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Finally, The two most useful functions of capacity planning are design capacity and effective
capacity. Design capacity refers to the maximum designed service capacity or output rate and
the effective capacity is the design capacity minus personal and other allowances. These two
functions of capacity can be used to find the efficiency and utilization. These are calculated by
the formulas below:
Efficiency = Actual Output/ Effective Capacity x 100%
Utilization = Actual Output/ Design Capacity x 100%
-Chapter 5 Strategic Capacity Planning for Products and Services
Capacity refers to a system's potential for producing goods or delivering services over a specified time
interval. Capacity planning involves long-term and short term considerations. Long-term considerations
relate to the overall level of capacity; short-term considerations relate to variations in capacity
requirements due to seasonal, random, and irregular fluctuations in demand.
Excess capacity arises when actual production is less than what is achievable or optimal for a firm. This
often means that the demand in the market for the product is below what the firm could potentially supply
to the market. Excess capacity is inefficient and will cause manufacturers to incur extra costs or lose
market share. Capacity can be broken down in two categories: Design Capacity and Effective Capacity:
refers to the maximum designed service capacity or output rate. Effective capacity is design capacity
minus personal and other allowances. Product and service factors effect capacity tremendously.
Chapter 5 focuses on capacity planning for products and services. Capacity is the ability of a systems
potential for producing goods or delivering services over a specific time interval. The capacity decisions
within a company are very important because they help determine the limit of output and provide a major
insight to determining operating costs. Basic decisions about capacity often have long term
consequences and this chapter explains the ramifications of those choices. When considering capacity
planning within a company, three key inputs should be considered. The three inputs are the kind of
capacity to be determined, how much of the products will be needed, and when will the product be
needed.
The most important concept of capacity planning is to find a medium between long term supply and
capabilities of an organization and the predicted level of long term demand. Organizations also have to
plan for actual changes in capacity, changes in consumer wants and demand, technology and even the
environment. When evaluating alternatives in capacity planning, managers have to consider qualitative
and quantitative aspects of the business. These aspects involve economic factors, public opinions,
personal preferences of managers.
This chapter describes capacity planning as a key factor in designing systems. The capacity decision is
strategic and long-term in nature. Capacity planning is described as matching the capabilities of an
organization with the predicted level of future demand. Many organizations become involved with capacity
planning due to changes in demand, technology, the environment, etc. Organizations have capacities or
limits that their system can handle.
Facilities: The size and provision for expansion are key in the design of facilities. Other
facility factors include locational factors (transportation costs, distance to market, labor
supply, energy sources). The layout of the work area can determine how smoothly work
can be performed.
Product and Service Factors: The more uniform the output, the more opportunities
there are for standardization of methods and materials. This leads to greater capacity.
Human Factors: the tasks that are needed in certain jobs, the array of activities involved
and the training, skill, and experience required to perform a job all affect the potential and
actual output. Employee motivation, absenteeism, and labor turnover all affect the output
rate as well.
Policy Factors: Management policy can affect capacity by allowing or not allowing
capacity options such as overtime or second or third shifts
Supply Chain Factors: Questions include: What impact will the changes have on
suppliers, warehousing, transportation, and distributors? If capacity will be increased,
will these elements of the supply chain be able to handle the increase? If capacity is to be
decreased, what impact will the loss of business have on these elements of the supply
chain?
The most important parts of effective capacity are process and human factors. Process factors
must be efficient and must operate smoothly, if not the rate of output will dramatically decrease.
Human factors must be trained well and have experience, they must be motivated and have a low
absenteeism and labor turnover. In resolving constraint issues, all possible alternative solutions
must be evaluated. This is possible by using CVP analysis and the Break-Even Point formula.
a) capacity cushion
b) bottleneck operation
c) effective capacity
d) design capacity
e) both c and d
Answer: d, page 188
24) Given the following information, compute the efficiency: Effective capacity = 40 trucks per
day, Actual output = 36 trucks per day
a) 82%
b) 99%
c) 90%
d) 89.7%
e) 54%
Answer: c, page 189
25) Which of the following are steps in the capacity planning process?
a) estimate future capacity requirements
b) conduct financial analysis
c) monitor results
d) implement the selective alternative
e) all of the above
Answer: e, page 192
26) Which of these are NOT determinants of effective capacity?
a) Facilities
b) Process Factors
c) Human Factors
d) Policy Factors
e) All of above are determinants of effective capacity
Answer E (page 190)
27) What is a constraint?
a) Something that allows a system to perform more effectively and efficiently.
b) Something that hinders performance of a system in achieving its goals.
c) Something that attempts to smooth out capacity requirements.
d) Something that monitors results
e) Something that can never be overcome.
Answer B (page 201)
28) Which assumptions must be satisfied in order for cost-volume analysis to be a valuable tool?
a) Variable cost/unit exceeds revenue/unit
b) Everything produced may not be sold
c) Only one product involved
d) Revenue per unit may change depending on volume
e) Variable cost per unit may differ depending on volume
Alternatives
Small Facility
Medium Facility
Large Facility
High
$11
12
16
41. Use the information above to answer this question. If the company uses Maxi-min Criterion
to choose the best alternative, what would be the best choice for this company?
a) Small Facility
b) Medium Facility
c) Large Facility
d) Do Nothing
e) They are all incorrect answers.
Answer is A found on page 217 (Supplement to Chapter 5)
42. What is Capacity cushion? If utilization is 38%.
a) 72%
b) 74%
c) 12%
d) 22%
e) 62%
Answer is E found on page The formula is Capacity cushion = 100% - Utilization
Annual
Standard Processing Time per Unit Processing Time Needed
Product
Demand
(Hr)
(Hr)
1
300
5.00
1,500
2
400
8.00
3,200
3
700
2.00
1,400
Total
6,100
43. Use the information in the table to answer this question. Note: department is working one 8hour shift 250 days a year. How many machines would be needed to handle the required volume?
