Operations Management 2nd Ed By Gerard Cachon - Test Bank

Operations Management 2nd Ed By Gerard Cachon - Test Bank   Instant Download - Complete Test Bank With Answers     Sample Questions Are Posted Below   Operations Management, 2e (Cachon) Chapter 5   Process Analysis with Multiple Flows   1) All flow units will have the same exit point in a production process.   Answer:  …

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Operations Management 2nd Ed By Gerard Cachon – Test Bank

 

Instant Download – Complete Test Bank With Answers

 

 

Sample Questions Are Posted Below

 

Operations Management, 2e (Cachon)

Chapter 5   Process Analysis with Multiple Flows

 

1) All flow units will have the same exit point in a production process.

 

Answer:  FALSE

Explanation:  Attrition loss is an example of when flow units exit the process before completion. Therefore, some flow units exit the process earlier than others.

Difficulty: 1 Easy

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

2) A bottleneck resource must have an implied utilization less than 100%.

 

Answer:  FALSE

Explanation:  An implied utilization less than 100% simply means that the resource has capacity to meet demand. It has no bearing on whether or not the resource is a bottleneck.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

3) The overall process yield is the sum total of the yields of all resources.

 

Answer:  FALSE

Explanation:  The overall process yield is the product of the yields of all resources.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

4) When analyzing a process flow with flow-dependent processing times, the unit of analysis should be a unit of demand.

 

Answer:  FALSE

Explanation:  When analyzing a process flow with flow-dependent processing times, the unit of analysis for a flow unit becomes a time unit, such as number of minutes or hours of work.

Difficulty: 2 Medium

Topic:  Flow Unit–Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

5) Rework always lowers the process capacity.

 

Answer:  FALSE

Explanation:  Rework lowers the process capacity only when it involves a bottleneck resource in restoring reworked units.

Difficulty: 3 Hard

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

6) The demand rate for a resource that does rework is higher than for a resource with no rework.

 

Answer:  TRUE

Explanation:  Reworked units revisit a resource and therefore consume more time at that resource than good units.

Difficulty: 1 Easy

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

7) Customers at an e-retailer site abandon their shopping carts without completing their purchase. This is an example of ________.

  1. A) attrition loss
  2. B) attrition gain
  3. C) attention loss
  4. D) attention gain

 

Answer:  A

Explanation:  Attrition loss refers to flow units leaving the process without completion.

Difficulty: 1 Easy

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

8) A store manager at C&A notices that 40% of customers come to browse but not buy, 45% do not require any assistance before making a purchase, and 15% of customers need assistance during their visit. This is a ________ situation where customers take different paths through the shopping process.

  1. A) process mix
  2. B) operation mix
  3. C) product mix
  4. D) market mix

 

Answer:  C

Explanation:  A product mix refers to a combination of different flow unit types moving through a process.

Difficulty: 1 Easy

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

9) A store manager at C&A notices that about 35% of customers who walk into the store will make a purchase without assistance, about 40% come to browse but not buy, 10% need assistance from an assistant manager and make a purchase, and 5% need assistance from the store manager and do not buy. C&A has one greeter, two assistant managers, one store manager, and six cashiers. In setting up a demand table, how many rows of resource type and columns of customer type does C&A need?

  1. A) 10, 3
  2. B) 10, 4
  3. C) 4, 4
  4. D) 5, 5

 

Answer:  C

Explanation:  There are four types of resources and four types of customers.

Difficulty: 1 Easy

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

10) Not all of the 100 customers who walk into the C&A store per day will make a purchase. About 20% come to browse but not buy, 10% need assistance to complete a purchase, and 5% need assistance but leave without making a purchase. The other 65% purchase something without requiring assistance. C&A has one greeter (who greets every customer), two assistants (who deal with customers who need assistance), and two cashiers (who serve customers who purchase something). What does the demand table for C&A look like?

A)

  Browse Buy
Greeter 20 80
Assistant 0 10
Cashier 0 75

 

B)

  Browse Help Buy
Greeter 20 15 80
Assistant 0 15 0
Cashier 0 15 75

 

C)

  Browse Help Buy
Greeter 20 10 65
Assistant 0 10 0
Cashier 0 10 65

 

D)

  Browse Help + Buy Help + Leave Buy
Greeter 20 10 5 65
Assistant 0 10 5 0
Cashier 0 10 0 65

 

 

Answer:  D

Explanation:  There are four customer types and three resource types.

Difficulty: 2 Medium

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation

 

 

11) Not all of the 100 customers who walk into the C&A store per day will make a purchase. About 20% come to browse but not buy, 10% need assistance to complete a purchase, and 5% need assistance but leave without making a purchase. The other 65% purchase something without requiring assistance. C&A has one greeter (who greets every customer), two assistants (who deal with customers who need assistance), and two cashiers (who serve customers who purchase something). What is the total demand rate per day for the greeter?

  1. A) 100
  2. B) 20
  3. C) 15
  4. D) 10

 

Answer:  A

Explanation:  Demand for greeter = 20 + 10 + 5 + 65 = 100.

Difficulty: 2 Medium

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

12) Not all of the 100 customers who walk into the C&A store per day will make a purchase. About 20% come to browse but not buy, 10% need assistance to complete a purchase, and 5% need assistance but leave without making a purchase. The other 65% purchase something without requiring assistance. C&A has one greeter (who greets every customer), two assistants (who deal with customers who need assistance), and two cashiers (who serve customers who purchase something). What is the total demand rate per day for assistants?

  1. A) 100
  2. B) 20
  3. C) 15
  4. D) 10

 

Answer:  C

Explanation:  Demand for assistants = 10 customers who need assistance in completing a purchase + 5 who need assistance but leave without making a purchase = 15.

