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TLP TLP an ajee

Total questions: 50

Worksheet time: 25mins

Name
Class
Date
1.

Which layout best matches high product variety and low volume with many alternative routings?

a)

Process (functional) layout

b)

Product (line) layout

c)

Fixed-position layout

d)

Cellular layout with dedicated families

2.

A product with stable, repeatable routing at high volume is most suited to:

a)

Process layout

b)

Product (line) layout

c)

Random storage layout

d)

Project layout

3.

A central aim of facilities planning is to:

a)

Cut labor cost only

b)

Reduce capital cost only

c)

Reduce material handling distance/time while meeting quality and safety

d)

Reduce vendor lead time only

4.

Which sequence reflects Systematic Layout Planning (SLP) from data to evaluated alternatives?

a)

Data → Space → ARD → REL → Alternatives → Evaluation

b)

REL → Data → Space → ARD → Alternatives → Evaluation

c)

Data → ARD → REL → Alternatives → Space → Evaluation

d)

Data → REL chart → ARD → Space relationships → Alternatives → Evaluation

5.

In SLP, the REL chart encodes:

a)

Machine horsepower by department

b)

Desired closeness ratings with reasons (flow, safety, supervision, etc.)

c)

Actual distances between areas

d)

Maintenance intervals

6.

The Activity Relationship Diagram (ARD) is mainly used to:

a)

Compute handling tariffs

b)

Balance a paced assembly line

c)

Visualize connectivity implied by closeness ratings before assigning space

d)

Design racking details

7.

When closeness increases (e.g., I→A) but area is tight, a practical action is to:

a)

Remove aisles to force adjacency

b)

Ignore the REL chart

c)

Relocate both to the roof

d)

Use a shared boundary or corner adjacency without expanding footprint

8.

For travel along orthogonal aisles, the distance metric typically used in load–distance models is:

a)

Manhattan (rectilinear)

b)

Euclidean

c)

Great-circle

d)

Chebyshev

9.

The classic load–distance objective seeks to minimize:

a)

Weighted sum of flow × distance (× tariff)

b)

Sum of idle times

c)

Number of operators

d)

Square footage only

10.

A from–to chart primarily captures:

a)

Theoretical machine speeds

b)

Quantities of moves from i to j per period (can be asymmetric)

c)

Depreciation schedules

d)

Lighting levels

11.

A swap-based improvement method like CRAFT is best described as:

a)

Exact global optimizer

b)

Ergonomics audit

c)

Local search exchanging departments to reduce total LD cost

d)

Queuing model

12.

If the material handling tariff increases across the board, the first distances to shorten are usually those for:

a)

Pairs with the smallest flows

b)

Any random pair

c)

Pairs with no moves

d)

Pairs with the largest flows

13.

A complete space estimate for a department includes:

a)

Machine footprints only

b)

Machines + service clearance + internal circulation + aisles (+ WIP/stock if relevant)

c)

WIP only

d)

Aisles only

14.

The dominant determinant of minimum aisle width is:

a)

Supervisor count

b)

Corporate color palette

c)

Vehicle class & turning radius (with load), plus clearances

d)

Floor coating

15.

When Paint/Solvent must be near Welding for flow economy, the correct decision is to:

a)

Keep direct adjacency for lowest LD cost

b)

Merge both areas

c)

Only add fans

d)

Prioritize safety: separation by fire-rated barrier, dedicated ventilation, segregated routes

16.

Adding a cross-aisle in a long corridor will primarily:

a)

Reduce average travel for pickers/vehicles

b)

Increase average travel

c)

Reduce demand variability

d)

Change takt time

17.

For receiving design, the most layout-sensitive KPI is commonly:

a)

Dock-to-stock time

b)

Supplier lead time

c)

Purchase price variance

d)

Scrap rate

18.

Takt time is defined as:

a)

Sum of task times divided by stations

b)

Available production time per period divided by required output

c)

Fastest station time

d)

Cycle time plus setup

19.

Given total work content of 468 s/unit and cycle time target 78 s, the theoretical minimum number of stations is:

a)

5

b)

7

c)

6

d)

8

20.

Line efficiency equals:

a)

(Stations × Cycle) / Total work

b)

Total idle / Total work

c)

1 – Balance delay (%)

d)

Total work / (Stations × Cycle)

21.

A frequent cause of balance delay even with good assignments is:

a)

All tasks have identical times

b)

Precedence constraints force unavoidable idle time in some stations

c)

Cycle equals shortest task

d)

No parallel branches exist

22.

In mixed-model assembly under a common takt, the single most important lever is:

a)

Separate lines for every variant

b)

Eliminate all testing

c)

Workload smoothing with standardized work across variants

d)

Inflate WIP buffers indiscriminately

23.

Cellular layout formation primarily relies on:

a)

Color coding of floors

b)

ISO audit tables

c)

Random clustering

d)

Part–machine incidence analysis to identify families and group machines

24.

An 'exceptional element' in a cell is:

a)

A part that must visit machines outside its assigned cell

b)

Any part completed within the cell

c)

A task longer than cycle

d)

A machine with high uptime

25.

Fixed-position layout success depends most on:

a)

JIT arrival of subassemblies/specialists at the workface with kitted logistics

b)

Shortest Euclidean distances building-wide

c)

Maximizing stationary buffers

d)

Eliminating inspections entirely

26.