(Round your answer to the whole number)
a) 3 machines
b) 1 machines
c) 5 machines
d) 2 machines
e) 4 machines
Answer is A found on page 194.
Based on the information below answer the following Questions 44-47.
The owner of Cookies Inc., Zoya, is contemplating adding a new line of cookies, which require leasing
for a monthly payment of $4,000. Variable costs would be $2 per cookie, and cookies retail price for $6
each.
44. How many cookies must be sold in order to break-even?
a) 1000 cookies/month
b) 1200 cookies/moth
c) 2100 cookies/moth
d) 1100 cookies/moth
e) None of the above.
Answer is A found on page 204. FC=$4,000; VC=$2 per cookie: Rev.=$6 per cookie; Q=FC/(Rev-VC);
Q=$4,000/($6-$2)=1000 cookies/month.
45. What would be the profit (loss) if 900 cookies are made and sold in a month?
a) 400 profit
b) 400 loss
c) 4000 profit
d) 4000 loss
47. If 2,500 cookies can be sold, and a profit is $8,000, what price should be charged per cookie?
a) $7.00
b) $7.50
c) $6.80
d) $6.50
e) $7.80
Answer is C found on page 204.
Profit = Q(R - v) - FC
$8,000=2,500(R-$2)-$4,000
$8,000+$4,000=2,500R-$5,000
$17,000=2,500R
R=$6.8
Number of Machines Total Annual Fixed Costs
Corresponding Range of Output
1
$12,00
0 to 300
2
15,000
301 to 600
3
24,000
601 to 900
Variable Cots is $12 per unit, and revenue is $42 per unit.
Use the table above to answer the following Questions 8-10.
48. Determine the break-even point for range (0 to 300).
a) 400 units
b) 320 units
c) 420 units
d) 380 units
e) 520 units
Answer is A found on page 205. Q=FC/(R-v); 12,000/($42-$12)=400 units.
49. Determine the break even point for range (301 to 600).
a) 500 units
b) 400 units
c) 320 units
d) 420 units
e) 520 units
Answer is A found on page 205.
50. If projected annual demand is between 580 and 650 units, how many machines should the
manager purchase. If break-even point for
One machine: 400 units Range (0 to 300)
Two machines: 500 units Range (301 to 600)
Three machines: 800 units Range (601 to 900)
a) 2 machines
b) 3 machines
c) 1 machine
d) a&b both are correct
e) None of the above; the manager should do nothing.
Answer is A found on page 205.
Comparing the projected range of demand to the two ranges for which a break -even point, you
can see that the break-even point is 500 units, which is in the range 301 to 600. This means that
even if demand is at the low end of the range, it would be above the break even point and thus
yield a profit. That is not true of range 601 to 900. At the top end of projected demand, the
volume would still be less than the break-even point for that range, so there would be no profit.
Thus, the manager should choose two machines.
51) If the output rate is less than the optimal level, increasing the output rate results in decreasing
average unit costs according to:
a) diseconomies of scale
b) economies of scale
c) capacity cushion
d) efficiency
e) utilization
Answer B (Page 200)
52) If: Design capacity= 60 trucks per day, effective capacity = 40 trucks per day, actual output =
36 trucks per day, compute the efficiency:
a) 20%
b) 30%
c) 40%
d) 50%
e) 90%
Answer E (Efficiency=Actual output/effective capacity=36trucks per day/40 trucks per
day=90%) (Page 188)
54) What is capacity cushion?
a) Extra amount of capacity intended to offset uncertainty in demand
b) Estimate in future capacity requirement
c) Common demand pattern
d) External service or good
e) All of the above
Answer A (Page 192)
55) What do long term considerations relate to?
a) demand
b) capacity cushion
c) supply
d) overall level of capacity requirements
e) short term events
Answer D (Page 192)
56) What are the three primary strategies of a strategy formulation?
a. leading, following, and concluding
b. start up, following, and tracking
c. leading, following, and tracking
d. start up, leading, and follow up
e. leading, processing, concluding
answer is c. (found on page 191)
There are three basic environments in which decisions need to be made: certainty, uncertainty,
and risk. In order to make decisions under uncertainty, the following four decision criteria are
used:
Certainty: Values of parameters and known to users (such as cost, demand..etc)
Risk: Probabilistic outcomes
Uncertainty: The parameters are unknown, and it is not possible to assess probabilities of
certain outcomes.
1. Maximin (choose the alternative with the best of the worst possible payoffs)
2. Maximax (choose the alternative with the best possible payoffs)
3. Laplace (choose the alternative with the best average payoff of any of the alternative)
4. Minimax Regret (choose the alternative that has the least of the worst regrets)
Tools like Decision Tree, which presents a visual and schematic representation of the available
alternatives and their possible consequences, can be used for decision making under risk. Other
useful methods for manager to make decisions include Expected Value of Perfect Information
(EVPI), Sensitivity Analysis, and Expected monetary value criterion (EMV). EVPI considers the
possibility of state of nature that will occur in the future, while Sensitivity Analysis determines
the payoffs and the range of possibility for which a best decision can be made. EMV finds the
expected payoff of all alternatives to reveal the one with the best payoff. In addition to the
different decision making methods, the decision-making process is also discussed which includes
the following steps:
1. Identifying the problem
2. Specify objectives
3. Develop alternatives
4. Analyze and compare alternatives
5. Select the best alternative
6. Implement the solution
7. Monitor to see if the desired result is achieved
Test Questions
1.) A manager needs to decide the capacity of their facility which will be used to store company's
inventory and the manager has three options on capacity size: Large, Medium, or Small. Which
method should the manager use in order to determine the best possible payoff?
a) Expected monetary value (EMV) criterion
b) Decision tree
c) Laplace
d) Sensitivity analysis
e) Minimax
Answer: b, page 219
2.) Which type of decision method is defined as a schematic representation of the available
alternatives and their possible outcomes?
a) Bounded rationality
b) Maximin
c) Payoff table
d) Decision tree
e) None of the above
Answer: d, page 219
3.) A manager had a choice between two alternatives and wanted to determine the range of
probabilities for which the chosen alternative has the best expected payoff. Which type of
decision method is the MOST useful?
a) Sensitivity Analysis
b) Decision Tree
c) Risk
d) Minimax Regret
e) None of the above
Answer: a, page 222
4.) I: Is the following statement true or false: a decision tree is read from left to right with
circular nodes representing decision points and square nodes representing chance events.
