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ChE4212 ChE Design II > Final Examination > Flashcards

Final Examination Flashcards

1
Q

3 factors that depend on plant site

A
  • cost of energy and raw materials
  • type of transportation to be used
  • availability of labor
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2
Q

3 major site selection factors

A
  • Location of Markets
  • Location of Raw Materials
  • Transportation
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3
Q

_________ often are delivered in small shipments to a large number of customers. They also involve packaging in small attractive containers that decrease the amount of product per unit volume and add mass.

A

Consumer products

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4
Q

The least expensive method of shipping is usually by _____

A

water

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5
Q

the most expensive method of shipping is by ______

A

truck

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6
Q

In between of water and truck as method of shipping are _____ & _____

A

pipelines and trains

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7
Q

_______ costs: When the transport company obtains full load on the return trip.

A

lower

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8
Q

_____ costs: When the carrier returns empty.

A

Higher

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9
Q

The difference in costs between various forms of transportation may be expected to __________ with increase in energy costs because those forms of transportation that are now the cheapest require the least amounts of energy and manpower.

A

increase

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10
Q

Logical extrapolations are often ________ because the government often subsidizes various transportation industries

A

faulty

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11
Q

While shipping firms must charge everyone having the same circumstances similarly, they can make certain types of _____.

A

deals

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12
Q

The rates given in the tables are not ____ because the final rate is negotiated with the transportation company.

A

exact

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13
Q

In these negotiations, _______ may be granted. It is a preferential allowance or rate given by an organization

A

concessions

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14
Q

It a tax or duty to be paid on a particular class of imports or exports

A

tariffs

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15
Q

A ______ is the cheapest form of transportation to operate, but it requires a large capital investment and therefore a large throughput.

A

pipeline

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16
Q

Until 1969 the long-distance pipelines carried almost exclusively __________ products.

A

natural gas or petroleum

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17
Q

In that year a pipeline running 850 miles (1,370 km) from Texas to Iowa began carrying __________ to markets in the Midwest.

A

anhydrous ammonia

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18
Q

Three factors favored construction of ammonia pipelines.

A
  1. Over 50% of this country’s agricultural nitrogen is used in the Midwest and between 40 and 65% of this total is applied directly to the soil as anhydrous ammonia.
  2. The low price of natural gas needed for the production of ammonia favored a Gulf Coast plant site or one near a large gas field.
  3. Much of the Midwest is inaccessible to cheap barge transportation
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19
Q

The railroads have introduced the ______

A

unit train.

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20
Q

This is a single train consisting of 75 or more cars periodically going from one source to a specific destination.

A

unit train

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21
Q

The train merely follows the most direct route between two points. It can cut freight costs by as much as ________%

A

30%

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22
Q

The railroads have also introduced the ______, which can hold 43,000 gallons.

A

jumbo tank car

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22
Q

The cargo ships have also begun using ______. These prepackaged standardized boxes have slashed handling charges by over 50%.

A

containerized cargos

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22
Q

Since all tank cars must be individually charged and discharged, increasing the ____ reduces the number of manual operations per unit volume of material and reduces costs.

A

size

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23
Q

They can be loaded directly on trucks or trains, thus eliminating the need for expensive dock storage facilities and greatly reducing loading and unloading charges.

A

containerized cargos

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24
Q

One of the highest costs in ocean shipping is _______.

A

docking

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25
Q

To eliminate the high cost, some ships are carrying the cargo on barges that can be removed from the ship without its _____. The barges are then ready for transportation up the various rivers to inland cities.

A

docking

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26
Q

The trucking industry has convinced some states that a _____ can haul two cargo units on interstate highways. The result is that each truck driver can transport twice as much per man-hour. The interstate highway system itself has sped up trucking service.

A

tractor trailer

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27
Q

In 1971 there were over 10,000 train accidents, many of which involved hazardous chemicals. There were also similar accidents involving barges, pipelines, and trucks. As a result, the federal government and many state governments considered _________.

A

stringent safety regulations

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28
Q

17 Other Site Selection Factors

A
  1. Transportation
  2. Sources and costs of raw materials
  3. Prospective markets for products
  4. Corporation long range planning
  5. Water source-quality and quantity
  6. Special incentives
  7. Climatic conditions
  8. Pollution requirements (Waste disposal)
  9. Utilities-cost, quantity and reliability; fuel-costs, reliability and availability
  10. Amount of site preparation necessary (site conditions)
  11. Construction costs
  12. Operating labor
  13. Taxes
  14. Living conditions
  15. Corrosion
  16. Expansion possibilities
  17. Other factors
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29
Q

9 Signs of Successful Layout

A
  1. Directed flow patterns
  2. Predictable processing time
  3. Little WIP in the facility
  4. Open Floors: allow communication and easy tracking of work & employees
  5. Bottleneck operations under control
  6. Work stations close together
  7. Orderly handling and storage of raw materials and finished products
  8. No extra handling or unnecessary handling of materials
  9. Can easily adapt to changing conditions
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30
Q

2 signs of a successfullayout gas with Directed flow patterns

A
  1. Straight line or other smooth patterns of movement
  2. Backtracking kept to a minimum
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31
Q

Little’s Law formula

A

L = λ x W
*Work in Progress (L) is the number of items in process in any system.
*Throughput (λ) represents the rate at which items arrive in/out of the system.
*Lead time (W) is the average time one item spends in the system.

