CH 10

File: ch10, Chapter 10: Layout Planning
Multiple Choice

1. Which of the following is not a resource that might not be included in deciding a facility
layout?
a) desk
b) work center
c) telephone switch
d) work center
e) person

Ans: c
Section Ref: What is Layout Planning?
Level: moderate

2. Which of the following may not be a result of a poor layout?
a) wasted time
b) wasted energy
c) confusion
d) poor communication
d) increased flow of information

Ans: d
Level: easy

3. Intermittent operations are seen in organizations that produce:
a) a small variety of different products
b) high volumes of a few standard products
c) a large variety of different products
d) a large volume of many standardized products
e) assembly line manufacturing

Ans: c
Level: easy

4. Which of the following is not one of the four basic layout types?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: a
Section Ref: Types of Layouts
Level: easy

5. The challenge in process layouts is to arrange resources to maximize _____ and minimize
____
a) movement, effectiveness
b) effectiveness, efficiency
c) efficiency, waste of movement
d) efficiency, effectiveness
e) efficiency, labor cost

Ans: c
Level: moderate

6. A company with a pure continuous processing system is most likely to use which layout
type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: e
Level: moderate

7. Process layouts have
a) less automation
b) more automation
c) fewer employees
d) more cycle time
e) less cycle time

Ans: a
Level: easy

8. A job shop is most likely to use which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: c
Level: moderate

9. A hospital is an example of which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: c
Level: moderate

10. A grocery store is most like which of the following layout types?
a) inverted
b) circular
c) process
d) fixed position
e) product

Ans: c
Level: moderate

11. A university is an example of which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: c
Level: moderate

12. Which of the following is least like a process layout?
a) job shop
b) automobile plant
c) hospital
d) university
e) grocery store

Ans: b
Level: moderate

13. Which of the following is more like a product layout as compared to a process layout?
a) Resources used are general purpose.
b) Facilities are less capital intensive.
c) Processing rates are slower.
d) Space requirements for inventory storage are lower.
e) Scheduling resources is more challenging.

Ans: d
Level: moderate

a) Resources used are specialized.
d) Space requirements for inventory storage are higher.

Ans: a
Level: moderate

b) Facilities are more capital intensive.

Ans: b
Level: moderate

c) Processing rates are faster.

Ans: c
Level: moderate

e) Scheduling resources is less challenging.

Ans: e
Level: moderate

c) Material handling costs are lower.

Ans: c
Level: moderate

c) Less skilled workers can be used.

Ans: c
Level: moderate

c) Products cannot be easily added or deleted from the existing product line.

Ans: c
Level: moderate

21. A company with a pure intermittent processing system is most likely to use which
layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: c
Level: moderate

22. A single-line cafeteria is an example of which layout type?
a) inverted
b) disjointed
c) process
d) fixed position
e) product

Ans: e
Level: moderate

23. A car wash is an example of which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: e
Level: moderate

24. A high-volume paper mill is an example of which layout type?
a) inverted
b) circular
c) process
d) fixed position
e) product

Ans: e
Level: moderate

25. Which of the following is least like a product layout?
a) high-volume paper mill
b) automobile plant
c) hospital
d) single-line cafeteria
e) car wash

Ans: c
Level: moderate

26. In a product layout facility the manager must decide
a) employees salary
b) exactly what tasks will not be performed by every workstation
c) exactly what tasks will be performed by every workstation
d) exactly what vacation schedule must be followed
e) general sequence the work must be performed in

Ans: d
Level: easy

27. Which company is widely considered to be the leader of just-in-time production?
a) Ford
b) Timex
c) Gateway
d) Toyota
e) Sony

Ans: d
Section Ref: Designing Process Layouts
Level: moderate

28. A hybrid layout combines
a) fixed and product
b) fixed and process
c) inverted and product
d) services and manufacturing
e) process and product

Ans: e
Level: moderate

29. A wheat farm is an example of which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: d
Level: moderate

30. Shipbuilding is an example of which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: d
Level: moderate

31. Building construction is an example of which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: d
Level: moderate

32. Bridge construction is an example of which layout type?
a) inverted
b) hybrid
c) process
d) fixed position
e) product