Difficulty: 2 Medium

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

13) Not all of the 100 customers who walk into the C&A store per day will make a purchase. About 20% come to browse but not buy, 10% need assistance to complete a purchase, and 5% need assistance but leave without making a purchase. The other 65% purchase something without requiring assistance. C&A has one greeter (who greets every customer), two assistants (who deal with customers who need assistance), and two cashiers (who serve customers who purchase something). What is the total demand rate per day for cashiers?

  1. A) 100
  2. B) 75
  3. C) 65
  4. D) 25

 

Answer:  B

Explanation:  Demand for cashiers = 10 customers who need assistance + 65 who do not require assistance = 75.

Difficulty: 2 Medium

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

14) A ________ is a combination of different types of flows through a process.

  1. A) capacity mix
  2. B) demand matrix
  3. C) product matrix
  4. D) product mix

 

Answer:  D

Explanation:  A product mix is a combination of different types of flows moving through a process.

Difficulty: 1 Easy

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

15) A ________ determines how many flow units of each type are flowing through each ________.

  1. A) demand table, process
  2. B) demand table, resource
  3. C) product mix, process
  4. D) product mix, resource

 

Answer:  B

Explanation:  A demand table determines how many flow units of each type are flowing through each resource.

Difficulty: 1 Easy

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

16) All students register with the receptionist upon arrival at a university orientation. The receptionist will assign each student to one of four groups, each of which takes a different path during their tour of the campus. Each campus tour has its designated tour guide. In setting up a demand table, how many rows of resource type and columns of flow unit type does the situation have?

  1. A) 4, 5
  2. B) 2, 2
  3. C) 5, 4
  4. D) 2, 4

 

Answer:  C

Explanation:  Each student will be assigned to one of the four tour groups. Therefore, there will be four types of students and five types of resources (the receptionist and tour guides 1 through 4).

Difficulty: 1 Easy

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

17) C&A makes two types of products using four machines. Product A visits machines 1, 2, and 4. Product B only visits machines 1 and 3. The demand per day is 40 units for Product A and 160 units for Product B. What does the demand table for C&A look like?

A)

  All products
Machine 1 200
Machine 2 40
Machine 3 160
Machine 4 40

 

B)

  Product A Product B
Machine 1 1 1
Machine 2 1 0
Machine 3 0 1
Machine 4 1 0

 

C)

  Product A Product B
Machine 1 40 160
Machine 2 40 0
Machine 3 0 160
Machine 4 40 0

 

D)

  Product A Product B
 All machines 40 160

 

 

Answer:  C

Explanation:  Demand rate for Product A is 40 units per day. Demand rate for Product B is 160 units per day. Machine 1 is visited by Products A and B. Machine 2 is visited by Product A only. Machine 3 is visited by Product B only. Machine 4 is visited by Product A only.

Difficulty: 2 Medium

Topic:  Generalized Process Flow Patterns

Learning Objective:  05-01 Compute the demand for a resource in a process serving/producing a mix of customers/products.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation

 

 

18) Which of the following statements is TRUE regarding implied utilization?

  1. A) A resource with an implied utilization of 1.7 means that capacity exceeds demand by 1.7%.
  2. B) A resource with an implied utilization of 1.7 means that demand exceeds capacity by 1.7%.
  3. C) A resource with an implied utilization of 1.7 means that demand exceeds capacity by 70%.
  4. D) A resource with an implied utilization of 1.7 means that capacity exceeds demand by 70%.

 

Answer:  C

Explanation:  Implied utilization = Total demand at the resource/Capacity at the resource. Therefore, if implied utilization is 1.7, that means demand exceeds capacity by 1.7 – 1 = 0.7 or  70%.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

19) Which of the following statements is TRUE regarding utilization and implied utilization?

  1. A) Utilization measures by how much demand exceeds the capacity of the resource.
  2. B) Utilization can exceed 1.
  3. C) Implied utilization can exceed 1.
  4. D) Implied utilization is a measure of demand variability.

 

Answer:  C

Explanation:  Implied utilization measures by how much demand exceeds the capacity of the resource. If it exceeds 1, then it means the process is capacity constrained.

Difficulty: 1 Easy

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

20) A process is ________ constrained if the implied utilization of any resource is above 100%.

  1. A) supply
  2. B) demand
  3. C) bottleneck
  4. D) inventory

 

Answer:  A

Explanation:  A process is supply constrained if the implied utilization of any resource is above 100%.

Difficulty: 1 Easy

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

21) A process is ________ constrained if the highest implied utilization of all resources is less than or equal to 100%.

  1. A) capacity
  2. B) demand
  3. C) bottleneck
  4. D) supply

 

Answer:  B

Explanation:  A process is demand constrained if the implied utilization of the resource is below 100%.

Difficulty: 1 Easy

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

22) The steps involved in finding the bottleneck in a process with a product mix include all the following EXCEPT ________.

  1. A) compute the total demand for each resource
  2. B) compute the capacity level for each resource
  3. C) compute the flow rate for each resource
  4. D) compute the implied utilization for each resource

 

Answer:  C

Explanation:  The bottleneck in a process with a product mix is the resource with the highest implied utilization, and does not involve the flow rate. Besides, flow rate should be computed in relation to each flow unit type.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

23) The resource with the ________ is the bottleneck in a process with multiple types of flow units.

  1. A) highest capacity
  2. B) lowest capacity
  3. C) highest implied utilization
  4. D) lowest implied utilization

 

Answer:  C

Explanation:  The resource with the highest implied utilization is the bottleneck in a process with multiple types of flow units.

Difficulty: 1 Easy

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

24) C&A makes two types of products using four machines from 9 a.m. to 5 p.m. each day. Product A visits machines 1, 2, and 4. Product B only visits machines 1 and 3. The capacity is 0.4 unit per minute at machine 1, 0.12 unit per minute at machine 2, 0.2 unit per minute at machine 3, and 0.3 unit per minute at machine 4. The demand per day is 40 units for Product A and 160 units for Product B. Which is the implied utilization for the bottleneck resource?