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32
Q

3 considerations for changing conditions in a layout

A
  1. Considers demand growth or decline
  2. Considers product change over time
  3. Considers technological change
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33
Q

Its main objective consists of organizing equipment and working areas in the most efficient way, and at the same time satisfactory and safe for the personnel doing the work.

A

Plant Layout

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34
Q

The feeling of being a unit pursuing the same objective.

A

Sense of Unity

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35
Q

4 consideration for a Plant Layout

A
  1. Sense of Unity
  2. Minimum Movement of people, material and resources
  3. Safety
  4. Flexibility
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36
Q

It is dictated by the number and size of facilities, buildings, etc. and required spacing. It is usually based on the number of personnel or vehicles

A

Plant Layout

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37
Q

8 Factors Affecting Plant Layout

A
  1. Materials
  2. Machinery
  3. Labor
  4. Material Handling
  5. Waiting Time
  6. Auxiliary Services
  7. The building
  8. Future Changes
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38
Q

Factors Affecting Plant Layout:
The layout of the productive equipment will depend on the characteristics of the product to be managed at the facility, as well as the different parts and materials to work on

A

Materials

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39
Q

5 Main factors to be considered for a material, since they influence the manufacturing methods and storage and material handling processes.

A
  1. size
  2. shape
  3. volume
  4. weight
  5. physical-chemical characteristics
40
Q

The ______ and ________ will affect plant layout as well, taking into account the variety and quantity to produce.

A

sequence & order of the operations

41
Q

Factors Affecting Plant Layout:
Having information about the processes, machinery, tools and necessary equipment, as well as their use and requirements is essential to design a correct layout.

A

Machinery

42
Q

The ______ & _____ to improve the processes are closely linked to the plant layout.

A

methods and time studies

42
Q

Factors Affecting Plant Layout:
we have to consider the type, total available for each type, as well as type and quantity of tools and equipment

A

Machinery

43
Q

Factors Affecting Plant Layout:
It’s essential as well to know about space required, shape, height, weight, quantity and type of workers required, risks for the personnel, requirements of auxiliary services, etc.

A

Machinery

44
Q

Factors Affecting Plant Layout:
____ has to be organized in the production process (direct labor, supervision and auxiliary services)

A

Labor

45
Q

5 Environment considerations Affecting Plant Layout

A
  1. employees’ safety
  2. light conditions
  3. ventilation
  4. temperature
  5. noise
46
Q

4 Process considerations Affecting Plant Layout

A
  1. personnel qualifications
  2. flexibility
  3. number of workers required at a given time
  4. the type of work to be performed by them
47
Q

Material handling does not add value to the product; it’s just “________”

A

waste

48
Q

Minimize _____ as well as combining with other operations when possible, eliminating unnecessary and costly movements

A

material handling

49
Q

Factors Affecting Plant Layout
Objective: Continuous Material Flow through the facility, avoiding the cost of waiting time and demurrages that happen when the flow stops.

A

Waiting time - Stock

50
Q

The material waiting to flow through the facility NOT always represents a _____ to avoid.

A

cost

51
Q

It’s necessary then to consider _____ for the required stock at the facility when designing the layout.

A

space

52
Q

Factors Affecting Plant Layout
Support the main production activities at the plant

A

Auxiliary Services

53
Q

3 types of Auxiliary Services

A
  1. Related to labor
  2. Related to material
  3. Related to machinery
54
Q

Type of an auxiliary Services: Accessibility paths, fire protection installations, supervision, safety, etc.

A

Related to labor

55
Q

Type of an auxiliary Services: quality control

A

Related to material

56
Q

Type of an auxiliary Services: maintenance and electrical and water lines

A

Related to machinery

57
Q

The auxiliary services represent around _____% of the space at a facility

A

30%

58
Q

The space dedicated to auxiliary services is usually considered as _____.

A

waste

59
Q

It’s important to have efficient services to insure that their indirect costs have been ______.

A

minimized

60
Q

Factors Affecting Plant Layout:l
If it has been already selected, its characteristics will be a constraint at the moment of designing the layout, which is
different if it has to be built

A

the building

61
Q

One of the main objectives of plant layout is ____

A

FLEXIBILITY

62
Q

It’s important to forecast the future changes to avoid having an inefficient plant layout in a ________.

A

short term

63
Q

_____ can be reached keeping the original layout as free as possible regarding fixed characteristics, allowing the adjustment to emergencies and variations of the normal process activities.

A

Flexibility

64
Q

Possible _____ of the facility must be taken into account, as well as the feasibility of production during re-layout

A

future extensions

65
Q

4 Classification of Plant Layout

A
  1. Process layout
  2. Product layout
  3. Combination layout
  4. Fixed position layout
66
Q

Process layout is recommended for ________ production.

