Chapter 4 Problem Solutions Fall 2011

# Chapter 4 Problem Solutions Fall 2011 - Chapter 04...

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Chapter 04 - Production Processes 4-1 CHAPTER 4 PRODUCTION PROCESSES Review and Discussion Questions 1. What kind of layout is used in a physical fitness center? Process layout similar equipment or functions are grouped together, such as rowing machines in one area, and weight machines in another. The exercise enthusiasts move through the fitness center, following an established sequence of operations. 2. What is the objective of assembly-line balancing? How would you deal with the situation where one worker, although trying hard, is 20 percent slower than the other 10 people on a line? The objective is to create an efficient balance between the tasks and workstations to minimize idle time. If the employee is deemed valuable, training may enhance his/her speed. It is also possible to place him/her in the ―choice‖ job, i.e., that workstation which has most idle time to adjust for the slowness. Also, faster workers may assist the slowpoke if the balance and physical features of the line permit. 3. How do you determine the idle-time percentage from a given assembly-line balance? Idle- time percentage is given as ―balance delay‖ in the chapter. It is simply one minus efficiency, where efficiency is equal to the sum of the task times divided by the number of workstations times the cycle time. 4. What is the essential requirement for mixed-model lines to be practical? A company needs to develop a cycle mix that minimizes inventory build-up while keeping cycle time constant. 5. Why might it be difficult to develop a manufacturing cell? a. Distinct parts families must exist. This requires developing and maintaining a computerized parts classification and coding system. This can be a major expense. b. Several of each type of machine must be available. This could be an expensive proposition, given the cost of purchasing and maintaining duplicate sets of machinery. c. Taking a machine out of a cluster should not rob a cluster of all of its capacity.

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