Ans: d
Level: moderate

33. Which of the following is least like a fixed-position layout?
a) farm
b) shipbuilding
c) bridge construction
d) building construction
e) car wash

Ans: e
Level: moderate

34. The first step in designing a layout is
a) identifying the facility
b) gathering information
c) selecting the correct layout software package
d) developing a REL chart
e) developing a from-to matrix

Ans: b
Level: moderate

35. What are the two primary tools used to identify closeness measures during the layout
design process?
a) REL chart and from-to matrix
b) MRP chart and from-to matrix
c) x-bar chart and from-to matrix
d) MRP chart and x-bar chart
e) x-bar chart and REL chart

Ans: a
Level: easy

36. According to the text, the available space of a facility is best seen by using a
a) photograph
b) detailed floor plan
c) architecture software package
d) block plan
e) overview plan

Ans: d
Level: moderate

37. Which layout design tool is primarily based on managers opinions?
a) x-bar chart
b) REL chart
c) MRP chart
d) from-to matrix
e) Gantt chart

Ans: b
Level: easy

38. What is typically used to quantitatively compare the effectiveness of layouts?
a) trial and error
b) process control charts
c) load-distance model
d) mean absolute deviation (MAD)
e) exponential smoothing

Ans: c
Level: easy

39. What is the shortest distance between two locations using north-south and east-west
movements called?
a) Euclidean distance
b) triangulated distance
c) rectilinear distance
d) Socratic distance
e) latitude-longitude (LL) distance

Ans: c
Level: easy

40. Using a relationship chart to develop acceptable layouts is part of a classic layout
technique called
a) Real layout planning
b) systematic layout planning
c) systematic from-to planning
d) systematic layout planning
e) SRP

Ans: d
Level: hard

41. Which type of movement is most like rectilinear?
a) driving cross-country on an interstate highway
b) flying an airplane
c) climbing a mountain
d) driving in New York City
e) riding a roller coaster

Ans: d
Level: moderate

42. How many different layout solutions are possible with 7 departments?
a) 7
b) 720
c) 28
d) 7000
e) 5040

Ans: e
Section Ref: Special Cases of Process Layout
Level: hard

43. How many different layout solutions are possible with 7 departments?
a) 7!
b) 6!
c) 7! 1
d) (1!)(2!)(3!)(4!)(5!)(6!)(7!)
e) 8!

Ans: a
Level: moderate

44. What are two of the most popular facility layout software packages?
a) CONWIP and CRAFT
b) ALDEP and CRAFT
c) CONWIP and MRP
d) ALDEP and MRP
e) ALDEP and CONWIP

Ans: b
Level: easy

45. Which popular facility layout software package works from an REL chart?
a) CONWIP
b) MRP
c) ALDEP
d) LAYOUT
e) CRAFT

Ans: c
Level: moderate

46. Which popular facility layout software package uses a from-to matrix?
a) CONWIP
b) MRP
c) ALDEP
d) LAYOUT
e) CRAFT

Ans: e
Level: moderate

47. Which facility layout software was developed for designing multistory layouts?
a) MULTICRAFT
b) MULTISTORY
c) CRAFT++
d) SPACECRAFT
e) SUPERLAYOUT

Ans: d
Level: hard

48. Warehouse layouts have the key characteristics of process layouts except
a) number of loads is not a design consideration
b) location isnt a major consideration
c) there is movement between the storage areas
d) from trips are the only consideration
e) there is no movement between the storage areas

Ans: e
Level: moderate

49. For the general warehouse layout problem, which department should be located
furthest from the dock?
a) least trips needed
b) most area needed
c) highest ratio of trips needed to area needed
d) smallest ratio of area needed to trips needed
e) smallest ratio of trips needed to area needed