A

batch

67
Q

All machines performing similar type of operations are ______ at one location in the process layout

A

grouped

68
Q

The arrangement of facilities are grouped
together according to their _______ .

A

functions

69
Q

The flow paths of material through the facilities from one functional area to another vary from ______.

A

product to product

70
Q

3 considerations for the analysis involved in the design of production lines and assembly lines

A

1 timing
2 coordination
3 balance among individual stages in the
process.

71
Q

5 Design Approach

A
  1. List and describe each functional work center.
  2. Obtain a drawing and description of the facility being designed.
  3. Identify and estimate the amount of material and personnel flow among work centers.
  4. Use structured analytical methods to obtain a good general layout.
  5. Evaluate and modify the layout, incorporating details such as machine orientation, storage area location, and equipment access
72
Q

7 Advantages of having a Process Layout

A
  1. In process layout machines are better utilized and fewer machines are required.
  2. Flexibility of equipment and personnel.
  3. Lower investment - lower cost of general purpose machines.
  4. Higher utilization of production facilities.
  5. A high degree of flexibility with regards to work distribution to machineries and workers.
  6. Job challenging
  7. Supervisors will become highly knowledgeable
73
Q

3 Limitations of a Process Layout

A
  1. Backtracking and long movements may occur in the handling of materials thus, reducing material handling efficiency.
  2. Material handling cannot be mechanized which adds to cost.
  3. Process time is prolonged which reduce the inventory turnover and increases the in-process inventory
74
Q

Process Layout examples: Hospitals

A
  • maternity
  • intensive care
  • pediatrics
75
Q

Process Layout examples: Banks

A
  • mortgage
  • business
  • insurance
76
Q

2 Methods for Process Layout Design

A
  1. RELATIONSHIP CHART / MUTHER’S GRID
  2. TWO TOOLS / FROM-TO CHART (Hollier Method)
77
Q

also known as Systematic Layout Planning (SLP)

A

MUTHER’S GRID

78
Q

a series of workers and machines in a factory by which a succession of identical items is progressively assembled.

A

Assembly line

79
Q

Machines and equipment are
arranged to suit the sequence of _____

A

operations

80
Q

Used in ___ volume of standardized products

A

high

81
Q

They set time targets for each stage of production

A

Operations managers

82
Q

Work flows from

A

station to station

83
Q

The most common assembly-line is a moving conveyor that passes a series of workstationsb in a uniform time interval called the ______

A

workstation cycle time

84
Q

_____ and _____ is lined up in the
order of their input into the production process

A

Technology and labor

85
Q

The ______ product moves around the plant floor

A

unfinished

86
Q

The most controversial aspect of product layout is ______.

A

behavioral response

87
Q

Studies have shown that ______ and ______ lower job satisfaction

A

paced production and high specialization

88
Q

9 Advantages of having a Product Layout

A
  1. The flow of product will be smooth and logical in flow lines.
  2. In-process inventory is less.
  3. Throughput time is less.
  4. Minimum material handling cost.
  5. Simplified production, planning and control systems are possible
  6. Less space is occupied by work transit and for temporary storage.
  7. Reduced material handling cost.
  8. Manufacturing cycle is short due to uninterrupted flow of materials.
  9. Unskilled workers can learn and manage the production
89
Q

5 Limitations of Product Layout

A
  1. A breakdown of one machine in a product line may cause stoppages of machines in the downstream of the line.
  2. A change in product design may require major alterations in the layout.
  3. The line output is decided by the bottleneck machine.
  4. Comparatively high investment in equipment is required.
  5. Lack of flexibility. A change in product may require the facility modification
90
Q

Characterized as:
 Customized goods
 Functional grouping of activities
 Varied route
 Low/fluctuating demand
 General purpose equipment
 Fixed cost=low; variable cost=high
 Labor skills high/varied

A

Process Layout

91
Q

Characterized as:
 Standardized goods
 Sequential arrangement of activities
 Fixed route
 High/stable demand
 Special purpose equipment
 Fixed cost=high; variable cost=low
 Labor skills limited

A

Product Layout

92
Q

A ______of process and product layouts combines the advantages of both types of layouts.

A

COMBINATION

93
Q

Possible where an item is being made in different _____ and _____.

A

types and sizes

94
Q

Machinery is arranged in a _____ layout

A

process

95
Q

the _____ grouping is then arranged in a
sequence to manufacture various types and sizes of products.

A

process

96
Q

It is to be noted that the sequence of operations _________ with the variety of products and sizes

A

remains same

97
Q

4 Advantages of having a Combination Layout

A
  1. Helps in job enlargement and upgrades the skills of the operators.
  2. The workers identify themselves with a product in which they take interest and pride in doing the job.
  3. Greater flexibility with this type of layout.
  4. Layout capital investment is lower
98
Q

Characterized as:
Large scale bulky tasks
 The labor and machinery come to the product
 The product remains in one location

A

Fixed Position Layout

ChE4212 ChE Design II (3 decks)

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