WorksheetsProduction and Facility Layout Questions
Total questions: 100
Worksheet time: 50mins
The layout that best matches high product variety and low volume with many alternative routings is:
Process layout
Product layout
Fixed-position layout
Cellular layout
A product with stable, repeatable routing at high volume is most suited to:
Continuous production
Job shop production
Project production
Batch production
A central aim of facilities planning is to:
Optimize the use of space and resources
Increase product prices
Reduce employee salaries
Expand marketing campaigns
Which sequence reflects Systematic Layout Planning (SLP) from data to evaluated alternatives?
Data collection, analysis, development of alternatives, evaluation of alternatives
Evaluation of alternatives, data collection, development of alternatives, analysis
Development of alternatives, data collection, analysis, evaluation of alternatives
Analysis, evaluation of alternatives, data collection, development of alternatives
In SLP, the REL chart encodes:
the relationship between entities
the syntax of programming languages
the execution time of programs
the memory allocation of variables
The Activity Relationship Diagram (ARD) is mainly used to:
show the relationships between different activities in a process
calculate the cost of a project
design the physical layout of equipment
analyze the financial performance of a company
When closeness increases (e.g., I→A) but area is tight, a practical action is to:
Reduce the number of items
Increase the area
Ignore the closeness
Add more items
For travel along orthogonal aisles, the distance metric typically used in load–distance models is:
Manhattan distance
Euclidean distance
Chebyshev distance
Great-circle distance
The classic load–distance objective seeks to minimize:
the total weighted distance traveled
the number of loads handled
the time required for transportation
the cost of equipment used
A from–to chart primarily captures:
the movement of materials between locations
the cost of production
the number of workers in a department
the quality of finished products
A swap-based improvement method like CRAFT is best described as:
an iterative technique that exchanges locations to improve layout
a method for forecasting demand
a tool for quality control charts
a process for scheduling production
If the material handling tariff increases across the board, the first distances to shorten are usually those for:
short hauls
long hauls
international shipments
bulk cargo
A complete space estimate for a department includes:
all areas required for operations, storage, and circulation
only the main working area
just the storage space
only the circulation paths
The dominant determinant of minimum aisle width is:
Type of material handling equipment used
Lighting conditions
Floor color
Number of workers present
When Paint/Solvent must be near Welding for flow economy, the correct decision is to:
Provide adequate ventilation and use fire-resistant barriers
Ignore the risk and proceed as usual
Store paint/solvent directly next to welding area
Allow open containers of solvent near welding
Adding a cross-aisle in a long corridor will primarily:
Reduce travel distance
Increase storage capacity
Decrease lighting requirements
Increase ceiling height
For receiving design, the most layout-sensitive KPI is commonly:
Dock-to-stock time
Order fill rate
Inventory turnover
Cycle count accuracy
Takt time is defined as:
The rate at which a finished product needs to be completed to meet customer demand.
The total time taken to manufacture a product from start to finish.
The amount of time a machine is in operation during a shift.
The time taken for a product to move from one workstation to another.
Given total work content of 468 s/unit and cycle time target 78 s, the theoretical minimum number of stations is:
6
5
7
8
Line efficiency equals:
(Actual output / Standard output) x 100%
(Standard output / Actual output) x 100%
(Actual output + Standard output) / 2
(Actual output - Standard output) x 100%
A frequent cause of balance delay even with good assignments is:
Lack of synchronization
Excessive resources
Overstaffing
High efficiency
In mixed-model assembly and common takt, the single most important lever is:
Line balancing
Inventory reduction
Supplier management
Product design
Cellular layout formation primarily relies on:
grouping of similar machines
random machine placement
product layout principles
continuous flow processes
An 'exceptional element' in a cell is:
an element present in very small quantities
an element that is always present in large amounts
an element that is never found in cells
an element that forms the main structure of the cell
Fixed-position layout success depends most on:
Location of work centers
Amount of raw materials
Number of employees
Type of machinery used
ABC slotting policy implies that Class-A items are typically stored:
in the most accessible locations
in the least accessible locations
randomly throughout the warehouse
in remote storage areas
To validate two-way aisle capacity at peak, the preferred method is:
Conducting a time-motion study
Estimating based on average flow
Using historical sales data
Relying on staff feedback
Centers A(12, 8) and B(36, 10). The Manhattan distance between A and B is:
26
24
28
30
The Manhattan distance between centers H(14, 42) and J(58, 10) is:
76
36
64
86
The hourly MH cost for A→B, given A→B = 80 u/h, distance 22 m, and tariff Rp12/m/unit, is:
Rp21,120
Rp19,800
Rp20,000
Rp22,000
Takt (rounded to a whole second) is:
The time interval between two beats, rounded to the nearest second.
The total duration of a song.
The number of beats per minute.
The length of a musical note.