II: Decision trees are not useful for analyzing sequential decisions.
a) I is False and II is True
b) I is False and II is False
c) I is True and II is False
d) I is True and II is True
e) Cannot be determined
Answer: B, Page 220
(This question should be considered for determining whether one statement is true/false rather
than determining two)
5.) Which decision process involves a graph providing a visual indication of the range of
probability over which the various alternatives are optimal?
a) Decision Tree
b) Payoff Table
c) Sensitivity Analysis
d) There is no decision process that involves a graph
e) Decision making under risk
Answer: c, page 222-223
6) Using Minimax regret, you would choose the alternative that has:
a) the best of the best possible payoffs
b) the least of the worst regrets
c) the worst of the best possible payoffs
d) the best possible payoff
e) none of the above
Answer: b, page 217
7) If the expected payoff under certainty is $15, the expected monetary value is $12, the expected
payoff under risk is $13, and the expected payoff under uncertainty is $16, then the expected
value of perfect information is:
a) $28
b) $4
c) $2
d) $25
e) $20
Answer: c, page 221
9) What is the type of environment in which relevant parameters such as costs, capacity, and
demand have known values?
a) Suboptimization
b) Certainty
c) Risk
d) Design capacity
e) All of the above
Answer: b, page 216
10. Which of the following is a reason for poor decision making?
a. unforeseeable circumstances
b. bounded rationality
c. mistakes in the decision process
d. suboptimization
e. all of the above
Answer: e, page 215 and 216
11. Determining the average payoff for each alternative and choosing the alternative with the
highest average is the approach called:
a. Weighted factor analysis
b. Laplace
c. Minimin
d. Maximin
e. Maximax
Answer: e, page 217
12. Bounded rationality is a phrase that refers to the limits imposed on decision-making because
of the following factors:
a. costs
b. human abilities
c. technology
d. time
e. all of the above
Answer: e, page 216
13. Which of the following treats the states of nature as equally likely:
a. Maximax
b. Maximin
c. Laplace
d. Minimax regret
e. None of the above
Answer:c, page 217
14. Which of the following approaches is widely used in decision making under risk?
a. Sensitivity Analysis
b. EMV
c. Laplace
d. EVPI
e. None of the above
Answer: b, page 218
15. Sensitivity analysis provides a range of probability over which the choice of alternatives
would remain:
A. above 1
B. equal
C. the same
D. below 1
E. none of the above
Answer: c, page 222
16. Decision theory represents an approach to decision making.
A. perfect
B. consistent
C. inconsistent
D. general
E. none of the above
Answer: d, page 214
17. The type of illustration that shows the expected payoffs for each alternative in every possible
state of nature is known as a:
A. expectance table
B. profit table
C. decision table
D. certainty table
E. none of the above
Answer: e (payoff table), page 215
18. Which of the follwing is not a cause of poor decision making?
A. develop alternatives
B. implement the solution
C. specify objectives
D. all of the above
E. none of the above
Answer: d, page 215
19. Which of the following method chooses the best alternative with the best of the worst
possible payoffs?
a) Maximin
b) Laplace
c) Maximax
d) Minimax
e) None of the above
Answer: a, page 217
20. True or False? The difference between the expected payoff with perfect information and
expected payoff under risk is expected monetary value criterion.
A. True
B. False
Answer: b (expected value of perfect information), page 221
21. When various departments each try to reach the best solution for that department, it is called:
a) Bounded Rationality
b) decision making under certainty
c) Maximax
d) Suboptimization
e) EVPI
Answer: D (pg. 216)
22. Which of the following shows the best expected value out of the alternatives?
a) Decision trees
b) EMV
c) EVPI
d) Suboptimization
e) None of the above
Answer: B (pg. 218)
23. What is the equation for EVPI?
a) Expected payoff under risk - Expected payoff under certainty
b) Expected payoff under risk - Expected payoff under uncertainty
c) Expected payoff under certainty - Expected payoff under risk
d) Expected payoff under uncertainty - Expected payoff under risk
e) None of the above
Answer: c (pg. 221)
24. All of the following are categories of decision environments, except:
a) risk
b) bounded rationality
c) uncertainty
d) certainty
e) none of the above
Answer: B (pg. 216)
25. Which of the following approaches represent maximax:
a. Determine the best possible payoff
b. Determine the worst possible payoff
c. Determine average payoff
d. Determine the worst regret for each possible alternative
e. None of the above
Answer: A p.217
26. The expected monetary value approach is most appropriate when a decision maker is:
a. risk neutral
b. risk averse
c. risk seeking
d. risk taking
e.none of the above
Answer: A p.219
27. Which or who plays the critical role in total quality management (TQM):
a. employees
b. CEO
c. management
d. customers
e. technology
Answer: C p. 427
28. Who developed the concept of zero defects?
a. Joseph Juran
b. Philip B. Crosby
c. Genichi Taguchi
d. Armand Feigenbaum
e. None of the above
Answer: B p. 411
29. The limitations on decision making caused by cost, human abilities, time, technology and
availability of information is called:
a. suboptimization
b. certainty
c. risk
d. bounded rationality
e. sensitivity analysis
Answer: D p. 216
30. The difference between a given payoff and the best payoff for a state of nature is called?
a. risk
b. sensitivity analysis
c. maxmin
d. regret
e. maximax
Answer: d, page 209
31. Which the following is not a step of the decision process?
a. develop suitable alternatives
b. identify the problem
c. receive feedback
d. specify objectives
e. implement the solution
Answer: c, page 206
32. means the relevant parameters such as costs, capacity, and demand have known values.
