Manufacturing Systems
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Course Introduction
Manufacturing Systems explores the principles, design, and operation of modern manufacturing environments, focusing on the integration of people, equipment, processes, and information to efficiently produce goods. The course covers topics such as system layouts, automation, flexible manufacturing, production planning and control, quality management, and the role of technology in optimizing manufacturing processes. Students will gain an understanding of how manufacturing systems are structured, how they respond to market demands, and how to analyze and improve system performance through case studies and practical examples.
Recommended Textbook
Operations Management Creating Value Along the Supply Chain 7th Edition by
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Page 2
Roberta S. Russell
Chapter 1: Operations Management
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Sample Questions
Q1) A nation's productivity is unrelated to its standard of living.
A)True
B)False
Answer: False
Q2) A firm who is adept at recognizing global windows of opportunity,acting on those very quickly,with tight linkages can be said to be competing on:
A)flexibility
B)speed
C)quality
D)cost Answer: B
Q3) A major challenge and opportunity for many firms is the globalization of the supply chain.
A)True
B)False Answer: True
Q4) Core competencies tend to be processes and not products or technologies.
A)True
B)False
Answer: True
Page 3
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Chapter 2: Quality Management
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Sample Questions
Q1) Directly involving employees in the quality-management process is referred to as A)partnering
B)a quality circle
C)Six Sigma
D)participative problem solving
Answer: D
Q2) Companies that satisfy its customer quality requirements often require the commitment of their suppliers.
A)True
B)False Answer: True
Q3) Deming advocated continuous process improvement to reduce variability and achieve conformance to design specifications.
A)True
B)False
Answer: True
Q4) Today total quality management has been displaced by quality management systems.
A)True
B)False
Answer: True
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Chapter 3: Statistical Quality Control
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Sample Questions
Q1) One goal of statistical process control is to prevent a process from producing items that have to be scrapped or reworked.
A)True
B)False
Answer: True
Q2) Statistical process control is based on a philosophy of inspection as opposed to prevention.
A)True
B)False
Answer: False
Q3) In some cases,the xbar-chart is used without the R-chart because the within sample variation is not of concern.
A)True
B)False
Answer: True
Q4) Tolerances reflect the amount of common cause variation allowed in a process. A)True
B)False
Answer: False
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Chapter 4: Product Design
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Sample Questions
Q1) Creating preliminary design models that are quickly tested and either discarded or further refined is known as rapid prototyping.
A)True
B)False
Q2) Computer-aided manufacturing CAM)has replaced computer-aided design CAD)in the product design process.
A)True B)False
Q3) To increase system reliability redundant parts can be built in to back up a failure.
A)True B)False
Q4) Products designed to withstand variations in operating conditions are said to be robust.
A)True
B)False
Q5) One quantitative measure of maintainability is mean time to repair MTTR).
A)True B)False
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Chapter 5: Service Design
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Questions
Q1) A small diner has one employee and a counter with seating for 8 customers.The diner does not package food for takeout.Customers arrive at the diner at the rate of 20 per hour Poisson distributed).Service times are exponentially distributed and average 24 per hour.Customers that arrive when all seats are taken do not enter the diner.What is the average number of customers in the diner?
A)2.0432
B)2.8364
C)3.7536
D)5.4837
Q2) The ______________ refers to the order in which waiting customers are served. A)calling population
B)queue discipline
C)number of channels
D)service rate
Q3) What is a calling population in terms of a waiting line system?
Q4) How can psychology be used to improve waiting lines? Provide an example.
Q5) The calling [population is the source of customers used in waiting line analysis. A)True B)False
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Chapter 6: Processes and Technology
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Sample Questions
Q1) Mass production is characterized by high volumes of a customized product for a mass market.
A)True
B)False
Q2) Steel,paper,paints,and chemicals are examples of products that use A)batch production.
B)repetitive production.
C)continuous production.
D)mass production.
Q3) Supplier reliability is often an important consideration in outsourcing decisions.