With cycle time 68 s and total work 476 s, the theoretical minimum number of stations is:
7
6
8
9
An 8-station line at C = 68 s has total idle 60 s/cycle. Approximate line efficiency is:
89%
75%
82%
92%
Receiving best practice emphasizes:
Accuracy and efficiency in handling goods
Delaying the inspection process
Ignoring documentation
Overlooking damaged items
The unit load principle suggests you should:
Move items in groups as a single unit to improve efficiency.
Handle each item individually to ensure accuracy.
Always use manual labor instead of machinery.
Store items in random locations to save space.
In MH equipment justification, a common target is:
cost reduction
increased downtime
higher manual labor
reduced automation
The classic quadratic assignment problem (QAP) models:
the assignment of facilities to locations to minimize the total cost based on flow and distance
the scheduling of jobs on machines to minimize makespan
the allocation of resources to maximize profit
the routing of vehicles to deliver goods efficiently
Simulated annealing in layout design is useful because it can:
find near-optimal solutions to complex problems
guarantee the absolute best solution every time
eliminate the need for any manual adjustments
work only for small and simple layouts
A robust evaluation of two block layouts includes:
a comparison of their performance metrics
the use of only one layout for all scenarios
ignoring the differences between layouts
focusing solely on visual appearance
Main/mail aisles in a block plan are primarily for:
Movement of materials and personnel
Storage of finished goods
Placement of machinery
Office space allocation
Before adding a shipping lane to handle peaks, you should primarily use:
existing capacity efficiently
increase shipping costs
reduce customer orders
delay shipments
Facilities planning integrates material and information flow with the goal of:
optimizing overall system efficiency
increasing product variety
maximizing marketing reach
reducing employee turnover
In SLP, reasons behind closeness ratings most often include:
shared experiences and emotional support
physical distance and time apart
differences in communication styles
competition and rivalry
From–to data combined with rectilinear distances provide the basis to estimate:
material handling costs
employee productivity
machine efficiency
inventory turnover
When space is evaluated, which constraint category often dominates feasibility?
Physical constraints
Economic constraints
Legal constraints
Social constraints
Under mixed-model production, standardized work primarily serves to:
Ensure consistency and efficiency across varying product types
Increase the number of product models produced
Eliminate the need for worker training
Reduce the cost of raw materials
In forming cells, the main design objective is to:
maximize efficiency and minimize waste
increase the number of workers
reduce the size of the facility
focus only on automation
For receiving-to-storage flow, a near-dock slotting policy supports:
quick putaway of received goods
delayed storage of items
random placement of inventory
manual sorting of shipments
Continuous improvement in facility layout means you should:
Regularly evaluate and update the layout for efficiency.
Keep the layout unchanged once it is set up.
Only make changes when problems arise.
Focus solely on reducing costs without considering layout.
What is the meaning of 'Process (functional) layout'?
A type of layout where similar processes are grouped together.
A layout where products are assembled in a straight line.
A layout used only in retail stores.
A layout that focuses on individual customer preferences.
What does 'Cut labor cost only' refer to?
Reducing expenses by focusing solely on minimizing labor costs.
Increasing labor costs to improve productivity.
Eliminating all non-labor expenses.
Hiring more employees to reduce workload.
What is meant by 'Machine horsepower by department'?
The total horsepower of machines allocated to each department.
The number of employees operating machines in each department.
The total cost of machines in each department.
The average speed of machines in each department.
What does 'Compute handling tariffs' mean?
Calculating the fees or costs associated with handling goods.
Determining the weight of the goods.
Identifying the destination of the shipment.
Packing the goods for transportation.
What is 'Manhattan (rectilinear)' distance?
A distance metric that measures the sum of the absolute differences of the coordinates, like moving along a grid.
A distance metric that measures the shortest straight line between two points.
A distance metric that calculates the product of the coordinates' differences.
A distance metric that ignores the direction and only considers the magnitude of displacement.
What is the 'Weighted sum of flow × distance (× tariff)' used for?
It is used to calculate the total cost or efficiency by multiplying flow, distance, and tariff values.
It is used to measure the speed of a vehicle over a certain distance.
It is used to determine the shortest path between two locations.
It is used to calculate the total number of goods transported regardless of distance.
What are 'Theoretical machine speeds'?
The maximum speeds at which machines are designed to operate under ideal conditions.
The average speeds at which machines operate during normal use.
The speeds at which machines operate when overloaded.
The minimum speeds required for machines to function.
What is an 'Exact global optimizer'?
A method or algorithm that finds the best possible solution for a problem across all possible options.
A tool used for approximate solutions in local regions only.
A process for randomly selecting solutions without evaluation.
A technique for optimizing only a subset of variables in a problem.
What does 'Pairs with the smallest flows' mean?
Matching items or processes that have the least amount of flow between them.
Pairs that have the highest amount of flow between them.
Pairs that are always adjacent in a process.