  1. A) 1.67
  2. B) 1.04
  3. C) 0.69
  4. D) 0.28

 

Answer:  A

Explanation:  Total demand rate for machine 1 = 40 + 160 = 200 units per day. Total demand rate for machine 2 = 40 units per day. Total demand rate for machine 3 = 160 units per day. Total demand rate for machine 4 = 40 units per day. Implied utilization for machine 1 = 200/(0.4 × 8 × 60) = 1.04. Implied utilization for machine 2 = 40/(0.12 × 8 × 60) = 0.69. Implied utilization for machine 3 = 160/(0.2 × 8 × 60) = 1.67. Implied utilization for machine 4 = 40/(0.3 × 8 × 60) = 0.28. The bottleneck is the resource with the highest implied utilization, which is machine 3.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

25) C&A makes two types of products using four machines from 9 a.m. to 5 p.m. each day. Product A visits machines 1, 2, and 4. Product B only visits machines 1 and 3. The capacity is 0.4 unit per minute at machine 1, 0.12 unit per minute at machine 2, 0.2 unit per minute at machine 3, and 0.3 unit per minute at machine 4. The demand per day is 40 units for Product A and 160 units for Product B. What is the implied utilization for machine 1?

  1. A) 1.67
  2. B) 1.04
  3. C) 0.69
  4. D) 0.28

 

Answer:  B

Explanation:  Total demand  for machine 1 = 40 + 160 = 200 units per day. Capacity for machine 1 = 0.4 unit per minute or 0.4 × 8 × 60 units per day. Implied utilization for machine 1 = 200/(0.4 × 8 × 60) = 1.04.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a General Process Flow

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

26) C&A makes two types of products using four machines from 9 a.m. to 5 p.m. each day. Product A visits machines 1, 2, and 4. Product B only visits machines 1 and 3. The capacity is 0.4 unit per minute at machine 1, 0.12 unit per minute at machine 2, 0.2 unit per minute at machine 3, and 0.3 unit per minute at machine 4. The demand per day is 40 units for Product A and 160 units for Product B. Which resource is the bottleneck?

  1. A) Machine 1
  2. B) Machine 2
  3. C) Machine 3
  4. D) Machine 4

 

Answer:  C

Explanation:  Total demand for machine 1 = 40 + 160 = 200 units per day. Total demand for machine 2 = 40 units per day. Total demand for machine 3 = 160 units per day. Total demand for machine 4 = 40 units per day. Implied utilization for machine 1 = 200/(0.4 × 8 × 60) = 1.04. Implied utilization for machine 2 = 40/(0.12 × 8 × 60) = 0.69. Implied utilization for machine 3 = 160/(0.2 × 8 × 60) = 1.67. Implied utilization for machine 4 = 40/(0.3 × 8 × 60) = 0.28. The bottleneck is the resource with the highest implied utilization, which is machine 3.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a General Process Flow

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

27) C&A makes two types of products using four machines from 9 a.m. to 5 p.m. each day. Product A visits machines 1, 2, and 4. Product B only visits machines 1 and 3. The capacity is 0.4 unit per minute at machine 1, 0.12 unit per minute at machine 2, 0.2 unit per minute at machine 3, and 0.3 unit per minute at machine 4. The demand per day is 40 units for Product A and 160 units for Product B. Assume the relative proportion between the two product types remains constant. What is the flow rate for Product B in units per day?

  1. A) 24
  2. B) 96
  3. C) 120
  4. D) 192

 

Answer:  B

Explanation:  Product B visits machines 1 and 3. Product A also visits machine 1, but not machine 3. Therefore, implied utilization of machine 1 = 200/(.4 × 8 × 60) = 1.04. Implied utilization of machine 3 = 160/(.2 × 8 × 60) = 1.67. The implied utilization is highest at machine 3, and 1.67 is greater than 1, so the process is capacity constrained. Flow rate for Product B = Demand rate/Implied utilization of the bottleneck = 160/1.67 = 96 units per day

Difficulty: 3 Hard

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

28) About 80% of customers who receive a promotion coupon will visit the store, but only 20% of those in the store will make a purchase. What is the overall process yield of the promotion?

  1. A) 25%
  2. B) 60%
  3. C) 20%
  4. D) 16%

 

Answer:  D

Explanation:  Of the 100% of customers who received a coupon, 80% visited the store, and 20% of those made a purchase. Overall process yield = 1 × 0.80 × 0.20 = 0.16.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

29) About 80% of customers who receive a promotion coupon will visit the store, but only 20% of those in the store will make a purchase. How many promotion coupons have to be sent in order to get 100 customers to make a purchase?

  1. A) 1600
  2. B) 625
  3. C) 500
  4. D) 125

 

Answer:  B

Explanation:  Use the formula “Number of units started to get Q good units = Q/Process yield”. Q is 100, and process yield is 1 × 0.80 × 0.20 = 0.16.  Number of promotion coupons that have to be sent = 100/0.16 = 625

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

30) Which of the following is an example of attrition loss?

  1. A) All customers renew their magazine subscriptions.
  2. B) Defective units in a manufacturing process are reworked.
  3. C) More loan applications are received than approved.
  4. D) The number of students at the beginning of a course is the same at the end.

 

Answer:  C

Explanation:  Loan applicants who are rejected in the loan application process are regarded as attrition losses.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

31) In a process with attrition loss, all flow units start at ________ resource and drop out of the process at ________ points.

  1. A) the same, different
  2. B) a different, the same
  3. C) the same, the same
  4. D) a different, different

 

Answer:  A

Explanation:  In a process with attrition loss, all flow units start at the same resource but then drop out of or are removed from the process at different points.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

32) When defective flow units are removed from the process and do not return, this process is known as ________.