A)True
B)False
Q4) Process planning determines how a manufactured good is produced or a service is provided.
A)True
B)False
Q5) A process is a group of unrelated tasks with specific inputs and outputs.
A)True B)False
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Chapter 17: Scheduling
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Sample Questions
Q1) The assignment method of linear programming can be used for both loading and employee scheduling.
A)True
B)False
Q2) The first-come,first-served (FCFS)sequencing rule should be only used when operating at high levels of capacity.
A)True
B)False
Q3) What makes scheduling so difficult in a job shop?
Q4) What is the difference between infinite scheduling and finite scheduling?
Q5) Job shop scheduling is also known as shop floor control.
A)True
B)False
Q6) Scheduling using the theory of constraints (TOC)requires that process batch sizes and transfer batch sizes always match.
A)True
B)False
Q7) List some of the objectives in scheduling.
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Q8) Why is monitoring an important component of job shop scheduling?
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Chapter 7: Capacity and Facilities
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Sample Questions
Q1) Line balancing is constrained by precedence requirements and cycle time restrictions.
A)True
B)False
Q2) A company has a target output rate of 40 units every five 5)hours when its line is fully operational.To achieve this target the firm must have a cycle time of
A)more than 12.50 minutes
B)more than 10.00 minutes
C)7.5 minutes or less
D)8 minutes or less
Q3) Precedence requirements reflect physical restrictions on the order in which operations are performed in a product layout.
A)True
B)False
Q4) Briefly describe facility layout and the different objectives involved with facility layout decision.
Q5) Product layouts have a higher degree of flexibility than process layouts. A)True
B)False
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Chapter 8: Human Resources
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Sample Questions
Q1) List 5 of the attributes of good job design identified by Frederick Herzberg.
Q2) While still an important issue,diversity issues in U.S.companies is on the decline.
A)True
B)False
Q3) A worker-machinechart illustrates the amount of time a worker and a machine are working or idle.
A)True
B)False
Q4) How has the trend toward quality management changed the way companies view their employees?
Q5) In a piece-rate wage system,pay is based on the efficiency of the overall process.
A)True
B)False
Q6) With total quality management,employees receive broad job training making them more flexible in where they can work
A)True
B)False
Q7) What is empowerment and why is it important to total quality management (TQM)?
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Chapter 9: Project Management
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Sample Questions
Q1) A unique,one-time operational activity or effort is referred to as a process.
A)True
B)False
Q2) A project team is typically cross-functional consisting of members throughout an organization.
A)True
B)False
Q3) Using Table 9.1,the critical path for this project consists of activities
A)A-B-C-D-E-F.
B)A-C-E-F.
C)A-B-C-F.
D)A-B-D-F.
Q4) The _______________ is a document that provides a common understanding,justification,and expected result for a project.
A)statement of work
B)work breakdown structure
C)scope statement.
D)responsibility assignment matrix
Q5) Briefly describe the makeup of the project management team.
Q6) What is a scope statement?
Page 12
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Chapter 10: Supply Chain Management: Strategy and Design
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Sample Questions
Q1) A computer-to-computer exchange of business documents in a standard format is known as electronic data interchange EDI).
A)True
B)False
Q2) _______________________ is not a perceived advantage of radio frequency identification RFID)technology.
A)Loss of personal privacy
B)Reduced stock-outs
C)Prevention of fraud or theft
D)Lower distribution costs
Q3) Which of the following is not a key to effective supply chain management?
A)communication among members
B)independence among members
C)collaboration among members
D)trust among members
Q4) Increasing supply chain transparency only magnifies the bullwhip effect.
A)True
B)False
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Q5) What is the role of information and information technology in managing the supply chain?
Chapter 11: Global Supply Chain Procurement and Distribution
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Q1) A value-added tax is based on the total cost of producing a product and not the value added by the supply chain partner.
A)True
B)False
Q2) Purchasing from a supplier is called procurement. A)True
B)False
Q3) Most favored-nation (MFN)status is an agreement where members of the WTO extend to other members the most favorable treatment given to any trade partner.