a. certainty
b. expected value of perfect information
c. decision criterion
d. bounded rationality
e, uncertainty
Answer: a, page 207
Small Facility
Medium Facility
Large Facility
Low
$12
$5
$-2
Moderate
$12
$6
$6
33. Based on the table above, find the Laplace criterion for the medium facility
a. 12.6
b. 14.6
c. 7.7
d. 9.6
e. 4.6
High
$14
$12
$19
Process Selection is basically the way goods or services are made or delivered, which
influences numerous aspects of an organization, including capacity planning, layout of
facilities, equipment and design of work systems. Process selection is primarily used
during the planning of new products or services that is subject to technological advances
and competition. Process selection is dependent on the company's process strategy, which
has two main components: capital intensity and process flexibility.
Capital Intensity is simply the combination of equipment and labor that an organization
uses to accomplish some objective.
Process Flexibility is as its name implies: how well a system can be adjusted to meet
changes in processing requirements that are interdependent on variables such as product
or service design, volume of production, and technology.
Facility Layout is simply the way a facility is arranged in order to maximize processes
that are not only efficient but effective towards the overall organizational goal. It is also
dependent on process selection.
Within those two categories, you will also learn about technology,
operations tour, process strategy, designing product layouts, and designing
process layouts. The main concept between process selection and facility
layout is technology. Technology is a method that is used to improve and
develop various services, operation processes, and products. While process
selection is used in many organizations, facility layouts signifies the work
centers, implementations, and the configuration of departments by special
importance on activity of work throughout the system. An example of a
layout can be seen with businesses that use automation. Automation is the
process of technology-sensing when one task is completed and then
automatically beginning another task. This layout is very effective in
today's world for mass production. The purpose of layout design is to
increase the efficiency and fluidity of work, data through the system, and
material.
Exam Questions:
1.) An ideal tool to use in line balancing is a/an . (page 264)
A. Balance delay
B. Assembly line
C. Automation
D. Precedence diagram E. Both a and b
E. Cellular production
2.) How do we calculate efficiency of a line? (page 265)
A. 10% -Percent idle time
B. 15% -Percent idle time
C. 50% -percent idle time
D. 75% -percent idle time
E. 100% -percent idle time
3.) What does the acronym CIM stand for? (page 258)
b). testing
c). loading and unloading of machines,
d). Painting
e). writing a letter
8). Which of the following is a feature(s) of fixed automation? (p.246)
a). minimal variety of products
b). Low cost, high volume.
c). Specialized equipment for a fixed sequence of operation.
d). a) and b)
e). All of above
9). An organization that adopts automation should consider: ( p.246)
a). What level of automation is appropriate?
b). How changes should be managed?
c). What are the risks of automating?
d). How would automation affect the flexibility of an operation system?
e). All of the above.
10). Which is a disadvantage(s) of automation? ( p.246)
a). Technology is cheap.
b). Automation is more flexible than human labor
c). Very high initial costs
d). Workers fear losing their jobs to machines
e). Both c) and d).
11) The maximum time allowed at each workstation to complete its set of tasks on a unit is
referred to as:
a) cycle time
b) reciprocal time
c) line balancing
d) task time
e) efficiency
The answer is a. (found on page 262)
12) Which of the following is a type of processing?
a) job shop
b) batch
c) repetitive
d) continuous
e) all of the above
The answer is e. (found on page 239)
13) A(n) _ is a standardized layout arranged according to a fixed sequence of assembly tasks.
a) product layout
b) production line
c) assembly line
d) assembly sequence
e) service layout
The answer is c. (found on page 250)
14) What are the major differences between process layout from product layout?
a) process layout is used for intermittent processing and product layout is used for repetitive
processing
b) process layout is functional and product layout is sequential
c) process layout is sequential and product layout is funtional
d) both a and b
e) none of the above
The answer is d. (found on page 253)
15) What areas of technology have a major influence on today's business processes?
a) Product and service technology
b) Process technology
c) Information technology
d) Automatic technology
e) Answers a, b, & c
The answer is e. ( found on page 238)
16) What three types of technology is operations management primarily concerned with?
a. Information, assistive, instructional
b. Product, instructional, service
c. Product and service, process, information
d. Information, product, alternative
e. Assistive, process, information
Answer: C (pg.238)
17) Which of the following will NOT yield competitive advantages for companies?
a. Lowering costs
b. Increasing productivity
c. Expanding processing capabilities
d. Lowering prices
e. Increasing quality
Answer: D (pg. 239)
18) Which of the following is NOT one of the five basic process type?
a. Batch
b. Strategic
c. Repetitive
d. Continuous
e. Project
Answer: B (pg. 239)
19) Which of these are a disadvantage(s) to the continuous process?
a. Rigidity
b. Lack of variety
c. Costly to change
d. Very high cost of downtime
e. All of the above
Answer: E (pg. 241)
20) Which type of process is sometimes referred to as assembly?
a. Repetitive
b. Job shop
c. Continuous
d. Project
e. Strategic
Answer: A (pg. 240 & 241)
21) An eyeglass repair shop would be best matched with which basic process type?
a. Continuous
b. Job Shop
c. Repetitive
d. Batch
e. Project
Answer: B. Job Shop (p. 239)
22) Products and services often go through life cycles that begin with:
a. high volume
b. standardized products/services
c. low volume
d. customized products/services
e. moderate volume
Answer: C. low volume (p. 241)
23) Which of the following statements is NOT true regarding process types?