  1. A) reworking
  2. B) yielding
  3. C) scrapping
  4. D) eliminating

 

Answer:  C

Explanation:  Scrapping is the process of removing defective flow units from a process which are not returned to the process for rework.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

33) The ________ of a resource measures the percentage of ________ units that are processed at this resource.

  1. A) yield, defective
  2. B) yield, non-defective
  3. C) capacity, defective
  4. D) capacity, non-defective

 

Answer:  B

Explanation:  The yield of a resource measures the percentage of non-defective units that are processed at this resource.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

34) Which of the following statements about the yield of a process is FALSE?

  1. A) A process can have a yield of 100%.
  2. B) A process with attrition loss has a lower yield than one without attrition loss.
  3. C) A process without attrition loss will have a yield of 100%.
  4. D) A process can have a yield that exceeds 100%.

 

Answer:  D

Explanation:  The yield of a process is the percentage of units processed correctly. It cannot exceed 100%.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

35) A three-step process is used to make a product. The yield of step 1 is 90%; of step 2, 70%; and of step 3, 50%. What is the yield of the overall process?

  1. A) 45%
  2. B) 40%
  3. C) 31.5%
  4. D) 21%

 

Answer:  C

Explanation:  The yield of the overall process = 0.9 × 0.7 × 0.5 = 0.315.

Difficulty: 2 Medium

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Understand

AACSB:  Analytical Thinking

 

36) A three-step process is used to make a product. The yield of step 1 is 50%; of step 2, 80%; and of step 3, 20%. How many units must be started at step 1 to get 100 good units from the process?

  1. A) 500
  2. B) 200
  3. C) 150
  4. D) 1250

 

Answer:  D

Explanation:  Process yield = 0.5 × 0.8 × 0.2 = 0.08 or 8%. Number of good units = Q/Process yield = 100/0.08 = 1250.

Difficulty: 2 Medium

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

37) A three-step process is used to make a product. The yield of step 1 is 80%; of step 2, 40%; and of step 3, 50%. Step 1 takes 2 minutes per unit. Step 2 takes 4 minutes per unit. Step 3 takes 5 minutes. Which step in the process is the bottleneck, and how many good units can be produced from this process in one 8-hour day?

  1. A) Step 3, 15
  2. B) Step 3, 38
  3. C) Step 2, 48
  4. D) Step 2, 24

 

Answer:  D

Explanation:  To determine the bottleneck, we multiply capacity for a resource by its “yield of good finished units” and determine which step has the smallest capacity of good units per minute. To find capacity for each step, we divide 1/processing time. Step 1 has a capacity of ½= 0.50, step 2’s capacity is ¼ or 0.25, and step 3’s capacity is 1/5 or 0.20. “Yield of good finished units” is that step’s yield times the yield of each subsequent step. Step 1 has a finished unit yield of 0.8 × 0.4 × 0.5 = 0.16. Step 2 is 0.4 × 0.5 = 0.2 unit. Step 3 is 0.50. Capacity of good finished units per minute for step 1 is 0.5 × 0.16 = 0.08; step 2 is 0.25 × 0.2 = .05; step 3 is 0.2 × 0.5 = 0.1. Step 2 is the bottleneck.  Yield per day is set by the bottleneck’s yield, which is 8 hours × 60 minutes × 0.05 good units per minute = 24.

Difficulty: 1 Easy

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

38) A three-step process is used to make a product. The yield of step 1 is 80%; of step 2, 40%; and of step 3, 50%. Step 1 takes 2 minutes per unit. Step 2 takes 4 minutes per unit. Step 3 takes 5 minutes. How many good units can the process produce per hour?

  1. A) 0.05
  2. B) 0.1
  3. C) 3
  4. D) 6

 

Answer:  C

Explanation:  The bottleneck step determines the hourly rate of good units. Capacity for good units at each step is capacity × yield in good units per minute.  For capacity, use 1/processing time. Yield of finished units for each step is that step’s yield × yield of each subsequent step.  For step 1: (1/2) × (0.8 × 0.4 × 0.5) = 0.08. For step 2: (1/4) × (0.4 × .5) = 0.05. For step 3: (1/5) × 0.5 = 0.1. Step 2 is the bottleneck.  Given the bottleneck’s capacity of 0.05 good products per minute, in one hour the system can product 60 × 0.05 = 3 good units.

Difficulty: 3 Hard

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

 

39) When analyzing a process flow with flow-dependent processing times, the flow unit is changed from using ________ to ________.

  1. A) a minute of work, a unit of demand
  2. B) a unit of demand, a unit of work
  3. C) a unit of resource, a unit of demand
  4. D) a unit of demand, a unit of resource

 

Answer:  B

Explanation:  When analyzing a process flow with flow-dependent processing times, the flow unit is changed from using a unit of demand to a unit of work.

Difficulty: 1 Easy

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

40) A workload table has ________ as columns and ________ as rows.

  1. A) resource types, load types
  2. B) work types, load types
  3. C) work types, flow unit types
  4. D) flow unit types, resource types

 

Answer:  D

Explanation:  A workload table has flow unit types as columns and resource types as rows.

Difficulty: 1 Easy

Topic:  Flow Unit–Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

41) A workload table captures the ________ that each flow unit type requires for each resource.

  1. A) amount of work
  2. B) amount of demand
  3. C) amount of revenue
  4. D) amount of supply

 

Answer:  A

Explanation:  A workload table captures the amount of work that each flow unit type requires for each resource.

Difficulty: 1 Easy

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

42) Which of the following statements is TRUE regarding a process flow with flow-dependent processing times?

  1. A) Processing times at a given resource are the same for each product/customer type.
  2. B) A unit of demand is used as a flow unit.
  3. C) The bottleneck is the resource with the highest implied utilization.
  4. D) The bottleneck is the resource with the highest workload.

 

Answer:  C

Explanation:  The bottleneck in a process flow with flow-dependent processing times is the resource with the highest implied utilization.

Difficulty: 1 Easy

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

43) Which of the following statements is FALSE regarding the workload table?

