various process options and their relationship to volume and variety is known as ________. Answer: product-process matrix Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Application of Knowledge 20) Discuss the product-process matrix. What happens when a product is assigned to be made with the wrong process? Explain. Answer: The product-process matrix matches the characteristics of the product with the "right" process to make it. Product characteristics that are important include the production volume and product variety. At one end of the spectrum in the matrix includes very standardized products with high volume production. These products are ideally made using a continuous flow process or an assembly line type of process. Each of these processes usually involves advanced technology requiring machines and equipment which are very expensive (capital intensive with high fixed costs). Hence the high volume production justifies such high fixed cost investments. If such processes are used to make products with low production volumes, it will lead to inefficiencies due to diseconomies of scale. The other end of the spectrum includes products which have high variety and are customizable and usually made in low volumes. Such products are usually made using a job-shop type process which uses many general purpose (inexpensive) tools and is labor intensive. If job-shop type processes are attempted to be used for high volume standardized products, the costs would be very high due to the process being labor intensive and it would also be impossible to achieve high volume production. Difficulty: Moderate Learning Obj.: LO 3.1: Understand and Explain the Steps of Process Design AACSB: Reflective Thinking Learning Objective 3-2 1) In a process map, the diamond symbol indicates that work is actually performed. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 2) In a fixed position layout, the workstation stays fixed and product moves from workstation to workstation. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge

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3) U-shaped production lines that are more efficient for low-volume production as compared to a job shop are known as flexible manufacturing systems. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 4) In Muther's grid the Symbol "X" represents Important. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 5) In a process map, a diamond symbol indicates A) a decision. B) work performed. C) materials leaving the process. D) data input. Answer: A Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 6) In a process map, a rectangle indicates A) a decision. B) work performed. C) materials leaving the process. D) data input. Answer: B Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 7) What is takt time? A) Time between placement and receipt of an order B) The latest time an activity can be completed in a project C) Cycle time for a product D) The time spent by a customer waiting in queue Answer: C Difficulty: Easy Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge

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8) Cellular manufacturing systems (choose two) A) are usually U-shaped production lines. B) allow parts to move in a variety of different directions. C) support low-volume production more efficiently than in a job shop. D) support mass assembly of products. Answer: A, C Difficulty: Challenging Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 9) The benefits of flexible manufacturing systems (FMS) include A) reduced labor costs. B) higher flexibility as compared to an assembly line. C) quick changeover from part to part. D) all of the above. Answer: D Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 10) Fixed position layouts A) support mass assembly of products. B) are layouts in which products remain fixed and machines or equipment are moved to products. C) are usually U-shaped production lines. D) are layouts in which equipment and machines remain fixed and products are moved to machines. Answer: B Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 11) The process of allocating tasks to process workstations in an efficient manner is called A) idle time analysis. B) cycle time optimization. C) kanban allocation. D) line balancing. Answer: D Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge

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12) The minimum possible cycle time in a production line is determined by the A) longest task time. B) shortest task time. C) average task time. D) total task time. Answer: A Difficulty: Challenging Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Reflective Thinking 13) The cycle time in a production line is determined by A) amount of time available divided by total task time. B) production volume divided by amount of time available. C) amount of time available divided by production volume. D) production volume multiplied by amount of time available. Answer: C Difficulty: Challenging Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 14) If a line is balanced with 80-percent efficiency, the "balance delay" would be A) 20 percent. B) 80 percent. C) 100 percent. D) depends on the next operation. Answer: A Difficulty: Easy Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Analytical Thinking 15) A production manager wants to design an assembly line that will turn out 800 widgets per day. There will be eight working hours in each day. What is the optimum cycle time? A) 36 seconds B) 60 seconds C) 6 seconds D) 3.6 seconds Answer: A Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Analytical Thinking