a. They influence many activities of the organization
b. Job shop, batch, repetitive and continuous are typically ongoing operations
c. They always exist in their pure forms
d. Manager must know when to shift from one process type to the next
e. Hybrid processes have elements of other process types embedded in them
Answer: C. They always exist in their pure forms (p. 241-243)
24) Answering which question will guide the process selection?
a. What is the expected volume of output?
b. How much variety in products/services will the system need to handle?
c. What degree of equipment flexibility will be needed?
d. All of the above
e. None of the above matter in selecting a process
Answer: D. All of the above (p.239)
25) Which process type has the disadvantage of a moderate cost per unit?
a. Repetitive
b. Continuous
c. Job Shop
d. Project
e. Batch
Answer: E. Batch (p.241)
26) Which of the following types of processing is used for production of customized goods or
services?
a. Batch
b. Repetitive
c. Job Shop
d. Continuous
e. Project
Answer: C: Job Shop p. 241
27) Robot is a machine consisting of a mechanical arm, power supply, and a(n) _.
a. Controller
b. Computer
c. Assembly Line
d. Product Line
e. Product Layout
Answer: A: Controller p.247
28) Which facility layout utilizes stationary products, move workers, and materials as needed?
a. Fixed Position
b. Product
c. Process
d. CAD
e. Robot
Answer: A: Fixed Position p.254
29) The management of Tiffanys designs an output rate of 200 units of silver pendants per 8hour day. What is the cycle time? (The tasks times and precedence relationships are shown
below)
.1 .4 .2 .1 .4
a. .42
b. 2.4
c. 100
d. 240
e. 8
Answer: B: 2.4 p.263
30) Which diagram shows the elemental tasks and requirements?
a.) Product Layout Diagram
b.) Precedence Diagram
c.) Line Balancing Diagram
d.) Muther Grid Diagram
e.) None of the above
Answer: B. p. 264
31) Machinery that has sensing and control devices that enable operate automatically is known
as:
a. Automation (pg.245)
b. Product Profiling
c. Projects
d. Variety
e. Technology
32) Standardized layout arranged according to a fixed sequence of assembly tasks refers to a(n):
a. Product line
b. Product Layout
c. Assembly Line (pg.250)
d. Process Layout
e. None of the Above
33) Job Shop, Batch, Repetitive, Continuous, and project are all types of:
a. technologies
b. Process Types (pg. 239)
c. Forms of competitive advantages
d. Process design
e. None of the above
34) Which of the following enables an organization to quickly convert a machine or process to
produce a different (but similar) product type:
a. Fixed-position layout
b. Single-minute exchange of die (SMED) (pg. 255)
c. Combination layouts
d. Cellular production
e. None of the Above
35) A robot consists of which of the following?
a. mechanical arm
b. power supply
c. controller
d. Both a and c are correct.
e. All of the above (pg. 247)
36) What is the efficiency of a line with a balance delay of 20%? (p. 265)
a. 60%
b. 100%
c. 80%
d. 120%
e. 40%
37) What is the cycle time if 500 minutes per day were spent making 25 units? (p. 263)
a. 20 products per minute
b. One product every 20 minutes
c. 25 products per minute
d. One product every 25 minutes
e. None of the above
38) What is the output rate if the operating time per day is 500 minutes and the cycle time is 2.5
minutes per unit? (p. 263)
a. 100 units every minute
b. One unit every 100 minutes
c. 200 units every minute
d. One unit every 200 minutes
e. None of the above
39) What is defined as the maximum time allowed at each workstation to complete its set of
A. Process (254)
B. Fixed-Position
C. They are all the same
D. Cellular
E. Process and Fixed-Position
51) Choose the best process you would need for the following project: custom-made
handbag that requires a lot of detailed work.
A. Repetitive
B. Assembly Line workers
C. Job Shop
D. Batch
E. Projects
(C) Job Shop Page. 239
52) A group of machines that include supervisory computer control, automatic handling,
and robots or other automated processing is_.
A. Job Shop
B. FMS ( flexible manufacturing system)
C. Group Technology
D. CIM ( Computer-Integrated Manufacturing)
E. Mixed Mode
(B) FMS ( flexible manufacturing system) Page 258
53) The equation for cycle time is
A. Output/Labor Hours
B. Output/ Total Cost
C. Cycle time per unit/Output
D. Operating Time/Desired Output Rate
E. Total Hours Worked/ Desired Output Rate
(D) Operating Time/Desired Output Rate Page 263
54) Compute the output rate. Fixed units per hour 500. Operating time per day 200
mins. Cycle Time is 1.0 per unit. CM per unit is 5. Total Units is 1000.
A. 5000
B. 700
C. 4500
D. 1000
E. 200
(E).200 Equation found on page 263
55) Operations management is concerned with which of the following technologies:
JOB DESIGN
Specialization
Specialization relates with different work that concentrates on some aspect of a product or
service. Similarly, it emphasizes the ability to concentrate one's efforts on a type of work and
thereby becoming proficient in it. Examples of specialization include college professors teaching
certain courses, medical doctors working in a specific field, and bakers who specialize in
wedding cakes. The advantages of specialized assembly line workers are high productivity and
relatively low unit costs. Consequently, these lower-level jobs are often times described as
monotonous which results in turnover and absenteeism. However, some workers who are not
capable of handling jobs with greater scopes prefer low-level jobs that have limited requirements
and responsibility.
Job Design/Specialization
This chapter explains the two basic approaches to job design and the advantages and
disadvantages of specialization. The most important topic is the purpose of methods analysis and
how these methodical studies are performed. Job Design is the act of specifying the contents and
methods of jobs. Current practices in job design contain elements of two basic schools of
thought, efficiency and satisfaction of wants and needs. Specialization describes jobs that have a
very narrow scope. The amount of knowledge, or training required of a specialist, and the
complexity of the work, suggest that such individuals choose such work because they are fully
interrogated in the work flow of the product or service.