Ans: e
Level: moderate

50. Approximately how much of the U.S. workforce works in an office environment?
a) 10%
b) 25%
c) 50%
d) 75%
e) 90%

Ans: c
Section Ref: Designing Product Layouts
Level: hard

51. Studies mentioned in the text have shown that workers that are in close proximity to
each other are more likely to ________________________________________.
a) catch a cold
b) date each other
c) get on each others nerves
d) have greater understanding, tolerance, and trust for one another
e) play practical jokes on each other

Ans: d
Level: moderate

52. On which key tradeoff does the textbook focus concerning office layouts?
a) cost vs. comfort
b) pictures vs. windows
c) cubes vs. doors
d) network printers vs. individual printers
e) proximity vs. privacy

Ans: e
Level: moderate

53. One important consideration in designing any layout is
a) consistency
b) flexibility
c) equitability
d) uniformity
e) tenure

Ans: b
Level: moderate

54. What is the term for the number of units we wish to produce over a specific period of
time?
a) job flow
b) output rate
c) cycle time
d) output flow
e) flow time

Ans: b
Level: easy

55. What is the term for the maximum amount of time each workstation has to complete its
assigned task?
a) output rate
b) task time
c) station time
d) cycle time
e) output time

Ans: d
Level: easy

56. What term tells us how frequently a product is completed?
a) output rate
b) task time
c) station time
d) cycle time
e) output time

Ans: d
Level: moderate

57. Which of the following statements is not true?
a) A perfectly balanced line has no bottlenecks.
b) It might be possible to split a bottleneck task into two smaller non-bottleneck tasks.
c) A production process always has at least one bottleneck.
d) A bottleneck task is the longest task in a process.
e) The bottleneck determines the lowest possible cycle time.

Ans: a
Level: moderate

58. What is the longest task in a process called?
a) obstruction
b) bottleneck
c) blockade
d) hindrance
e) constrainer

Ans: b
Level: easy

59. The bottleneck determines ______________________________.

a) which station has the minimum cycle time
b) the minimum cycle time of the whole process
c) the maximum cycle time of the whole process
d) the point at which a product layout converts to a process layout
e) which station has the maximum output rate

Ans: b
Level: hard

60. Assigning tasks to workstations is known as _____________________________.

a) offsetting the line
b) harmonizing the line
c) stabilizing the line
d) balancing the line
e) counterbalancing the line

Ans: d
Level: moderate

61. The theoretical minimum number of stations is the number of workstations that would
be needed if:
a) all stations were balanced.
b) all task times were the same.
c) the line was 100% efficient.
d) every task had a separate station.
e) the company had no absenteeism.

Ans: c
Level: easy

62. When line balancing, which rule does the textbook suggest for assigning tasks to
workstations?
a) shortest task time
b) first come first served
c) fewest predecessors
d) longest task time
e) most successors

Ans: d
Level: easy

63. Which production line shapes are particularly useful for the sharing of resources?
a) S and U
b) L and O
c) O and S
d) L and S
e) O and U

Ans: e
Section Ref: Group Technology (Cell) Layouts
Level: moderate

64. What is the amount by which the efficiency of a production line falls short of 100%?
a) balance delay
b) efficiency deficiency
c) efficiency delay
d) balance shortfall
e) percentage deficiency

Ans: a
Level: easy

65. What is the term for a system in which the product being worked on is physically
attached to the line and automatically moved to the next station when the cycle time has
elapsed?
a) cyclical line
b) paced line
c) autoline
d) continuous line
e) constrained line

Ans: b
Level: easy

66. Group technology creates groupings of products primarily based on what?
a) product cost
b) raw materials requirements
c) similar processing requirements
d) operating characteristics
e) market segmentation

Ans: c
Level: moderate

67. The items listed below are stored in a one-dock warehouse. Which of them should be
stored at the very back (furthest away from the dock)?

