CH 6 - Manufacturing Processes

Question 1

What are the three steps required to make something?

Answer 1

1. Sourcing the parts
2. Making the item
3. Sending item to customer

Question 2

Time needed to respond to a customer order is called?

Answer 2

Lead Time

Question 3

Determines where inventory is positioned to allow processes or entities to operate independently is called?

Answer 3

Customer Ordering Decoupling Point

Question 4

What’s the potential trade off when responding quickly to customer demands?

Answer 4

Can come at the expense of greater inventory due to finished goods being more expensive than raw material

Question 5

Firms that serve customers from finished goods inventory

Answer 5

Make-To-Stock

Question 6

Firms that combine a number of preassembled modules to meet customer’s specifications

Answer 6

Assemble-To-Order

Question 7

Firms that make customer’s products from raw materials, parts, and components

Answer 7

Make-To-Order

Question 8

Firm that works with customer to design a product and then make it from purchased materials, parts, and components

Answer 8

Engineer-To-Order

Question 9

Make-To-Stock firms invest in __________ programs in order to achieve higher service levels for a given inventory investment

Answer 9

Lean Manufacturing

Question 10

What two states can a material in process be in?

Answer 10

First state is where the material is moving or “in transit”

Second state is where the material is sitting in inventory and acting as a “buffer” waiting to be used

Question 11

Material that is in a manufacturing process in a factory can also be called?

Answer 11

Work In Process Inventory

Question 12

Sum of the value (at cost) of raw material, work in process, and finished goods inventory

Answer 12

Total Average Value of Inventory

Question 13

What is the essential issue in satisfying customers in the Make-to-Stock environment?

Answer 13

To balance the level of finished inventory against level of service to the customer

Question 14

What measure should you use if you want to evaluate the performance of a process?

Answer 14

Inventory Turn

Question 15

Long term average rate that items are flowing through the process

Answer 15

Throughput

Question 16

The time that it takes a unit to flow through the process from start to end

Answer 16

Flow Time

Question 17

Inventory = Throughput X Flow time. This is called?

Answer 17

Little’s Law

Question 18

Mathematically related inventory, throughput and flow time

Answer 18

Little’s Law

Question 19

Strategic decision of selecting which kind of production processes to use

Answer 19

Process Selection

Question 20

What are the five basic structures of a workflow?

Answer 20

1. Project Layout
2. Workcenter
3. Manufacturing Cell
4. Assembly Line
5. Continuous Process

Question 21

Product remains in a fixed location and manufacturing equipment is moved to the product. This structure is called?

Answer 21

Project Layout

Question 22

Similar equipment or functions are grouped together where a part being worked on travels through an established sequence of operations. This structure is called?

Answer 22

Workcenter

Question 23

Dedicated area where products that are similar in processing requirements are produced. Typically used in lower volume production levels. This is called?

Answer 23

Manufacturing Cell

Question 24

Similar to an assembly line, production follows a predetermined sequence of steps but the flow is continuous. This is called?

Answer 24

Continuous Process

Question 25

Where work processes are arranged according to progressive steps by which the product is made. This is called?

Answer 25

Assembly Line

Question 26

The relationship between layout structures is known as?

Answer 26

Product-Process Matrix

Question 27

Variations in the product that is produced is called?

Answer 27

Standardization

Question 28

What’s the most common approach to developing a workcenter layout?

Answer 28

To arrange workcenters in a way that optimizes the movement of material

Question 29

Formed by allocating dissimilar machines to cells that are designed to work on products that have similar shapes and processing requirements. This is known as a?

Answer 29

Manufacturing cell

Question 30

The 3 steps of developing a manufacturing cell are?

Answer 30

1. Group parts into families that follow a common sequence of steps
2. Dominate flow patterns are identified in each family
3. Machines and associated processes are physically regrouped into cells.

Question 31

A layout design for the special purpose of building a product by going through a progressive set of steps

Answer 31

Assembly Line

Question 32

Moving conveyor that passes a series of workstations in a uniform time interval

Answer 32

Workstation Cycle Time

Question 33

Assigning all tasks to a series of workstations so each station has no more than can be done in a cycle and do idle time is minimized

Answer 33

Assembly Line Balancing

Question 34

Specifies the order in which tasks must be performed in the assembly process

Answer 34

Precedence Relationship

Question 35

What are ways we can accommodate a task that would take longer than the cycle period? (Ex. 40 sec task in a 36 second cycle) (name 6)

Answer 35

1. Split the task
2. Share the task
3. Use Parallel Workstations
4. Use a more skilled worker
5. Work Overtime
6. Redesign