QUESTIONS ON CH. 7
1.) Time standards derived from a firm's historical time data is:
A.) Predetermined time standards
B.) Standard elemental times
C.) Post-determined time standards
D.) Time measurement standards
E.) None of the above
Answer: B. page 344
2. Which is NOT a behavioral approach to job design?
a. job enrichment
b. job rotation
c. job enlargement
d. increased use of mechanization
e. job improvement
Answer: e pg.314
3. Which of these are helpful in visualizing the portions of a work cycle during which an
operator and equipment are busy?
a. micromotion study
b. work machine chart
c. flow process chart
d. stopwatch time study
e. work measurement
Answer: b pg.320
4. Which is NOT a technique used in motion study?
a. charts
b. micromotion study
c. decision making
d. analysis of therbligs
e. motion study principles
Answer: c pg. 337
5. What reflects quality and productivity results?
a. depth skills
b. specialized skills
c. horizontal skills
d. vertical skills
e. none of above
Answer: A pg. 342
6. What is NOT an advantage of specialization in management?
a. High productivity
b. High costs
c. Simplified training
d. Low costs
e. None of the above
Answer: B pg. 328
7. Concerning labor, what is NOT a disadvantage of specialization?
a. Limited opportunities for advancement
b. Little control over work
c. Little mental effort needed
d. Monotonous work
e. Little opportunity for self-fulfillment
Answer: C pg. 328
8. Which is a general guideline that supervisors use to select a job to study?
a. Have a high labor content
b. Are done frequently
c. Are unsafe, tiring, unpleasant, and/or noisy
d. Are designated as problems
e. All of the above
Answer: E pg 333
This chapter discusses the decision to relocate a facility by considering costs and benefits. If you are
planning on moving or acquiring a new facility, there are many factors to consider: the size, the
geographic area, culture, transportation costs and others. After a location or locations have been chosen
a cost-profit-volume analysis is done.
The main factors that affect location decisions include regional factors, community considerations, and site-related
factors. Community factors consist of quality of life, services, attitudes, taxes, environmental regulations, utilities,
and development support.
alternatives:
1. Location Cost-Volume-Profit Analysis:
1. The Cost-Volume-Profit (CVP) Analysis can be represented either
mathematically or graphically. It involves three steps: 1) For each location
alternative, determine the fixed and variable costs, 2) For all locations, plot
the total-cost lines on the same graph, and 3) Use the lines to determine
which alternatives will have the highest and lowest total costs for expected
levels of output. Additionally, there are four assumptions one must keep in
mind when using this method:
1. Fixed costs are constant.
2. Variable costs are linear.
3. Required level of output can be closely estimated.
4. There is only one product involved.
5.
2. Total cost = FC = v(Q)
where FC=Fixed Cost, v=Variable Cost per Unit, Q=Number of Units (Also shown below but
not in the same format)
1. Factor Rating
1. This method involves qualitative and quantitative inputs, and evaluates
alternatives based on comparison after establishing a composite value for
each alternative. Factor Rating consists of six steps:
1. Determine relevant and important factors.
2. Assign a weight to each factor, with all weights totaling 1.00.
3. Determine common scale for all factors, usually 0 to 100.
4. Score each alternative.
5. Adjust score using weights (multiply factor weight by score factor);
add up scores for each alternative.
6. The alternative with the highest score is considered the best option.
2. Minimum scores may be established to set a particular standard, though this is not
necessary.
2. Center of Gravity Method:
1. This technique is used in determining the location of a facility which will
either reduce travel time or lower shipping costs. Distribution cost is seen
as a linear function of the distance and quantity shipped. The Center of
Gravity Method involves the use of a visual map and a coordinate system;
the coordinate points being treated as the set of numerical values when
calculating averages. If the quantities shipped to each location are equal ,
the center of gravity is found by taking the averages of the x and y
coordinates; if the quantities shipped to each location are different , a
weighted average must be applied (the weights being the quantities
shipped).
Company Relocating
There are many factors that contribute to a company relocating. Some of the reasons include
expanding the market and diminishing resources. For an existing company to relocate, they must
weigh their options when planning to relocate elsewhere. They can expand their existing facility,
add new ones and keep their existing facilities open, move to another location and shut down one
location, or keep things the way they are and not do anything. Globalization has led many
companies to set up operations in other countries. Two factors that make relocation appealing are
advances in technology and trade agreements. By going global, companies will expand their
markets and be able to cut costs in labor, transportation, and taxes. They also have gained ideas
for new products and services.
IDENTIFYING A COUNTRY, REGION, COMMUNITY, AND SITE (Page 376)
factors that influence location decisions are:
Manufacturing :
o Availability of energy and water
o Proximity to raw materials
o Transportation cost
Service:
o Traffic patterns
o Proximity to markets
o Location of competitors
important factors have been determined, an organization will narrow down alternatives to
a specific geographic region. These factors that influence location selection are often different
depending on whether the firm is a manufacturing or service firm. When deciding on a location,
mangers must take into account the culture shock employees might face after a location move.
Culture shock can have a big impact on employees which might affect workers productivity, so it
is important that mangers look at this.
v IDENTIFYING A COUNTRY
o A decision maker must understand the benefits and risks as well as the probabilities of them
occurring
v IDENTIFYING A REGION- 4 major considerations
o Location to Raw Materials: The three most important reasons for a firm to locate in a
particular region includes raw materials, perishability, and transportation cost. This often
depends on what business the firm is in.
o Location to Markets: Profit maximizing firms locate near markets that they want to serve as
part of their competitive strategy. A Geographic information system(GIS) is a computer based
tools for collecting, storing, retrieving, and displaying demographic data on maps.
o Labor Factors : Primary considerations include labor availability, wage rates, productivity,
attitudes towards work, and the impact unions may have.
o Other : Climate is sometimes a consideration because bad weather can disrupt operations.