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Use the information below to answer the following question(s). A production line operates for 450 minutes per day. Desired production volume is 80 units per day. Total task time to make the product is 56 minutes. 16) What is the optimal cycle time? A) 3.6 minutes B) 7.25 minutes C) 5.625 minutes D) 3.875 minutes Answer: C Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Analytical Thinking 17) What is the minimum number of workstations required? A) 5 B) 8 C) 10 D) 12 Answer: C Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Analytical Thinking 18) What is the efficiency of the production line? A) 99.56% B) 11.11% C) 66.67% D) 33.33% Answer: A Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Analytical Thinking 19) What is the balance delay? A) 88.88% B) 0.44% C) 66.67% D) 33.33% Answer: B Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Analytical Thinking

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20) The model used in designing functional layouts where movement is minimized is called the A) product-process matrix. B) load-distance model. C) center of gravity model. D) line balancing method. Answer: B Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 21) In Muther's grid the Symbol "X" represents A) Absolutely necessary. B) Important. C) Unimportant. D) Undesirable. Answer: D Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 22) In Muther's grid the Symbol "I" represents A) Absolutely necessary. B) Important. C) Unimportant. D) Undesirable. Answer: B Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 23) A schematic picture of a process using symbols is called a ________. Answer: process map Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 24) In a process map, the diamond symbol indicates that ________. Answer: a decision is to be made Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 25) In a process map, a rectangle indicates that ________. Answer: work is actually performed Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 10 Copyright © 2016 Pearson Education, Inc.

26) Layouts in which the product is stationary and equipment or machines are brought to the product is known as a ________. Answer: fixed-position layout Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 27) A process that represents a trade-off between mass assembly operations and job shops in terms of flexibility and production volumes is known as ________. Answer: flexible manufacturing system (FMS) Difficulty: Challenging Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 28) U-shaped production lines that are more efficient for low-volume production as compared to a job shop are known as ________. Answer: cellular manufacturing Difficulty: Challenging Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 29) The required cycle time necessary to meet forecasted needs for a product.is known as ________. Answer: takt time Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 30) The process of allocating tasks to process workstations in an efficient manner is called ________. Answer: line balancing Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 31) The model used in designing functional layouts where movement is minimized is called the ________. Answer: load-distance model Difficulty: Moderate Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 32) In Muther's grid the Symbol "U" represents ________. Answer: Unimportant Difficulty: Easy Learning Obj.: LO 3.2: Understand and Explain the Steps of Process Mapping AACSB: Application of Knowledge 11 Copyright © 2016 Pearson Education, Inc.

Learning Objective 3-3 1) The process of designing products that are complete changes from existing products is called continuous design. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge 2) Goods that use similar technologies that can coexist in a family of products are known as substitute products. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge 3) ATVs and snowmobiles are examples of complementary products. Answer: TRUE Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Reflective Thinking 4) Insurance policies are products that have very short product life cycles. Answer: FALSE Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Reflective Thinking 5) Applied research is practical exploration that often has a profit motive. Answer: TRUE Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge 6) A process of designing products that are enhancements to existing products is called A) discontinuous design. B) process design. C) continuous design. D) reverse design. Answer: C Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge

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7) Goods that use similar technologies that can coexist in a family of products are known as A) complementary products. B) substitute products. C) similar products. D) technological products. Answer: A Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge 8) The first phase of the product life cycle is A) development. B) introduction. C) growth. D) decline. Answer: A Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge 9) The last phase of the product life cycle is A) introduction. B) development. C) decline. D) growth. Answer: C Difficulty: Easy Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge 10) The difference between basic research and applied research is that applied research A) is generally not profit motivated. B) often has a profit motive. C) often leads to long product life cycles. D) requires technological push. Answer: B Difficulty: Moderate Learning Obj.: LO 3.3: Illustrate the Different Elements of Product Design AACSB: Application of Knowledge

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11) A manufacturer of detergent enhances their product offering by introducing new scents of their product. This is an example of which kind of R&D? A) Technological push B) N...