Item Trips Area Needed (blocks)
A 300 60
B 220 3
C 72 1
D 60 10
E 24 3
a) A
b) B
c) C
d) D
e) E

Ans: a
Response: See pages 357-358 (Trip ratio = trips/area needed: A = 300/60 = 5; B= 220/3 =
73.3; C = 72/1 = 72; D = 60/10 = 6; E = 24/3 = 8: A lowest trip ratio store furthest from
dock)
Level: moderate

68. Consider a production line that has a station with two machines, and each unit
produced at the station needs to be processed by both of the machines. (A unit cannot be
worked on by both machines simultaneously.) Each machine has a production capacity of 4
units per hour. What is the lowest possible cycle time of the station?
a) 4 minutes per unit
b) 8 minutes per unit
c) 7.5 minutes per unit
d) 30 minutes per unit
e) 15 minutes per unit

Ans: e
Level: hard

69. Which of the following is true?
a) A line with a lower cycle time has greater output than one with a higher cycle time.
b) A line with a higher cycle time has greater output than one with a lower cycle time.
c) Cycle time is unrelated to output rate.
d) A line must be arranged such that capacity grows with each successive station.
e) Cycle time cannot be greater than the task time of the bottleneck.

Ans: a
Level: moderate

stored at the very back (furthest away from the dock)?

Star Trek videos 2000 5
Ballet videos 5 1
Tom Cruise videos 200 2
The Simpsons videos 1000 2
Operations Management videos 500 1

a) Star Trek videos
b) ballet videos
c) Tom Cruise videos
d) The Simpsons videos
e) operations management videos

Ans: b
Level: moderate

stored at the very front (closest to the dock)?

A 300 60
B 220 3
C 74 1
D 60 10
E 24 3
a) A
b) B
c) C
d) D
e) E

Ans: c
Level: moderate

stored at the very front (closest to the dock)?

Star Trek videos 2000 5
Ballet videos 5 1
Tom Cruise videos 200 2
The Simpsons videos 1000 2
Operations Management videos 500 3

a) Star Trek videos
b) ballet videos
c) Tom Cruise videos
d) The Simpsons videos
e) operations management videos

Ans: d
Level: Moderate

73. Which of the following production line shapes is least likely to be found in a factory?
a) N
b) S
c) U
d) O
e) L

Ans: a
Level: hard

74. What is Wal-Marts primary consideration for its store layout decision regarding the
number and size of aisles in its stores?
a) predictability
b) comfort
c) ease of navigation through the store
d) customer exposure to merchandise
e) inventory control

Ans: d
Level: hard

75. The companys ______ dictates type of layout the company will have.
a) location
b) process
c) union agreements
d) HR policies
e) market share

Ans: b
Section Ref: Facility Layout Within OM: How it all Fits Together
Level: moderate

True/False

1. An assembly line is an example of an intermittent processing system.

Ans: F
Level: easy

2. A process layout is seen in companies with continuous processing systems.

Ans: F
Level: easy

3. A hospital is an example of process layout.

Ans: T
Level: moderate

4. As compared to a process layout, a product layout generally requires less skilled workers.

Ans: T
Level: moderate

5. In general, scheduling resources is less challenging under a process layout than it would
be under a product layout.

Ans: F
Level: moderate

6. At Wal-Mart, to maximize customer comfort and enjoyment, layouts are designed with a
limited number of aisles, but each of which is very wide, rather than with multiple but
narrow aisles.

Ans: F
Level: hard

7. In product layouts, the material moves continuously and uniformly through a series of
workstations until the product is completed.

Ans: T
Level: easy

8. Load-distance calculations are very concerned with the direction of the move.

Ans: F
Level: moderate

9. Maximizing worker proximity minimizes privacy issues.

Ans: F
Level: moderate

10. In a fixed position layout, resources are fixed in various locations and the products move
from one resource location to the next.

Ans: F
Level: easy

11. A predecessor can be worked in parallel with a successor.

Ans: F
Level: easy

12. Managers use a from-to matrix for facility layout design to identify both the number of
trips and the direction of those trips.

Ans: F
Level: moderate

13. Typically, an REL chart is more subjective than a from-to matrix.

Ans: T
Level: moderate

14. An REL chart can contain ratings of both desirability of closeness and undesirability of
closeness.

Ans: T
Level: moderate

15. The shortest distance between two locations is called rectilinear distance.

Ans: F
Level: moderate

16. When possible, managers should purchase and use CRAFT because it gives an optimal
solution to the facility layout problem.

Ans: F
Level: moderate

17. A heuristic solution always provides the best possible answer.

Ans: F
Level: moderate

18. For the general warehouse layout problem the department with the highest ratio of
trips to areas needed should be located closest to the dock.

Ans: T
Level: moderate

19. The cycle time of a production line is based on the workstation with the highest
potential output rate.

Ans: F
Level: moderate

20. If a process has a faster cycle time, then its cycle time has decreased.

Ans: T
Level: moderate

21. As the cycle time of a process decreases, its output also decreases.

Ans: F
Level: moderate

22. The theoretical minimum number of stations results in the production of daily
requirements when no inefficiency exists.

Ans: T
Level: moderate

23. Group Technology has the advantage of bringing the efficiencies of a process layout to a
product layout environment.

Ans: F
Section Ref: Group Technology Layouts
Level: hard

24. A product layout can look like an S-curve.

Ans: T
Level: moderate

25. Marketing is not highly affected by layout planning.

Ans: F
Section Ref: Facility Layout Across the Organization
Level: easy

Problems

1. Consider the following layout of departments.

Compute the ld score given the following from-to matrix.

Trips Between Departments
Department A B C D E F
A 12 45 3 14 29
B 16 72 5 42
C 30 20 90
D 10 4
E 12
F

Answer: 743

A B

C
D F E

2. Consider the following two layouts of departments.

Layout 1 Layout 2

Compute the ld score for each and choose the best, given the following from-to
matrix.

Trips Between Departments
Department A B C D E
A 18 8 3 4
B 16 22 5
C 50 20
D 90
E

Answer: layout 1 = 344, layout 2 = 316, layout 2 is better

3. A firm has four departments to locate in the following space.

Department A has a daily average of 20, 10, and 60 trips to Departments B, C, and D,
respectively; Department B has a daily average of 25 and 30 trips to Departments C and D,
respectively; and Department C has a daily average of 50 trips to Department D. While
there are 24 different layout combinations, only three are effectively different (in terms of
distances between departments). Calculate the ld score for the three different
combinations and choose the best.

Ans: A diagonal from B = 265, A diagonal from C = 235, A diagonal from D = 280, best
layout is A diagonal from C

D

E

C
A

B
C

D

B
A

E

4. The items listed below are stored in a one-dock warehouse. Rank them in order from
closest to the dock to furthest away.

A 200 5
B 100 4
C 78 3
D 60 2
E 35 1

Ans: A-E-D-C-B

5. The items listed below are stored in a one-dock warehouse. Rank them in order from
closest to the dock to furthest away.

Golf balls 300 1
Basketballs 420 3
Ballet shoes 10 1
Aerobics tapes 20 1
Volleyballs 360 3

Ans: golf balls-basketballs-volleyballs-aerobics tapes-ballet shoes

6. If a production line produces 800 units per 8-hour workday, what is the cycle time in
minutes?

Ans: 0.6 minutes

7. Suppose that assembly of a product involves three different tasks taking 10 seconds, 20
seconds, and 30 seconds, respectively. What is the maximum possible output per hour of
the system?

Ans: 120

8. Maxines cookie factory bottleneck is the oven. It takes 45 seconds to cook a batch of 144
cookies. What is the maximum number of cookies that Maxine can produce every hour?

Ans: 11,520

9. Maxine has identified the following process times and desired output. What is the
theoretical minimum number of work stations?
mix dough 90 sec desired output
30
batches/hour
shape cookie 50 sec
cook 45 sec
cool 75 sec

Ans: 3

10. Suppose that assembly of a product involves four different tasks taking 40 seconds, 20
seconds, 30 seconds, and 80 seconds, respectively. What is the theoretical minimum
number of stations?

Ans: 3

11. Suppose that an assembly line consists of two stations. Station 1 involves three tasks,
taking 40 seconds, 20 seconds, and 30 seconds, respectively. Station 2 involves one task
that takes 80 seconds. Compute the efficiency and balance delay of the assembly line.

Ans: efficiency = 94.4%, balance delay = 5.6%

CH 10

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