Taxes are also an important factor due to the fact that taxes affect the bottom line in some
financial statements.
v IDENTIFYING A COMMUNITY
o There are many important factors for deciding upon the community in which move a business.
They include facilities for education, shopping, recreation and transportation among many
others. From a business standpoint these factors include utilities, taxes, and environmental
regulation.
v IDENTIFYING A SITE
o The main considerations in choosing a site are land, transportation, zoning and many others.
When identifying a site I]it is important to consider to see if the company plans on growing at
this location. If so, the firm must consider whether or not location is suitable for expansion.
There are many decisions that go into choosing exactly where a firm will establish its operations.
First, a company must determine the driving factors that will influence which areas are suitable
locations. After these factors have been determined, the company will identify potential countries
and examine the pros and cons of establishing operations in these countries. After looking at pro
and cons of the different countries and deciding on a country, then decision makers will identify
a region within the country. When identifying a region, decision makers must take the four major
factors explained above into consideration. The last two stages of the search include choosing a
community and a site.
Note: The above part is way too lengthy for this assignment.
Summary below..
Summary : There are several ways that are very helpful in evaluating location alternatives, such
as locational cost-profit-volume analysis, factor rating, and the center of gravity method. First,
let's take a look at Location Cost-Profit-Volume Analysis.
This analysis can be done numerically or graphically. The procedure for locational cost-profitvolume analysis involves these steps:
1. Determine the fixed and variable costs associated with each location alternative.
2. Plot the total-cost lines for all location alternatives on the same graph.
3. Determine which location will have the lowest total cost for the expected level of output.
Alternatively, determine which location will have the highest profit.
This method assumes the following:
1. Fixed costs are constant for the range of probable output.
2. Variable costs are linear for the range of probable output.
3. The required level of output can be closely estimated.
4. Only one product is involved.
Here're a couple of important formulas to remember:
Total cost = Fixed cost + Variable cost per unit * Quantity or volume of output
Total profit = Quantity(Revenue per unit - Variable cost per unit) - Fixed cost
In most situations, other factors besides cost must also be considered. We will now consider
another kind of cost often considered in location decisions: transportation costs.
Transportation costs sometimes play an important role in location decisions. The company can
include the transportation costs in a locational cost-volume analysis by incorporating the
transportation cost per unit being shipped into the variable cost per unit if a facility will be the
sole source or destination of shipments. When there is a problem with shipment of goods from
multiple sending points to multiple receiving points, and a new location is to be added to the
system, the company should undertake a separate analysis of transportation. In this case,
transportation model of linear programming is very helpful. The model is used to analyze each of
the configurations considered, and it reveals the minumum costs each would provide. Then the
information can be included in the evaluation of location alternatives.
Products or product lines are produced in separate plants, and each plant is usually
responsible for supplying the entire domestic market.
The plant locations may either be widely scattered or placed relatively close to one
another.
The individual plants can produce either most, or all of the company's products and
supply a limited geographical area.
The operating costs of this strategy are often times higher than those of product plants,
but savings on shipping costs for comparable products can be made.
This strategy is useful when shipping costs are high due to volume, weight, or other
factors.
It can also bring the added benefits of faster delivery and response times to local needs.
This strategy is most useful when products have numerous components; separating the
production of components results in less confusion than if all the production were done in
the same location.
A major issue with this strategy is the coordination of production throughout the system,
and it requires a highly informed, centralized administration in order to be an effective
operation.
It can bring about additional shipping costs, but a key benefit is that individual plants are
highly specialized and generate volumes that brings economies of scale.
It allows for a quick response to products and market changes, but can be less productive
than a more focused approach.
A benefit to this approach is the increase in learning opportunities that happens when
similar operations are being done in different plants. Solutions to problems as well as
improvements made at one plant can be shared with the other plants
Question 1:
From a company standpoint, which factors determine the desirability of a community as a place
for its workers and managers to live?
A) The amount of parking spaces
B) Retail stores
C) Schools
D) Locals attitudes towards the company.
E) Both C and D.
Answer: E. Page 380.
Question 2:
What is NOT a risk a corporation must consider when planning a location?
A) Political
B) Exporting
C) Economic
D) Cultural
E) Economic
Answer: B. Pages 373-374.
Question 3:
What do banks, fast-food chains, supermarkets, and retail stores view locations as?
A) One in many intricate decisions for their organizations
B) A crucial part of the marketing strategy.
C) An easier way to distribute their product or service.
D) New ideas for future investments.
E) A second home.
Question 5 needs an answer, also needs page numbers where answers are found
1) What does GIS stand for?
A. General Information Systems
B. Great Information Systems
C. Geographic Information Systems
D. General Institutions
E. None of the above
Answer: C
2)The primary consideration for identifying a site is?
A. Location
B. Zoning
C. Transportation
D. None of the Above
E. All of the above
Answer: E
3) What are the common techniques used to evaluate location alternatives?
A. Locational cost-profit-volume analysis
B. Factor ratings
C. Center of gravity method
D. Transportation model
E. All of the above
Answer: E
4) Mining operations, farming, forestry, and fishing are all examples of which primary reason for
firms locating near or at the source of raw materials?
A. Necessity
B. Perishability
C. Transportation costs
D. Processing
E. None of the above
Answer: A page 365 (9th edition)
5) Which of the following would you establish a composite value for?
A. The transportation model
B. Factor rating
C. The center of gravity method
D. Locational Cost-Profit-Volume Analysis
E. Geographic information system
Answer: B page 379 (9th edition)
1. Which of these is a computer-based tool for collecting, storing, retrieving, and displaying
demographic data on maps?