  1. A) It has the same number of columns and rows as the demand table.
  2. B) It computes the total amount of work requested at a resource across all customer types.
  3. C) It captures the time available at each resource.
  4. D) It has flow unit types as columns and resource types as rows.

 

Answer:  C

Explanation:  The workload table does not contain information about the time available at each resource.

Difficulty: 1 Easy

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

44) Two types of customers are served by a two-step process. Each resource is staffed by one employee. Customer A spends two minutes at resource X and five minutes at resource Y. Customer B spends five minutes at resource X and two minutes at resource Y. The demand rate per hour is 10 customer As and 15 customer Bs. Which of the following is the workload table for this situation?

  1. A)
  All customers
Resource X 95
Resource Y 80

 

  1. B)
  Customer A Customer B
Resource X 2 5
Resource Y 5 2

 

  1. C)
  Customer A Customer B
Resource X 20 75
Resource Y 50 30

 

  1. D)
  Customer A Customer B
All resources 70 105

 

 

Answer:  C

Explanation:  Workload for customer A at resource X = 10 × 2; Workload for customer A at resource Y = 10 × 5; Workload for customer B at resource X = 15 × 5; Workload for customer B at resource Y = 15 × 2.

Difficulty: 2 Medium

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation

 

 

45) Two types of customers are served by a two-step process. Each resource is staffed by one employee. Customer A spends two minutes at resource X and five minutes at resource Y. Customer B spends five minutes at resource X and two minutes at resource Y. The demand rate per hour is 10 customer As and 15 customer Bs. What is the workload for resource X across all customer types?

  1. A) 70 minutes per hour
  2. B) 80 minutes per hour
  3. C) 95 minutes per hour
  4. D) 105 minutes per hour

 

Answer:  C

Explanation:  Workload for resource X = (10 × 2) + (15 × 5) = 95 minutes per hour.

Difficulty: 2 Medium

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Understand

AACSB:  Analytical Thinking

 

46) Two types of customers are served by a two-step process. Each resource is staffed by one employee. Customer A spends two minutes at resource X and five minutes at resource Y. Customer B spends five minutes at resource X and two minutes at resource Y. The demand rate per hour is 10 customer As and 15 customer Bs. What is the workload for resource Y across all customer types?

  1. A) 70 minutes per hour
  2. B) 80 minutes per hour
  3. C) 95 minutes per hour
  4. D) 105 minutes per hour

 

Answer:  B

Explanation:  Workload for resource Y = (10 × 5) + (15 × 2) = 80 minutes per hour.

Difficulty: 2 Medium

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Understand

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

47) Two types of customers are served by a two-step process. Each resource is staffed by one employee. Customer A spends two minutes at resource X and five minutes at resource Y. Customer B spends five minutes at resource X and two minutes at resource Y. The demand rate per hour is 10 customer As and 15 customer Bs. Where in the process is the bottleneck and what is its implied utilization?

  1. A) Resource X, 1.58
  2. B) Resource X, 1.33
  3. C) Resource Y, 1.33
  4. D) Resource Y, 1.58

 

Answer:  A

Explanation:  Workload for resource X = (10 × 2) + (15 × 5) = 95 minutes per hour; Implied utilization for resource X = 95/60 = 1.58. Workload for resource Y = (10 × 5) + (15 × 2) = 80 minutes per hour; Implied utilization for resource Y = 80/60 = 1.33. Resource X has the higher implied utilization and therefore is the bottleneck.

Difficulty: 3 Hard

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

48) Two types of customers are served by a two-step process. Each resource is staffed by one employee. Customer A spends two minutes at resource X and five minutes at resource Y. Customer B spends five minutes at resource X and two minutes at resource Y. The demand rate per hour is 10 customer As and 15 customer Bs. What is the flow rate for customer A, holding the mix of A and B constant?

  1. A) 1.6 customers per hour
  2. B) 6.3 customers per hour
  3. C) 7.5 customers per hour
  4. D) 9.5 customers per hour

 

Answer:  B

Explanation:  Workload for resource X = (10 × 2) + (15 × 5) = 95 minutes per hour; Implied utilization for resource X = 95/60 = 1.58. Workload for resource Y = (10 × 5) + (15 × 2) = 80 minutes per hour; Implied utilization for resource Y = 80/60 = 1.33. Resource X has the higher implied utilization of 1.58, which is greater than 1. The process is capacity constrained. Flow rate for customer A = 10/1.58 = 6.3 customers per hour.

Difficulty: 3 Hard

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

49) Two types of customers are served by a two-step process. Each resource is staffed by one employee. Customer A spends two minutes at resource X and five minutes at resource Y. Customer B spends five minutes at resource X and two minutes at resource Y. The demand rate per hour is 10 customer As and 15 customer Bs. What is the flow rate for customer B, holding the mix of A and B constant?

  1. A) 1.6 customers per hour
  2. B) 6.3 customers per hour
  3. C) 9.5 customers per hour
  4. D) 11.25 customers per hour

 

Answer:  C

Explanation:  Workload for resource X = (10 × 2) + (15 × 5) = 95 minutes per hour; Implied utilization for resource X = 95/60 = 1.58. Workload for resource Y = (10 × 5) + (15 × 2) = 80 minutes per hour; Implied utilization for resource Y = 80/60 = 1.33. Resource X has the higher implied utilization of 1.58, which is greater than 1. The process is capacity constrained. Flow rate for customer B = 15/1.58 = 9.5 customers per hour.

Difficulty: 3 Hard

Topic:  Flow-Dependent Processing Times

Learning Objective:  05-03 Analyze a process with flow-dependent processing times.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

50) Rework is a ________ of activities that have to be completed by a ________ flow unit in order to be restored to a good flow unit.

