Chapter 3: Layouts

Question 1

Highly automated batch processes that can reduce the cost of making groups of similar products

Answer 1

Flexible manufacturing systems (FMSs)

Question 2

A type of manufacturing process used to produce a narrow range of standard items with identical or highly similar designs

Answer 2

Production line

Question 3

A type of layout where resources are arranged sequentially, according to the steps required to make a product

Answer 3

Product-based layout

Question 4

For a line process, the actual time between completions of successive units on a production line

Answer 4

Cycle time

Question 5

A type of manufacturing process that closely resembles a production line process; they produce highly standardized products using a tightly linked, pace sequence. The main difference is the form of the product, which usually cannot be broken into discrete units until the very end of the process

Answer 5

Continuous flow process

Question 6

A type of manufacturing process used to make a wide variety of highly customized products in quantities as small as one. are characterized by general-purpose equipment and workers who are broadly skilled

Answer 6

Job shop

Question 7

A type of layout where resources are physically grouped by function

Answer 7

Functional layout

Question 8

A type of manufacturing process where items are moved through the different manufacturing steps in groups, or batches

Answer 8

Batch manufacturing

Question 9

A type of manufacturing process in which the position of the product is fixed. Materials, equipment, and workers are transported to and from the product

Answer 9

Fixed-position layout

Question 10

A general term referring to a manufacturing process that seeks to combine the characteristics, and hence advantages, of more than one of the classic processes. Examples include flexible manufacturing systems, machining centers and group technology

Answer 10

Hybrid manufacturing process

Question 11

A type of manufacturing process that completes several manufacturing steps without removing an item from the process

Answer 11

Machining Center

Question 12

A type of manufacturing process that seeks to achieve the efficiencies of a line process in a batch environment by dedicating equipment and personnel to the manufacture of products with similar manufacturing characteristics

Answer 12

Group technology

Question 13

A type of layout typically used in group technology settings in which resources are physically arranged according to the dominant flow of activities for the product family

Answer 13

Cellular layout

Question 14

In group technology, a set of products with very similar manufacturing requirements

Answer 14

Product family

Question 15

An additive manufacturing process that creates a physical object from a digital design

Answer 15

3D Printing

Question 16

Products that require no customization. They are typically generic products and are produced in large enough volumes to justify keeping a finished goods inventory

Answer 16

Make to stock products (MTS)

Question 17

Products that are customized only at the very end of the manufacturing process

Answer 17

Assemble to order (ATO) or finish to order products

Question 18

Products that use standard components but have customer-specific final configuration of those components

Answer 18

Make to order products (MTO)

Question 19

Products that are designed and produced from the start to meet unusual customer needs or requirements. They represent the highest level of customization

Answer 19

Engineer to order products (ETO)

Question 20

In the context of manufacturing customization, activities that occur prior to the point of customization

Answer 20

Upstream activities

Question 21

In the context of manufacturing customization, activities that occur at or after the point of customization

Answer 21

Downstream activities

Question 22

According to Roger Schmenner and Morgan Swink, the greater the random variability either demanded of the process or inherent in the process itself or in the items processed, the less productive the process is. This law is relevant to customization because completing upstream activities offline helps isolate these activities from the variability caused by either the timing or the unique requirements of individual customers

Answer 22

Law of variability

Question 23

A package that includes all the value-added physical and intangible activities that a service organization provides to a customer

Answer 23

Service package

Question 24

The physical or virtual point where the customer interfaces directly with the service organization; one on one

Answer 24

Front room

Question 25

The part of a service operation that is completed without direct customer contact; do the service for customer while the customer isn’t there; no direct contact w customer

Answer 25

Back room

Question 26

In a production line setting, the available production time divided by the required output rate. Sets the maximum allowable cycle time for a line

Answer 26

Takt time

Question 27

When we talked about manufacturing and operations what example was used in class

Answer 27

Make it video with restaurant

Question 28

Manufacturing and Service processes are very important to firms because they tend to be

Answer 28

Expensive and far reaching

Question 29

Manufacturing and Service processes are very important to firms because: process decisions deserve extra attention because

Answer 29

Different processes have different strengths and weaknesses

Question 30

Questions to ask when selecting a manufacturing process

Answer 30

What are the physical req. of the company’s product? How similar to one another are the products the company makes? What are the company’s production volumes? Where in the chain does customization take place (if at all)?