Pairs that are unrelated to the flow process.
What are 'Machine footprints only'?
The physical space occupied by machines, not including other factors.
The total cost of operating all machines in a facility.
The number of machines required for a specific process.
The energy consumption of machines during operation.
Fill in the blank: ________ flexibility is an important consideration in process optimization.
Freeze
Heat
Pressure
Volume
Fill in the blank: Minimize exceptional elements while maintaining ________ and flow.
capacity
volume
speed
accuracy
Fill in the blank: Shorter put-away and quicker availability is also known as ________ (dock-to-stock).
quicker availability
cycle counting
cross docking
wave picking
Fill in the blank: Freeze the layout after ________.
commissioning
designing
planning
fabrication
Fill in the blank: ________ is a type of layout mentioned in Option 2.
Product (line) layout
Process layout
Fixed position layout
Cellular layout
Fill in the blank: To reduce expenses, one should ________ capital cost only.
Reduce
Increase
Ignore
Multiply
Fill in the blank: The process REL involves Data → Space → ARD → Alternatives → ________.
Evaluation
Analysis
Synthesis
Decision
Fill in the blank: Desired closeness ratings should be given with reasons such as flow, safety, supervision, and ________.
etc.
distance
cost
location
Fill in the blank: To improve efficiency, one should balance a ________ assembly line.
paced
random
manual
unstructured
Fill in the blank: Ignore the ________ chart when not relevant.
REL
BAR
PIE
LINE
Fill in the blank: The distance metric used is ________.
Euclidean
Manhattan
Cosine
Jaccard
Fill in the blank: The sum of ________ times is important in process analysis.
idle
active
waiting
processing
Fill in the blank: Quantities of moves from i to j per period can be ________.
asymmetric
symmetric
constant
equal
Fill in the blank: ________ audit is important for workplace safety and efficiency.
Ergonomics
Financial
Environmental
Marketing
Fill in the blank: Any ________ pair can be selected for analysis.
random
fixed
ordered
specific
Fill in the blank: Machines plus service clearance and internal circulation plus aisles, plus WIP/stock if relevant, are considered in ________.
layout planning
inventory management
quality control
production scheduling
Fill in the blank: The ________ color palette is used for corporate branding.
corporate
pastel
neon
earth
Fill in the blank: To optimize space, one should ________ both areas.
merge
separate
ignore
expand
Fill in the blank: To improve performance, increase ________ average.
average
minimum
maximum
median
Fill in the blank: ________ lead time affects supply chain efficiency.
Supplier
Customer
Product
Warehouse
Fill in the blank: Available production time per period divided by required output gives the ________.
production rate
lead time
inventory turnover
cycle time
Fill in the blank: The number ________ is mentioned as a key value in Option 2.
7
3
12
5
Fill in the blank: Total idle divided by total work gives the ________ ratio.
idle/work
work/idle
work/total
idle/total
Fill in the blank: Precedence constraints force unavoidable idle time in some ________.
stations
machines
workers
tasks
Fill in the blank: To improve efficiency, eliminate all ________ testing.
ISO audit
manual
regression
unit
Fill in the blank: ________ audit tables are used for compliance.
ISO
SQL
User
Access
Fill in the blank: Any part completed within the ________ is considered for analysis.
cell
unit
section
zone
Fill in the blank: Shortest Euclidean distances are measured ________-wide.
building
street
block
city
Fill in the blank: Closest to the dock/pick ________ is a key consideration.
face
side
corner
edge
Fill in the blank: One-time ________ inspection is mentioned in Option 2.
visual
manual
electrical
chemical
Fill in the blank: The distance 22 ________ is mentioned as a key value.
m
cm
km
mm
Fill in the blank: The distance 76 ________ is mentioned as a key value.
m
cm
km
mm
Fill in the blank: The cost is mentioned in Option 2. What is the currency?
Rp (Indonesian Rupiah)
₹ (Indian Rupee)
$ (US Dollar)
¥ (Japanese Yen)
Fill in the blank: Layout Y is cheaper by ________ compared to another layout.
Rp1,200
Rp2,000
Rp500
Rp3,000
Fill in the blank: The time 67 ________ is mentioned as a key value.
s
m
h
ms
Fill in the blank: The number ________ is mentioned as a key value in Option 2.
8
5
12
20
Fill in the blank: The percentage ≈______% is mentioned as a key value.
89
75
62
95
Fill in the blank: Locating receiving far from ________ is a key consideration.
storage
office
entrance
packing area
Fill in the blank: Always use the largest ________ for material handling.
forklift
ladder
crane
cart
Fill in the blank: Payback within ~2 years via labor/overhead savings and ________ benefits is mentioned.
safety
marketing
training
transport
Fill in the blank: Warehouse ________ grouping is mentioned in Option 2.
ABC
XYZ
DEF
LMN