ABC slotting policy implies that Class-A items are typically stored:

a)

Farthest from the dock

b)

Closest to the dock/pick face

c)

Randomly

d)

In deep reserve only

27.

To validate two-way aisle capacity at peak, the preferred method is:

a)

Static width tables only

b)

One-time visual inspection

c)

Discrete-event simulation or queuing with realistic arrivals & turning dynamics

d)

Ignore pedestrians

28.

Centers A(12, 8) and B(36, 10). The Manhattan distance between A and B is:

a)

24 m

b)

22 m

c)

20 m

d)

26 m

29.

Centers H(14, 42) and J(58, 10). The Manhattan distance is:

a)

A. 82 m

b)

B. 76 m

c)

C. 72 m

d)

D. 68 m

30.

Given A→B = 80 u/h, distance 22 m, tariff Rp12/m/unit, the hourly MH cost for A→B is:

a)

Rp19,200

b)

Rp22,880

c)

Rp21,120

d)

Rp20,240

31.

Two plans with flows/hour A→B=70, B→C=50, C→A=40 and tariff Rp10. Plan X distances (m): AB=20, BC=16, CA=30. Plan Y: AB=24, BC=12, CA=28. Which is lower cost?

a)

Layout X cheaper by Rp1,200

b)

Layout Y cheaper by Rp1,200

c)

Layout X cheaper by Rp800

d)

They tie (no cost difference)

32.

Available time 7.5 h/shift; required output 400 units. Takt (rounded to a whole second) is:

a)

68 s

b)

67 s

c)

70 s

d)

75 s

33.

With cycle time 68 s and total work 476 s, the theoretical minimum number of stations is:

a)

7

b)

8

c)

6

d)

9

34.

An 8-station line at C = 68 s has total idle 60 s/cycle. Approximate line efficiency is:

a)

≈86%

b)

≈89%

c)

≈92%

d)

≈84%

35.

Receiving best practice emphasizes:

a)

One narrow door for control

b)

Locating receiving far from storage

c)

Clear staging lanes, near-dock inspection as required, safe vehicle turning radii

d)

Mix inbound and outbound staging

36.

The unit load principle suggests you should:

a)

Move items one-by-one

b)

Always use the largest forklift

c)

Prefer manual handling

d)

Aggregate items into standardized containers to reduce handling frequency

37.

In MH equipment justification, a common target is:

a)

Ignore safety benefits

b)

Payback within ~2 years via labor/overhead savings and safety benefits

c)

Only tax effects matter

d)

Depreciation is irrelevant

38.

The classic quadratic assignment problem (QAP) models:

a)

Operator scheduling

b)

Warehouse ABC grouping

c)

Assigning departments to locations to minimize flow–distance cost

d)

Racking design

39.

Simulated annealing in layout design is useful because it can:

a)

Guarantee the global optimum instantly

b)

Replace safety review

c)

Be expressed as simple linear programming

d)

Escape local minima probabilistically and improve over simple swaps

40.

A robust evaluation of two block layouts includes:

a)

Safety compliance, expandability, REL satisfaction, and quantitative LD cost

b)

LD cost only

c)

Supervisor preference

d)

Number of corners

41.

Main/mail aisles in a block plan are primarily for:

a)

Structuring wide primary corridors to organize traffic and adjacency blocks

b)

Randomizing travel

c)

Removing signage needs

d)

Automatically reducing dock count

42.

Before adding a shipping lane to handle peaks, you should primarily use:

a)

REL chart

b)

Queuing/Discrete-Event Simulation to estimate queues and congestion

c)

A static sketch

d)

A color heatmap only

43.

Facilities planning integrates material and information flow with the goal of:

a)

Maximizing any single department’s metric

b)

Eliminating flexibility

c)

Improving overall system performance and customer service

d)

Increasing WIP intentionally

44.

In SLP, reasons behind closeness ratings most often include:

a)

Branding rules

b)

Tax policy

c)

Wallpaper color

d)

Flow volume, safety, supervision, shared resources, noise/contamination

45.

From–to data combined with rectilinear distances provide the basis to estimate:

a)

Ergonomic risk

b)

Material handling cost via load–distance

c)

Depreciation

d)

Lighting placement

46.

When space is evaluated, which constraint category often dominates feasibility?

a)

Corporate logo placement

b)

Paint color

c)

Columns/shafts/utilities and egress that shape block geometry and aisles

d)

Canteen menu

47.

Under mixed-model production, standardized work primarily serves to:

a)

Freeze flexibility

b)

Increase rework

c)

Eliminate training needs

d)

Stabilize task content across variants for smoother flow at a common takt

48.

In forming cells, the main design objective is to:

a)

Minimize exceptional elements while maintaining capacity and flow

b)

Maximize cross-cell travel

c)

Randomize routing

d)

Eliminate all buffers

49.

For receiving-to-storage flow, a near-dock slotting policy supports:

a)

Shorter put-away and quicker availability (dock-to-stock)

b)

Longer travel paths

c)

Random replenishment

d)

Wider aisles only

50.

Continuous improvement in facility layout means you should:

a)

Freeze the layout after commissioning

b)

Periodically reassess flows, safety, and cost; iterate alternatives

c)

Ignore tariff/distance changes

d)

Avoid data collection