  1. A) reduction, defective
  2. B) reduction, non-defective
  3. C) repetition, defective
  4. D) repetition, non-defective

 

Answer:  C

Explanation:  Rework is to repeat activities that have to be completed by a defective flow unit in order to be restored to a good flow unit.

Difficulty: 1 Easy

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

51) Which of the following process flow diagrams DOES NOT represent a process with rework?

A)

B)

C)

D)

 

Answer:  A

Explanation:  Rework is represented as a loop showing resources that a unit has revisited or an extra set of activities that have to be completed by a defective flow unit in order to be restored to a good flow unit.

Difficulty: 1 Easy

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation

 

 

52) Which of the following statements concerning rework is TRUE?

  1. A) Rework does not involve performing an extra set of activities.
  2. B) Rework does not involve inventories.
  3. C) Rework can never return a process yield to 100%.
  4. D) Rework increases the demand rate for a particular resource.

 

Answer:  D

Explanation:  Rework revisits a particular resource and thus increases the demand rate for that resource.

Difficulty: 1 Easy

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

53) Which of the following statements concerning rework is TRUE?

  1. A) Rework involves only bottleneck resources.
  2. B) Rework does not affect overall process capacity.
  3. C) Rework leads to a lower overall process yield than scrap.
  4. D) Rework leads to a higher overall process yield than scrap.

 

Answer:  D

Explanation:  Rework attempts to restore the overall process yield to 1. Scrap, on the other hand, simply exits the process according to the yield at a particular resource.

Difficulty: 1 Easy

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

54) Students who failed a course last semester are retaking it this semester. This is an example of ________.

  1. A) attrition loss
  2. B) rework
  3. C) compliance
  4. D) process reengineering

 

Answer:  B

Explanation:  Rework refers to a repetition of activities or an extra set of activities that have to be completed by a defective unit in order to be restored to a good flow unit.

Difficulty: 1 Easy

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

55) ________ refers to a ________ of activities or an extra set of activities that have to be completed by a defective unit in order to be restored to a good flow unit.

  1. A) Rework, removal
  2. B) Reduce, removal
  3. C) Rework, repetition
  4. D) Reduce, repetition

 

Answer:  C

Explanation:  Rework refers to a repetition of activities or an extra set of activities that have to be completed by a defective unit in order to be restored to a good flow unit.

Difficulty: 1 Easy

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Remember

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

56) A four-step process is used to make a product. The first resource takes 8 minutes per unit, the second takes 7 minutes per unit, the third takes 2 minutes per unit, and the fourth takes 10 minutes per unit. 20% of all units have to be reworked. For that, they have to revisit the third and fourth resources. Each resource is staffed by one worker. Rework takes the same processing times as the first pass and always fixes the problem. Where is the bottleneck?

  1. A) Resource 1
  2. B) Resource 2
  3. C) Resource 3
  4. D) Resource 4

 

Answer:  D

Explanation:  Workload for resource 1 = (0.8 × 8) + (0.2 × 8) = 8 minutes per unit; Workload for resource 2 = (0.8 × 7) + (0.2 × 7) = 7 minutes per unit; Workload for resource 3 = (0.8 × 2) + [0.2 × (2 + 2)] = 2.4 minutes per unit; Workload for resource 4 = (0.8 × 10) + [0.2 × (10 + 10)] = 12 minutes per unit. Each resource has one worker who can provide one minute of work each minute. The implied utilization for resource 1 is 8%; for resource 2, 7%; for resource 3, 2.4%; and for resource 4, 12%. The highest implied utilization is 12% at resource 4.

Difficulty: 3 Hard

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

57) A four-step process is used to make a product. The first resource takes 8 minutes per unit, the second takes 7 minutes per unit, the third takes 2 minutes per unit, and the fourth takes 10 minutes per unit. 20% of all units have to be reworked. For that, they have to revisit the third and fourth resources. Each resource is staffed by one worker. Rework takes the same processing times as the first pass and always fixes the problem. What is the capacity of the process in units per minute?

  1. A) 0.08
  2. B) 0.125
  3. C) 0.143
  4. D) 0.417

 

Answer:  A

Explanation:  Workload for resource 1 = (0.8 × 8) + (0.2 × 8) = 8 minutes per unit; Workload for resource 2 = (0.8 × 7) + (0.2 × 7) = 7 minutes per unit; Workload for resource 3 = (0.8 × 2) + [0.2 × (2 + 2)] = 2.4 minutes per unit; Workload for resource 4 = (0.8 × 10) + [0.2 × (10 + 10)] = 12 minutes per unit. Each resource has one worker who can provide one minute of work each minute. The implied utilization for resource 1 is 8%; for resource 2, 7%; for resource 3, 2.4%; and for resource 4, 12%. The highest implied utilization is 12%. Capacity = 1/12 = 0.08 unit per minute.

Difficulty: 3 Hard

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Analyze

AACSB:  Analytical Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

58) The salesforce of Small Travel Company (STC) is selling cultural immersion programs to U.S. college students that allow them to spend 3 months in Europe.

 

STC advertises in various college newspapers, as well as via social media. Potential customers fill out an online application form expressing their interest in more information about this experience. The form also includes their phone number for follow-up discussion, which sometimes, but not always, leads to the customer purchasing the package (more details below).

 

On 60 consecutive days in the winter, STC’s employees work hard to sell these programs to elite university students. The goal of the company is to sell, on average, two packages per day, leading to a total of 120 sold packages. The sales process works in four steps:

 

  1. One salesperson reaches out to the potential customer by phone in order to put together a full profile of the customer, including skills and location preferences (Germany, Italy, France, etc.). The call takes on average 20 minutes. After the call, each profile is forwarded to a language teacher.
  2. The language teacher looks at the student’s profile and also organizes a quick follow-up call. This takes, on average, 40 minutes per profile. The teacher rejects 60% of the profiles as the student would not have the language skills to benefit from an STC trip. From the remaining 40% of the profiles, half tell the teacher that they are no longer interested in participating. The teacher then forwards the remaining profiles to the STC accountant.
  3. STC’s accountant then contacts the student to make a 10% down payment. This takes about 20 minutes per customer.
  4. Finally, the teacher’s assistant contacts the customer to confirm the trip and start working on a travel schedule. At this point, an average of one-third of the students decide that they will not participate in the trip (in which case, STC and the student agree to give the 10% down payment to a charitable cause). This takes on average 50 minutes per student.