A. Geographic Data System
B. Geographic Information System
C. Demographic Data System
D. CAM
E. none of the above
Answer: B page 379
2. Which is a major consideration when choosing to operate in a region?
A. the minimum wage rate
B. identifying a community
C. location to raw materials
D. possible sites available
E. none of the above
Answer: C page 378
3. Considering global expansion, decision makers need to be absolutely clear on the benefits and
risks and the likelihood of their occurrences when deciding upon identifying:
A. a continent
B. a site
C. a community
D. a country
d. Financial
e. Customer Preferences
Answer: a ( page 378 )
4. When using the factor rating method of location alternative evaluation, which of the following
could be considered relevant factors?
a. Location of market
b. Water supply
c. Parking facilities
d. Revenue potential
e. All of the above
Answer: e ( page 387 )
5. Which of the following is not a step in the general procedure for making location decisions?
a. Develop location alternatives
b. Evaluate the alternatives and make a selection
c. Gain government approval of location alternatives
d. Decide on criteria for evaluating alternatives
e. Identify important factors (e.g., location of markets)
Answer: c ( page 376 )
Chapter 8
Summary:
The location of a business is crucial to its growth. There are many factors that come into play
when choosing a suitable location. Usually it is one or a few factors that dominate the decision
making process. For example, a change in market supply and/or demand, perhaps even if inputs
used by the business have run out. A business can suffer greatly if the right location is not
chosen. Therefore a business should evaluate all their options very carefully before making a
final conclusion.
There are generally four options a manager has with regard to location planning. The first option
would be to take the current facility and make it bigger. The second would be to keep the current
facility and just create a (or many) new one(s). The third would be to close down the current
facility entirely and build a new one. The last option would be to keep things the way they are.
Questions: Questions need to be multiple choice format.
1. What is the name of the computer-based tool used for collecting, storing, retrieving, and
displaying demographic data on maps?
x
8
6
4
3
y
5
2
3
5
A:
x = 21/4 = 5.25
y = 15/4 = 3.75
The center of gravity is located at (5.25, 3.75)
10. Determine the center of gravity based on the following information:
Destination
L1
L2
L3
L4
L5
Total
x
7
5
8
6
2
28
y
6
3
6
4
2
21
Weekly Quantity
700
500
800
600
200
2,800
A:
x = [7(700) + 5(500) + 8(800) + 6(600) + 2(200)] / 2,800 = 6.36
y = [6(700) + 3(500) + 6(800) + 4(600) + 2(200)] / 2,800 = 4.75
11. Use the table below and the cost-profit-volume analysis to determine the B Superior range
approximation.
Location
1
2
3
4
A:
Total Cost of C = Total Cost of B
350,000 + 25Q = 150,000 + 50Q
200,000 = 25Q
Q = 8,000
12. Use the table from Question 12 and the cost-profit-volume analysis to find the C Superior
range approximation.
A:
Total Cost of A = Total Cost of C
250,000 + 20Q = 350,000 + 25Q
5Q = 100,000
Q = 20,000
6. Which
The transportation model can also be used as a comparative tool providing business
decision makers with the information they need to properly balance cost and supply.
The use of this model for capacity planning is similar to the models used by engineers in
Exam Questions:
1. The transportation model relies on certain assumptions. They include all of the following
except
a) the items must be homogeneous
b) there is only one route being used between each origin and destination
c) the shipping cost per unit is the same
d) the items must be large scale
e) none of the above
Correct answer: D (pg. 398-399)
2. Which of the following are supply points that a transportation model can analyze?
a) factories
b) warehouses
c) departments
d) all of the above
e) none of the above
Correct answer: D (pg. 398)
3. The basis for the transportation model is
a) a way to provide a map for people to see results
b) a method to arrive at the lowest total shipping cost
c) so delivery drivers know where to go
d) a form of accounting
e) to provide data for use in other areas
Correct answer: B (pg. 397)
4. The following transportation model is a programming model:
a) analytical
b) non-linear
c) linear
d) rotating
e) variable
Correct answer: C (pg. 400)
5. Before the analyst of the transportation model can begin, what data would they need to
collect?
a) A list of destinations
b) Unit cost to ship
c) A list of origins
d) All of the above
e) None of the above
Correct answer: D (pg. 398)
6. What does the transportation problem involve finding:
a) highest cost-plan
b) lowest cost-plan
c) closest destinations
d) farthest destinations
e) none if the above
Correct answer: B (pg. 389)
7. Transportation problems be solved
a) manually
b) with a table
c) with excel
d) with software packages
a) Cost-volume analysis
b) Transportation model analysis
c) Factor rating analysis
d) Linear regression analysis
e) MODI analysis
Correct answer: B (pg. 399)
14. Destinationpointsare
a)pointsthatreceivegoodsfromfactories,warehouses,anddepartments
b)pointswheregoodsaresentfromfactories,warehouses,anddepartments
c)supplypoints
d)sellingpoints
e)noneoftheabove
Correctanswer:A(pg.389)
15.Transportationproblemscanbesolvedmanuallyinastraightforward
mannerexceptfor
a)mediumproblems
b)verysmall,buttimeconsumingproblems
c)largeproblems
d)alloftheabove
e)noneoftheabove
Correctanswer:D(pg.400)
16. The transportation model is a
a) linear model
b) quadratic model
c) model with two variables
d) both a and c
e) none of the above
Correct answer: D
17. The transportation model is used to determine
a) what type of transportation to use (boat, truck, train or plane) to transport goods, while
minimizing costs
b) what day of the week goods should be transportation on to minimize costs
c) how to distribute goods from multiple origins to multiple destinations to minimize total
shipping costs
d) how to best package goods so that they wouldn't break while transporting them
e) none of the above
Correct answer: C
18. What assumption is used in the transportation model?: