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Question 278 MCQ · 1.0 marks
Select the appropriate layout for Quadrants A, B, D in the following figure:
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A: Group layout, B: Product layout , D: Process layout
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A: Product layout, B: Process layout , D: Group layout
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A: Process layout, B: Group layout , D: Product layout
Published solution
**1. Concept:** Layout depends on variety and volume. High variety with low volume suits a process layout. Low variety with high volume suits a product layout. Between them is the group layout.
**2. Map the quadrants:**
- A (high variety, low volume): process layout.
- B (high variety, high volume): group layout.
- D (low variety, high volume): product layout.
**3. Conclude:** A: Process, B: Group, D: Product.
Answer: C — A: Process layout, B: Group layout, D: Product layout.
A: **Incorrect:** A needs a process layout, and D needs a product layout.
B: **Incorrect:** A is not a product layout; B is not a process layout.
C: **Correct:** A: Process, B: Group, D: Product matches the variety-volume chart.
Which of the following is an advantage of Process Layout?
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Low material handling
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Total production time per unit is small
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Low training cost for the operators
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It can accommodate high variety of products
Published solution
**1. Concept:** A process layout groups similar machines or functions together. It is flexible but has long, mixed routes.
**2. Check:** Low material handling, short production time per unit and low training cost are advantages of a product layout, not of a process layout. Process layout needs skilled operators and has heavy movement of materials.
**3. Conclude:** Its advantage is that it can handle a high variety of products.
Answer: D — It can accommodate high variety of products.
A: **Incorrect:** Process layout has high material handling because routes differ for each job.
B: **Incorrect:** Process layout has long production time because jobs move between departments.
C: **Incorrect:** Process layout needs skilled operators, so training cost is not low.
D: **Correct:** Flexibility for many products is the main advantage of process layout.
Following is the layout from an aircraft manufacturing company. Identify the layout from the
figure below.
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Product layout
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Process Layout
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Group layout
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Fixed position layout.
Published solution
**1. Concept:** In a fixed position layout, the large product stays in one place and workers, materials and equipment move to it.
**2. Apply:** Aircraft are too large and complex to move through stations, so assembly takes place in a fixed location.
**3. Conclude:** The layout is a fixed position layout.
Answer: D — Fixed position layout.
A: **Incorrect:** A product layout moves work along a line of stations.
B: **Incorrect:** A process layout groups similar machines, not one large product.
C: **Incorrect:** A group layout forms cells for families of parts.
D: **Correct:** Large products like aircraft stay in one place during assembly.
**1. Recall the eras:** Industry 1.0 = steam engine (mechanization). Industry 2.0 = mass production (electricity, assembly lines). Industry 3.0 = automation (CNC, computers). Industry 4.0 = digitization (smart, connected systems).
**2. Conclude:** 1.0: Steam Engine, 2.0: Mass production, 3.0: CNC, 4.0: Digitization.
Answer: D — 1.0: Steam Engine, 2.0: Mass production, 3.0: CNC, 4.0: Digitization.
A: **Incorrect:** Steam engine is 1.0 and digitization is 4.0; this mapping is reversed.
B: **Incorrect:** CNC belongs to 3.0 and digitization to 4.0.
C: **Incorrect:** Mass production is 2.0 and steam engine is 1.0.
D: **Correct:** Matches all four eras correctly.
When will of the following scenarios, a facility layout problem is relevant?
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A new facility is added
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A new product is introduced
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A new service is introduced
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Shift in technology
Published solution
**1. Concept:** A facility layout problem arises whenever the arrangement of work areas needs to be decided or revised.
**2. Check:** A new facility needs a layout. A new product or service changes the flow of work. A shift in technology changes equipment and flow.
**3. Conclude:** All four scenarios make the layout problem relevant.
Answer: A, B, C, D — all four scenarios.
A: **Correct:** A new facility needs a layout.
B: **Correct:** A new product changes the process flow.
C: **Correct:** A new service changes the work flow.
D: **Correct:** New technology changes equipment and flow.
Identify the examples for Offshoring from the list below:
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Shell, an oil company based in Netherlands, setting up a data science team in
India.
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Western Australia’s electricity network agency assigns Tata Consultancy
Services at Pune, to support it with an overhaul of its legacy IT systems, aimed at delivering
cheaper and more reliable power.
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Target Corporation, a retail giant based in US, setting up Supply Chain
Optimization team at Bengaluru.
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Tata Motors assigns the manufacturing of its braking system to TACO group.
A published solution is not available for this question yet.
Optimal solution in a facility location problem using Euclidean method will
result in a region
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Optimal solution in a facility location problem using Euclidean method rarely
matches the center of gravity
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Optimal solution in a facility location problem using Euclidean method will
result in a point
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Optimal solution in a facility location problem using Euclidean method
matches the center of gravity in not of the cases
Published solution
**1. Concept:** In the Euclidean (straight-line distance) single-facility location problem, we minimize the total weighted straight-line distance. The solution is a single point.
**2. Compare with center of gravity:** The center of gravity minimizes the weighted squared distance, which is a different objective. So the two usually do not coincide, and only rarely match.
**3. Check the options:**
- Region: false, the solution is a point.
- Rarely matches the center of gravity: true.
- Result is a point: true.
- 'Matches in none of the cases': false, since they sometimes match (for example, with one demand point).
Answer: B, C — the optimal solution is a point and rarely matches the center of gravity.
A: **Incorrect:** The optimal solution is a single point, not a region.
B: **Correct:** The Euclidean optimum and the center of gravity minimize different objectives, so they rarely match.
C: **Correct:** The Euclidean solution is a single point.
D: **Incorrect:** They can match in some special cases, so 'none of the cases' is too strong (the wording of this option is also unclear).
There are four demand points at A(1,2), B(2,3), C(3,5), D(4,1). The respective demand at these
points are 7, 1, 3, 5. Select the optimal location based on cross-median approach.
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(2,2)
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(3,2)
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(2.5,2)
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(2,3)
Published solution
**1. Concept:** The cross-median method finds the median location separately for x and y, weighted by demand. Total demand \(=7+1+3+5=16\), so half is 8.
**2. x-coordinate:** Sort by x and add demand: x=1 (7), x=2 (cumulative 8), x=3 (11), x=4 (16). Cumulative demand reaches exactly 8 at x=2, so any x between 2 and 3 is optimal.
**3. y-coordinate:** Sort by y: y=1 (5), y=2 (cumulative 12), y=3 (13), y=5 (16). Cumulative demand first passes 8 at y=2, so the optimal y is 2.
**4. Check options:** Points with \(2\le x\le3\) and \(y=2\) are optimal: (2,2), (3,2), (2.5,2). The point (2,3) has \(y=3\), which is not optimal.
Answer: A, B, C — (2,2), (3,2) and (2.5,2).
A: **Correct:** x=2 is in the median range and y=2 is the median, so it is optimal.
B: **Correct:** x=3 is the end of the median range and y=2, so it is optimal.
C: **Correct:** x=2.5 is in the median range and y=2, so it is optimal.
D: **Incorrect:** y=3 is not the weighted median of y (it is 2), so it is not optimal.
A factory works for two 8-hour shifts each day and produces a total of 30,000 electric bulbs using a
set of workstations. There are 8 activities required to manufacture the bulb, such that the sum of
all activity times is equal to 12 seconds. Answer the given subquestions:
What is the cycle time (in seconds) at any workstations (round your answer to one decimal).
Published solution
**1. Given:** Two 8-hour shifts, so total time per day \(=2\times8\times3600=57{,}600\) s. Output \(=30{,}000\) bulbs.
**2. Formula:** Cycle time \(=\frac{\text{available time}}{\text{output}}\).
**3. Calculate:**
\[
CT=\frac{57600}{30000}=1.92\approx1.9\text{ s}
\]
Answer: \(1.9\) seconds.
A factory works for two 8-hour shifts each day and produces a total of 30,000 electric bulbs using a
set of workstations. There are 8 activities required to manufacture the bulb, such that the sum of
all activity times is equal to 12 seconds. Answer the given subquestions:
What is the theoretical minimum number of workstations required?
Published solution
**1. Formula:** Theoretical minimum number of workstations \(=\frac{\sum t}{CT}\), rounded up.
**2. Calculate:** \(\sum t=12\) s and \(CT=1.92\) s:
\[
\frac{12}{1.92}=6.25\;\Rightarrow\;7
\]
**3. Conclude:** We round up because stations cannot be fractional.
Answer: \(7\).
Based on the above data, answer the given subquestions.
What is the minimum cycle time of the system? (in min)
Published solution
**1. Concept:** The cycle time of a line cannot be smaller than the longest single activity, because an activity cannot be split between stations.
**2. Activity times (min):** 5, 4, 12, 9, 10, 8, 7, 6, 9, 3, 5, 7. The longest is activity 3 with 12 min.
**3. Conclude:** The minimum cycle time is 12 min.
Answer: \(12\).
Based on the above data, answer the given subquestions.
What is the maximum cycle time of the system? (in min)
Published solution
**1. Concept:** The maximum cycle time occurs when all activities are done at a single workstation, so it equals the total work content.
**2. Add the times:**
\[
5+4+12+9+10+8+7+6+9+3+5+7=85
\]
**3. Conclude:** The maximum cycle time is 85 min.
Answer: \(85\).
Based on the above data, answer the given subquestions.
What is the balance delay of the following layout (round it to two decimals)
(1,2) -> (3) -> (4) -> (5) -> (6,7) -> (8,9) -> (10,11,12)
Published solution
**1. Station times (min):** (1,2): \(5+4=9\); (3): 12; (4): 9; (5): 10; (6,7): \(8+7=15\); (8,9): \(6+9=15\); (10,11,12): \(3+5+7=15\).
**2. Find n and CT:** There are \(n=7\) stations. The cycle time is the largest station time, \(CT=15\) min. Total work content \(\sum t=85\).
**3. Balance delay:**
\[
D=\frac{nCT-\sum t}{nCT}\times100=\frac{105-85}{105}\times100=19.05\%
\]
Answer: \(19.05\) (about \(19.0\%\)).
**Review note:** In the given station order, activity 5 comes before activity 6, but 6 must finish before 5 according to the diagram. The calculation below uses the station times exactly as the question gives them, which matches the supplied key.
Based on the above data, answer the given subquestions.
What is the efficiency of the layout, Mentioned in the previous question? (Round off to two
decimals without percentage sign)
Published solution
**1. Use the station data:** \(n=7\), \(CT=15\) min, \(\sum t=85\) min.
**2. Efficiency:**
\[
\text{Efficiency}=\frac{\sum t}{nCT}\times100=\frac{85}{105}\times100=80.95\%
\]
Answer: \(80.95\).
**Review note:** In the given station order, activity 5 comes before activity 6, but 6 must finish before 5 according to the diagram. The calculation below uses the station times exactly as the question gives them, which matches the supplied key.