 

All employees work 8 hours per day.

 

How many students does STC have to contact each day through its call center to fill, on average, its target of 120 students per season (2 students per day)?

  1. A) 5 students/day
  2. B) 15 students/day
  3. C) 35 students/day
  4. D) 120 students/day

 

 

Answer:  B

Explanation:  Step 1 passes 100%. Step 2 passes 20% (40% pass × 50% choose to continue). Step 3 passes 100%. Step 4 passes 67% (2/3 of students at this step choose to continue). Use the formula Number of good units per day = Q/process yield. Q = 2/(1 × .2 × 1 × .67) = 14.93 rounded up to 15.

Difficulty: 3 Hard

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Apply

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

59) The salesforce of Small Travel Company (STC) is selling cultural immersion programs to U.S. college students that allow them to spend 3 months in Europe.

 

STC advertises in various college newspapers, as well as via social media. Potential customers fill out an online application form expressing their interest in more information about this experience. The form also includes their phone number for follow-up discussion, which sometimes, but not always, leads to the customer purchasing the package (more details below).

 

On 60 consecutive days in the winter, STC’s employees work hard to sell these programs to elite university students. The goal of the company is to sell, on average, two packages per day, leading to a total of 120 sold packages. The sales process works in four steps:

 

  1. One salesperson reaches out to the potential customer by phone in order to put together a full profile of the customer, including skills and location preferences (Germany, Italy, France, etc.). The call takes on average 20 minutes. After the call, each profile is forwarded to a language teacher.
  2. The language teacher looks at the student’s profile and also organizes a quick follow-up call. This takes, on average, 40 minutes per profile. The teacher rejects 60% of the profiles as the student would not have the language skills to benefit from an STC trip. From the remaining 40% of the profiles, half tell the teacher that they are no longer interested in participating. The teacher then forwards the remaining profiles to the STC accountant.
  3. STC’s accountant then contacts the student to make a 10% down payment. This takes about 20 minutes per customer.
  4. Finally, the teacher’s assistant contacts the customer to confirm the trip and start working on a travel schedule. At this point, an average of one-third of the students decide that they will not participate in the trip (in which case, STC and the student agree to give the 10% down payment to a charitable cause). This takes on average 50 minutes per student.

 

All employees work 8 hours per day.

 

Which resource is the bottleneck?

  1. A) The salesperson
  2. B) The language teacher
  3. C) The accountant
  4. D) The teacher’s assistant

 

 

Answer:  B

Explanation:  Calculation of implied utilization

 

Resource Yield   Demand   Capacity   Implied utilization  
Salesperson 1.00   15/1 = 15   1/20 × 60 × 8 = 24 students per day   15/24 = 0.625
Language teacher 0.20   3/0.2 = 15   1/40 × 60 × 8 = 12 students per day   15/12 = 1.25
Accountant 1.00   3/1 = 3   1/20 × 60 × 8 = 24 students per day   3/24 = 0.125
Teacher’s assistant 0.67   2/0.67 = 3   1/50 × 60 × 8 = 9.6 students per day   3/9.6 = 0.3125

 

 

Yield is based on “1 good output.” Demand is the quantity which must be started at that resource. The Demand formula is “number of desired units” / “yield for that resource,” and we will work backwards starting at teacher’s assistant.  The goal is “2 good outputs” per day exiting the process at teacher’s assistant. 2/0.67 = 3 applications that must be started by the teacher’s assistant per day, in order to result in 2 good outputs. This demand is placed in the numerator of the previous resource, the accountant, and so on, backward to the salesperson. Implied utilization is demand/capacity. The highest implied utilization is the language teacher.

Difficulty: 3 Hard

Topic:  Attrition Losses, Yields, and Scrap Rates

Learning Objective:  05-04 Compute the yield of a process and be able to analyze a process flow with yield loss.

Bloom’s:  Apply

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation

 

 

60) Consider the following four-step assembly operation with quality problems. All resources are staffed by one employee.

 

  1. The first resource has a processing time of 5 minutes per unit.
  2. The second resource has a processing time of 6 minutes per unit.
  3. The third resource has a processing time of 3 minutes per unit. With a 30% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the first, second, and third resources are repeated. You can assume that (a) rework always succeeds (i.e., a unit going through the rework loop will always work after the third resource) and (b) the processing times for units in rework are the same as for regular units.
  4. The fourth resource has a processing time of 4 minutes per unit.

 

Which resource in the process is the bottleneck?

  1. A) The first resource
  2. B) The second resource
  3. C) The third resource
  4. D) The fourth resource

 

Answer:  B

Explanation:

    Good   Rework   Total per unit   IU per minute
  Resource 1 0.7 × 5   0.3 × [5 + 5]   3.5 + 3 = 6.5   6.5/1 = 6.5
WL = Resource 2 0.7 × 6   0.3 × [6 + 6]   4.2 + 3.6 = 7.8   7.8/1 = 7.8
  Resource 3 0.7 × 3   0.3 × [3 + 3]   2.1 + 1.8 = 3.0   3.9/1 = 3.9
  Resource 4 1.00 × 4           4           4/1 = 4

 

 

The second resource is the bottleneck since it has the highest implied utilization.

Difficulty: 3 Hard

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Analyze

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation

 

 

61) Consider the following four-step assembly operation with quality problems. All resources are staffed by one employee.