Question 31

Putting things in order on how the product is made

Answer 31

Product based layout

Question 32

Putting things in different areas where you have one type of machinery at one place and another type else-where

Answer 32

Functional layout

Question 33

5 manufacturing processes

Answer 33

``` Continuous flow Production line/ assembly line Batch manufacturing Job shop Fixed position layout ```

Question 34

Making a bunch of the same products at the same time

Answer 34

Batch manufacturing

Question 35

When you bring everything to where the product is being produced and used

Answer 35

Fixed position layout

Question 36

No individual products such as gasoline or other liquids/gases are made under what manufacturing process

Answer 36

Continuous Flow

Question 37

Process where you can easily see the individual products such as cars

Answer 37

Production line/ Assembly line process

Question 38

Equipment and people are highly specialized and arranged sequentially according to the steps required to make a product or product family

Answer 38

Product based layout (production line/assembly line)

Question 39

Production is often paced in this such as a car stops at each station for 1 minute

Answer 39

Production line/ assembly line

Question 40

Best suited to high-volume production of standardized products

Answer 40

Production/assembly line

Question 41

Advantages of a production line (4)

Answer 41

Lower variable cost per unit Lower but more specialized labor skills Easier production and planning control Higher equipment utilization (70-90%)

Question 42

Disadvantages of a production line (3)

Answer 42

Lower product flexibility More specialized equipment Usually higher capital investment

Question 43

Paper is an example of what kind of production

Answer 43

Continuous

Question 44

Soft drinks are an example of what kind of production line

Answer 44

Continuous and then discrete when it comes to packaging

Question 45

Light bulbs are an example of what kind of production line

Answer 45

Discrete

Question 46

Production line example we watched in class

Answer 46

Chocolate (Lucy’s famous chocolate scene) Pace became important Discrete w/ packaging

Question 47

Paint is an example of what kind of production

Answer 47

Continuous and then discrete when it comes to packaging

Question 48

This process has general purpose equipment and broadly skilled people

Answer 48

Job shop

Question 49

Requirement can change dramatically from one job to the next with what process

Answer 49

Functional layout (job shop)

Question 50

Hospital, bank, and a machine shop are examples of

Answer 50

Job shop

Question 51

Example used in class for hybrid manufacturing process

Answer 51

Making a sweater (yarn, fabric, cutting and sewing)

Question 52

In this process equipment and personnel are dedicated to the production of a product family

Answer 52

Group technology

Question 53

What layout is required for group technology

Answer 53

Cellular layout

Question 54

Resources are physically arranged according to the dominant flow of activities for the product family refers to a

Answer 54

Cellular layout

Question 55

In the product process matrix, one off or very low production volumes, customized products is best for

Answer 55

Job shop

Question 56

In the product process matrix, small to medium production volumes, some standardization refers to

Answer 56

Low-Volume batch

Question 57

In the product process matrix, medium to large production volumes, moderate product range refers to

Answer 57

High volume batch

Question 58

In the product process matrix, Hugh production volumes, highly standardized products competing on cost refers to

Answer 58

Production line

Question 59

The product process matrix is used for what types of products

Answer 59

New products

Question 60

Four levels of customization

Answer 60

Make to stock Assemble to order Make to order Engineer to order

Question 61

Totally custom and happens at the beginning of the supply chain before design

Answer 61

Engineer to order (go to architect and ask them to build you a house)

Question 62

Customization that happens between sourcing materials and fabrication in the supply chain

Answer 62

Make to order (ex/Nike custom shoe)

Question 63

Customization that happens between fabrication and assembly/finishing

Answer 63

Assemble to order (HP Power Cords based on country it’s being shipped to)

Question 64

Customization that happens between assembly/finishing and distribution

Answer 64

Make to stock (not really any customization)

Question 65

High customization to low

Answer 65

MTS ATO MTO ETO

Question 66

When customization occurs early in the supply chain (ETO) there are what three things

Answer 66

Lots of flexibility Lead time is long Costs more money

Question 67

When customization occurs late in the supply chain (MTS) there are what three things

Answer 67

Not as much flexibility Lead time is short Cheaper

Question 68

What video did we watch to show the different manufacturing processes

Answer 68

Tour of Winnebago Industries

Question 69

Three dimensions on which services can differ

Answer 69

The nature of the service package (tangible + intangible) The degree of customization The level of customer contact

Question 70

Service example we went through in class

Answer 70

Service at ten minute lube (tires) Circles represented potential failure points

Question 71

Example for service positioning box in class

Answer 71

Noodles and company (quality food with quick service and has a nicer environment)

Question 72

Three service approaches

Answer 72

Production line approach Self service approach Personal attention approach

Question 73

Example of production line approach with service

Answer 73

McDonalds

Question 74

Example of self service approach

Answer 74

Check in kiosk at the airport and self check out at the grocery

Question 75

Personal attention approach example

Answer 75

Nordstrom sales person who takes you through the entire store for every department

Question 76

Having one is better than none

Answer 76

Service guarantee (Alaska airline baggage and lands end)