A)True
B)False
Q4) Purchasing can be classified according to two broad categories: direct (manufacturing inputs)and indirect (operating inputs).
A)True
B)False
Q5) Cross docking is one of the reasons Wal-Mart has such an efficient supply chain. A)True
B)False
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Q6) List and explain the major components of a warehouse management system.
Chapter 12: Forecasting
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Sample Questions
Q1) Qualitative forecasts use mathematical techniques and statistical formulas.
A)True
B)False
Q2) Continuous replenishment systems rely heavily on extremely accurate long-term forecasts.
A)True
B)False
Q3) An exponential smoothing forecasting technique requires all of the following except
A)the forecast for the current period.
B)the actual demand for the current period.
C)a smoothing constant.
D)large amounts of historical demand data.
Q4) A long-range forecast would normally not be used to A)design the supply chain.
B)implement strategic programs.
C)determine production schedules.
D)plan new products for changing markets
Q5) Explain the difference between qualitative and quantitative forecasting methods.
Q6) Compare and contrast short-mid-range forecasts and long-range forecasts.
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Chapter 13: Inventory Management
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Sample Questions
Q1) The conventional approach to inventory management is to maintain a level of inventory that reflects a compromise between inventory cost and customer service.
A)True
B)False
Q2) With the economic order quantity (EOQ)model,increasing the order quantity reduces inventory carrying cost.
A)True
B)False
Q3) As the level of inventory increases to provide better customer service quality-related customer service costs decreases.
A)True
B)False
Q4) A service level of 95% means there is a 0.95 probability
A)of meeting all demand.
B)of a stockout.
C)that supply will exceed demand.
D)that demand will be met during the lead time.
Q5) Make a list of the basic steps involved in using the quantity discount model and discuss each.
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Chapter 13: Operational Decision-Making Tools: Simulation
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Q1) The Monte Carlo technique is a mathematical model used within a simulation.
A)True
B)False
Q2) An advantage of using a computer versus a manual approach when performing a simulation is that it often takes only seconds versus hours to reach a steady-state result.
A)True
B)False
Q3) The Monte Carlo technique selects numbers randomly from a probability distribution for use in a quantitative model.
A)True
B)False
Q4) A random number's likelihood of being selected is based on a normal distribution. A)True
B)False
Q5) As a simulation model becomes more complex,using a computer application is virtually impossible.
A)True
B)False
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Chapter 14: Operational Decision-Making Tools: Linear Programming
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Q1) A company produces product A and product B.Each product must go through two processes.Each A produced requires two hours in process 1 and five hours in process 2.Each B produced requires six hours in process 1 and three hours in process 2.There are 80 hours of capacity available each week in each process.Each A produced generates $6.00 in profit for the company.Each B produced generates $9.00 in profit for the company.If the company produces 6 units of A and 9 units of B the capacity constraint for Process 2 is
A)5A + 3B > 80
B)6A + 3 B < 80
C)5A + 3B < 80
D)5A + 3B < 80.
Q2) Briefly define the components that comprise a linear programming model.
Q3) The optimal solution for a linear programming problem will always occur
A)when the slack price equals the surplus price.
B)when the surplus price equals the slack price.
C)at an extreme point.
D)at a non-extreme point.
Q4) What is meant by the term "shadow price" in linear programming?
Q5) How is linear programming useful to an operations manager?
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Chapter 14: The Sales and Operations Planning Process
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Q1) Reconciliation of the sales plan and the operations plan may include adjusting capacity and/or managing demand.
A)True
B)False
Q2) All of the following are inputs to the aggregate production planning process except A)demand forecasts.
B)financial constraints.
C)sales plans.
D)capacity constraints.
Q3) Adjusting available capacity by hiring and firing workers to match demand is an example of a(n)________ strategy.
A)level production
B)chase demand
C)mixed production.
D)optimal production.
Q4) Most companies use mixed strategies for managing demand.