 

  1. The first resource has a processing time of 5 minutes per unit.
  2. The second resource has a processing time of 6 minutes per unit.
  3. The third resource has a processing time of 3 minutes per unit. With a 30% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the first, second, and third resources are repeated. You can assume that (a) rework always succeeds (i.e., a unit going through the rework loop will always work after the third resource) and (b) the processing times for units in rework are the same as for regular units.
  4. The fourth resource has a processing time of 4 minutes per unit. What is the capacity of the process (in units per hour)?

 

What is the capacity of the process (in units per hour)?

  1. A) 6.00
  2. B) 7.70
  3. C) 8.90
  4. D) 20.10

 

Answer:  B

Explanation:

    Good   Rework   Total per unit   IU per minute
  Resource 1 0.7 × 5   0.3 × [5 + 5]   3.5 + 3 = 6.5   6.5/1 = 6.5
WL = Resource 2 0.7 × 6   0.3 × [6 + 6]   4.2 + 3.6 = 7.8   7.8/1 = 7.8
  Resource 3 0.7 × 3   0.3 × [3 + 3]   2.1 + 1.8 = 3.0   3.9/1 = 3.9
  Resource 4 1.00 × 4           4           4/1 = 4

 

 

The second resource is the bottleneck since it has the highest implied utilization.

 

The capacity is 1/7.8 = 0.1282 unit per minute, × 60 = 7.7 units per hour.

Difficulty: 3 Hard

Topic:  Rework

Learning Objective:  05-05 Analyze a process with rework.

Bloom’s:  Analyze

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation

 

 

62) Consider a process that has multiple flow units with different demand rates and different paths through the process flow diagram. Consider the following statements:

 

 

  1. The resource with the largest total demand rate is the bottleneck.

 

  1. The implied utilization can never be bigger than 100%.

 

III. The resource that has the highest implied utilization is the bottleneck.

 

 

Which of the following choices identifies the correct statement(s)?

  1. A) III only
  2. B) I and II
  3. C) I and III
  4. D) II only

 

Answer:  A

Explanation:  Implied utilization can be higher than 100%. Total demand and capacity at the resource must be taken into account in determining where the bottleneck is located. The resource with the highest implied utilization is the bottleneck.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

63) GV is a small accounting firm supporting wealthy individuals in their preparation of annual income tax statements. Every December, GV sends out a short survey to its customers, asking for the information required for preparing tax statements. Based on 50 years of experience, GV categorizes its cases into the following two groups:

 

  • Group 1 (new customers): 20 percent of cases
  • Group 2 (repeat customers): 80 percent of cases

 

This year, there are 35 income tax statements arriving each week.

 

In order to prepare the income tax statement, GV has three resources, or employees. The following activities are carried out by employees:

 

  • An administrative support person processes every tax statement.
  • A senior accountant (the owner of GV) processes only tax statements for new customers.
  • A junior accountant processes tax statements for repeat customers.

 

The administrative support person can process 40 statements per week. The senior accountant can process 10 statements per week. The junior accountant can process 30 statements per week; these statements can be completed more quickly given past information on file about the clients.

 

What is the implied utilization for the junior accountant?

  1. A) 33.3%
  2. B) 66.7%
  3. C) 83.3%
  4. D) 93.3%

 

Answer:  D

Explanation:  Implied utilization is Total demand at the resource/Capacity at the resource. Demand for the junior accountant is 80% of the 35 statements arriving weekly, or 28 statements. The capacity is 30 statements per week. IU = 28/30 = 93.3%.

Difficulty: 3 Hard

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Apply

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

64) GV is a small accounting firm supporting wealthy individuals in their preparation of annual income tax statements. Every December, GV sends out a short survey to its customers, asking for the information required for preparing tax statements. Based on 50 years of experience, GV categorizes its cases into the following two groups:

 

  • Group 1 (new customers): 20 percent of cases
  • Group 2 (repeat customers): 80 percent of cases

 

This year, there are 35 income tax statements arriving each week.

 

In order to prepare the income tax statement, GV has three resources, or employees. The following activities are carried out by employees:

 

  • An administrative support person processes every tax statement.
  • A senior accountant (the owner of GV) processes only tax statements for new customers.
  • A junior accountant processes tax statements for repeat customers.

 

The administrative support person can process 40 statements per week. The senior accountant can process 10 statements per week. The junior accountant can process 30 statements per week; these statements can be completed more quickly given past information on file about the clients.

 

Which resource is the bottleneck?

  1. A) The administrative support person
  2. B) The senior accountant
  3. C) The junior accountant
  4. D) There is no bottleneck

 

Answer:  C

Explanation:  The bottleneck is the resource with the highest implied utilization. Administrative support person processes all 35 statements, and has capacity for 40.  IU = 35 /40 = 87.5%. Senior accountant IU = (0.2 × 35)/10 = 70%. Junior accountant IU = (0.8 × 35)/30 = 93.3%. Therefore, the junior accountant is the bottleneck resource.

Difficulty: 3 Hard

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Analyze

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

 

 

65) Which of the following statements about the concepts of “labor utilization” and “implied utilization” is correct?

  1. A) Labor utilization is above 100% if the process is capacity constrained.
  2. B) Labor utilization is above 100% if the process is demand constrained.
  3. C) If the process is capacity constrained, then implied utilization is bigger than the labor utilization.
  4. D) If the process is demand constrained, then implied utilization is bigger than the labor utilization.

 

Answer:  C

Explanation:  Labor utilization cannot be above 100%. Implied utilization can exceed 100%, as it includes additional information about how much demand exceeds capacity of the resource. In a capacity-constrained process, implied utilization will be bigger than utilization.

Difficulty: 2 Medium

Topic:  How to Find the Bottleneck in a Process with Multiple Flows

Learning Objective:  05-02 Compute implied utilization to find the bottleneck in a general process flow.

Bloom’s:  Understand

AACSB:  Reflective Thinking

Accessibility:  Keyboard Navigation; Screen Reader Compatible

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