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Exam 7: Constraint Management

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Question 61

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A(n)________ is an operation that has the lowest effective capacity of any operation in the process,and thus limits the system's output.

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Question 62

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The most controversial aspect of line-flow layout is:

A) the heuristic decision rules in assigning the next work element.
B) the number of models produced.
C) the cycle time.
D) behavioral response.

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Question 63

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________ is the maximum time allowed for work on a unit at each station.

Table 7.6 Burdell Industries makes four different models of computer printers: the E-1000,the S-2000,the P-2000 and the N-1000.The E-1000 sells for $200 and has $40 in parts and $40 in labor;the S-2000 sells for $150 and requires $30 in parts and $30 in labor;the P-2000 sells for $100 and has $20 in parts and $20 in labor;and the N-1000 sells for $75 but requires only $10 of parts and $10 of labor.Fixed overhead is estimated at $5,000 per week.The manufacture of each printer requires four machines,Machines #1,2,3 and 4.Each of the machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other.The processing requirements to make one unit of each product are shown in the table.Weekly product demand for the next planning period has been forecasted as follows: 80 E-1000s;65 S-2000s;35 P-2000s;and 20 N-1000s. In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.6.Using the traditional method,which product should be scheduled first?

The wages paid to workers on the line are categorized as ________ in the Theory of Constraints.

Table 7.5 A company makes four products that have the following characteristics: Product A sells for $50 but needs $10 of materials and $15 of labor to produce;Product B sells for $75 but needs $30 of materials and $15 of labor to produce;Product C sells for $100 but needs $50 of materials and $30 of labor to produce;Product D sells for $150 but needs $75 of materials and $40 of labor to produce.The processing requirements for each product on each of the four machines are shown in the table. Work centers W,X,Y,and Z are available for 40 hours per week and have no setup time when switching between products.Market demand for each product is 80 units per week.In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.5.Using the bottleneck method,what is the optimal product mix (consider variable costs only-overhead is not included in this profit calculation) ?

Table 7.5 A company makes four products that have the following characteristics: Product A sells for $50 but needs $10 of materials and $15 of labor to produce;Product B sells for $75 but needs $30 of materials and $15 of labor to produce;Product C sells for $100 but needs $50 of materials and $30 of labor to produce;Product D sells for $150 but needs $75 of materials and $40 of labor to produce.The processing requirements for each product on each of the four machines are shown in the table. Work centers W,X,Y,and Z are available for 40 hours per week and have no setup time when switching between products.Market demand for each product is 80 units per week.In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.5.Using the bottleneck method,what is the profit if the company manufactures the optimal product mix (consider variable costs only-overhead is not included in this profit calculation) ?

Figure 7.1 -Use the information in Figure 7.1.If each task has a work time of one minute and there are 8 hours in a day,what is the minimum number of stations if 240 units should be produced each day?

Table 7.7 A company makes four products that have the following characteristics: Product A sells for $75 but needs $20 of materials and $20 of labor to produce;Product B sells for $90 but needs $45 of materials and $20 of labor to produce;Product C sells for $110 but needs $50 of materials and $30 of labor to produce;Product D sells for $135 but needs $75 of materials and $40 of labor to produce.The processing requirements for each product on each of the four machines are shown in the table. Work centers W,X,Y,and Z are available for 40 hours per week and have no setup time when switching between products.Market demand is 50 As,60 Bs,70 Cs,and 80 Ds per week.In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.7.Using the bottleneck method,in what sequence should products be scheduled for production?

Balance the assembly line using the following task information contained in the table.The desired output is 360 units per day.Available production time per day is 480 minutes.What is the efficiency for the balanced assembly line?

Practical application of the Theory of Constraints involves the implementation of all of the following steps EXCEPT:

Line balancing applies only to line processes that do assembly work,or to work that can be bundled in many ways to create the jobs for each workstation in the line.

Table 7.15 The Terminal Company is attempting to balance its assembly line of high-voltage electrical connectors.The desired output for the line is 50 connectors per hour,and the information on the work elements for this assembly line is as follows. -Use the information from Table 7.15,and assume that the most efficient line balance possible ha been achieved.What is the total idle time for an eight hour work day?

Which one of the following statements is best concerning line balancing?

Schmidt Industries makes four different snake traps;the Harlan,the Gaylen,the Leah and the Matthew.The Harlan sells for $200 and has $40 in parts and $40 in labor;the Gaylen sells for $150 and requires $30 in parts and $30 in labor;the Leah sells for $100 and has $20 in parts and $20 in labor;and the Matthew sells for $75 but requires only $10 of parts and $10 of labor.Schmidt Industries has four machines (we'll call them A,B,C,and D for convenience)that are used in the production of each of these products.Each of these machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other.The processing requirements to make one unit of each product are shown in the table. Schmidt Industries has monthly fixed costs of $5000 and has a demand forecast of 80 Harlans,60 Gaylens,40 Leahs and 20 Matthews for the coming month.How many of each of the four models should Susan,the operations manager,schedule for production this month?

Balance the line in order to achieve maximum output for this eight-activity product.Then balance the line to maximize the efficiency of the operation.How do the levels of output (assume an eight hour day)and line efficiencies compare?

Every time a manufacturer uses one resource,they make a lot size of 300.Once a group of 30 units are completed,they are taken to the next step in the process.The lot of 300 is the ________ and the group of 30 is the ________.

What is contribution margin for a product? How might it be used to manage the productive resources on a shop floor?

Figure 7.1 -Use the information in Figure 7.1.If each task has a work time of one minute and there are 480 work minutes in a day,what is the task assignment at the fourth workstation if maximum output is desired?

You have been assigned a line balancing task and given a list of tasks,their precedence requirements,and the time needed to accomplish them.As you begin to balance the line,you realize that you must make some assumptions.What are these assumptions and which of them has the greatest impact on the success of your balance?