A)True
B)False
Q5) Briefly discuss the two primary objectives of aggregate planning.
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Chapter 15: Resource Planning
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Sample Questions
Q1) Lot sizing rules are used in MRP to determine work or purchase order quantities.
A)True
B)False
Q2) The quantities displayed on a master production schedule represent production and not actual demand.
A)True
B)False
Q3) The MRP process of determining requirements for lower level items based on the master production schedule is referred to as
A)lot sizing.
B)netting.
C)backward scheduling.
D)exploding.
Q4) A forecast of dependent demand requirements is one of the major inputs into the MRP process.
A)True
B)False
Q5) How does MRP differ from traditional inventory control systems?
Q6) What is a bill-of-material?
Q7) What is Enterprise Resource Planning (ERP)?
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Chapter 16: Lean Systems
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Q1) The concept of pull production is easy to implement because it is similar to traditional scheduling procedures.
A)True
B)False
Q2) The concept of cellular layouts was developed by a U.S.engineer in the 1920s.
A)True
B)False
Q3) Flexible resources is a basic element of lean production.
A)True
B)False
Q4) In a pull production system a card that corresponds to a standard quantity of production is known as a(n)
A)jidoka.
B)andon.
C)kanban.
D)kaizen.
Q5) Small-lot production reduces lead time but increases quality problems.
A)True
B)False
Q6) How does the pull system differ from the push system?
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Chapter 18: Operational Decision-Making Tools: Decision Analysis
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Q1) Which of the following techniques is the most widely used decision-making criterion under risk?
A)maximax criterion
B)minimax regret criterion
C)expected value criterion
D)Hurwicz criterion
Q2) A payoff table is a quantitative technique supporting decision making under uncertainty.
A)True
B)False
Q3) A decision criterion in which the decision payoffs are weighted by a coefficient of optimism is known as the Hurwicz criterion.
A)True
B)False
Q4) A decision criterion that results in the maximum of the minimum payoffs is called a maximin criterion.
A)True
B)False
Q5) What is decision analysis?
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Chapter 19: Operational Decision-Making Tools: Acceptance Sampling
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Q1) Six Sigma companies report defective parts per million (PPM)versus the more traditional defective parts per hundred.
A)True
B)False
Q2) Choosing among a single-,double- and multiple-sampling plans is a strategic versus an economic decision.
A)True
B)False
Q3) Acceptance sampling is still used today for all the following reasons except A)government regulations.
B)contractual requirements.
C)industry standards.
D)total quality management principles.
Q4) The consumer's willingness to accept lots with a small proportion of defective items is known as the acceptable
A)sampling plan.
B)quality level.
C)consumer's risk.
D)producer's risk.
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Chapter 20: Decision-Making Tools: Facility Location Models
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Q1) Which of the following is not a primary factor in location decisions for manufacturing plants?
A)proximity to raw materials
B)proximity to customers
C)proximity to different modes of transportation
D)proximity to significant labor pools
Q2) Service facilities are usually the largest and most expensive type of facility.
A)True
B)False
Q3) Common location incentives include all of the following except A)tax credits.
B)job training.
C)fixed exchange rates.
D)improvements to infrastructure.
Q4) The factors used to evaluate location of a manufacturing plant are usually different from the factors used in locating a service facility.
A)True
B)False
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Chapter 21: Operational Decision-Making Tools: Work Measurement
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Q1) The normal times for basic,generic micro motions developed by an outside organization in a laboratory-type environment are referred to as
A)standard times
B)normal times
C)predetermined motion times
D)elemental times
Q2) Under normal circumstances and conditions,the time required by an "average" worker to perform a job once is referred to as the cycle time.
A)True
B)False
Q3) In a time study,the normal time is computed as
A)the elemental average time multiplied by the rating factor
B)the elemental average time divided by the rating factor
C)the elemental average time minus the rating factor
D)the elemental average time plus the rating factor
Q4) Work sampling is a technique for determining the proportion of time a worker or machine is idle.
A)True
B)False
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