manufacturing first exam (combined flashcards)

machines, production facilities, employee amenities

the efficiency of production depends on how well the various __________, __________________, and ____________ are located in a plant

plant layout

a very critical part of running an efficient and cost-effective business

plant layout

technique of locating machines, processes, and plant services within the factory to achieve the right quantity and quality of output at the lowest possible cost of manufacturing

plant layout

ideally involves the allocation of space and arrangement of equipment in such a manner that overall operating costs are minimized

plant layout

its overall objective is to design a physical arrangement that most economically meets the required output - quantity and quality

plant layout

a systematic arrangement of physical facilities essential for producing goods, delivering services, grouping equipment, and operations in a factory for the greatest degree of efficiency

machinery, equipment, furniture, features that may not be quantifiable

plant layout involves the arrangement of physical facilities such as (4):

lowest, least

furniture, within the factory building in such a manner to have the quickest and most direct workflow of material at the __________ cost and with the ________ amount of handling in processing the product from the receipt of material to the shipment of the finished product

facilitating communication, improving staff safety

the plant layout includes the features of a layout that may not be immediately quantifiable, such as ______________ and ______________

highest, shortest

all work areas, production lines, material storage facilities, etc., should be designed to perform at the ___________ rate and the corresponding _________ cycle time

all

when designing, it is necessary to take into account _______ the functions within the business

needs, provisions

the design must include not only the ____________ of the present business levels, but should also have ____________ for future expansion

floor plan

plant layout is indicated on a ________________

floor plan

shows the distances between different plant features

product productivity, safety, quality

optimizing a plant's layout can improve __________________, ____________, and _________________

optimized

unnecessary materials handling efforts can be avoided when the plant layout is ________________

distances through which materials have to move, distances through which equipment have to move, distances through which operators have to move, types of handling equipment, energy required

Unnecessary materials handling efforts can be avoided when the plant layout is optimized. This is valid for; (5)

better or best functionality, streamline production, save and prevent unwanted costs

3 importance/objectives of manufacturing plant layout

close together

for better functionality, place necessary departments, such as the operating and recovery rooms, _____________

optimum relationship

an ideal plant layout should; provide the ____________ among output, floor area, and manufacturing process to eliminate downtime

flexible, efficient

an ideal plant layout should; ensure ___________ and _________ labor and operation

easy

an ideal plant layout should; provide _________ production flow

manpower

an ideal plant layout should; promote the effective utilization of _______________

convenience

an ideal plant layout should; employee's _____________

proficient communication

an ideal plant layout should; provide ______________ between workers and supervisors

natural light, ventilation

an ideal plant layout should; maximum exposure to _________________ and _________________

economical

an ideal plant layout should; make _______________ use of the building

static

an ideal plant layout should; ensuring material/product movement is not ______________

flexibility

an ideal plant layout should; consider _____________ for future workflow changes

manufacturing unit, trading unit, services centers and establishment, administrative unit

4 basic and general divisions/areas

product or line, process or functional, fixed position or location, combined or group

4 types of plant layout design in a manufacturing unit

product or line

manufacturing unit; all the machine tools or other items of equipment must be placed at the point or in one line demanded by the sequence of operations required of the products

product or line

manufacturing unit; the materials move from one workstation to another sequentially without any backtracking or deviation

product or line

manufacturing unit; in this arrangement, each following machine or section is arranged to perform the next operation performed by its preceding machine or section

product or line

manufacturing unit; there should be no points where one line crosses another

product or line

manufacturing unit; materials may be fed where required for assembly but not at one point

product or line

manufacturing unit; materials may be fed where required for assembly but not necessarily at one point

product or line

manufacturing unit; all the operations, including assembly and testing packing, must be included in the line

low cost

manufacturing unit; product or line layout advantage; ___________ of material handling due to straight and short routes and absence of backtracking

flow

manufacturing unit; product or line layout advantage; continuous __________ of work - no backtracking

inventory, work-in-progress

manufacturing unit; product or line layout advantage; lesser investment in ___________ and ___________

floor space

manufacturing unit; product or line layout advantage; optimum use of ______________

processing time, output

manufacturing unit; product or line layout advantage; shorter _______________ or quicker ________________

manufacturing

manufacturing unit; product or line layout advantage; lower cost of ______________ per unit

capital

manufacturing unit; product or line layout disadvantage; high initial ______________ investment in special-purpose machines

overhead charges

manufacturing unit; product or line layout disadvantage; heavy __________________

one machine

manufacturing unit; product or line layout disadvantage; breakdown of _________________, the whole production process is stopped

decreases

manufacturing unit; product or line layout disadvantage; if the output rate of one machine is slower than the other, the overall production rate ______________

product or line

manufacturing unit; useful for mass production of standardized products

product or line

manufacturing unit; useful for simple and repetitive manufacturing processes

product or line

manufacturing unit; useful for when operation time for different processes is more or less equal

product or line

manufacturing unit; useful for when there is reasonably stable and steady demand for the product

product or line

manufacturing unit; useful for when there is a continuous supply of materials and production materials

functional layout

other name for process layout

process

manufacturing unit; in this type of layout, machines of a similar type are arranged together in one place

process

manufacturing unit; is followed from the historical period and evolved from the handicraft method of production

process

manufacturing unit; the work has to be allocated to each department in such a way that no machines are chosen to do as many different jobs as possible or no such thing as a general-purpose machine

process

manufacturing unit; the distance between departments should be as short as possible to avoid long-distance movement of materials

process

manufacturing unit; all the similar machines are positioned together so that all the similar operations are performed at the same place

process

manufacturing unit; machines are arranged according to the nature or type of the operations or their functions

process

manufacturing unit; the departments should be in a sequence of operations

process

manufacturing unit; the arrangement should be convenient for inspection and supervision

process

manufacturing unit; is adopted when products are not standardized

process

manufacturing unit; is adopted when quantity produced is small or low-volume production

process

manufacturing unit; is adopted when there are frequent changes in the design and style of the product

process

manufacturing unit; is adopted when job shop type of work is done

process

manufacturing unit; is adopted when machines are very expensive

process

manufacturing unit; is suitable for job order production involving batch production and non-repetitive processes

lower

manufacturing unit; process layout advantages; ____________ initial capital investment in machines and equipment

does not

manufacturing unit; process layout advantages; breakdown of one machine _____________ result in a complete work stoppage

effective, specialized

manufacturing unit; process layout advantages; supervision can be more ______________ and ______________

greater

manufacturing unit; process layout advantages; there is __________ flexibility in the scope of expansion

backtracking

manufacturing unit; process layout disadvantages; material handling costs are high due to _____________

skilled labor

manufacturing unit; process layout disadvantages; more ______________ is required, resulting in higher costs

high

manufacturing unit; process layout disadvantages; work-in-progress inventory is _____________

storage

manufacturing unit; process layout disadvantages; needing greater __________ space

inspection

manufacturing unit; process layout disadvantages; more frequent ___________ is needed, which results in costly supervision

longer

manufacturing unit; process layout disadvantages; production time is _______________

bottlenecks

manufacturing unit; process layout disadvantages; ____________ occur due to more work in a queue and waiting for further operation

floor area

manufacturing unit; process layout disadvantages; more _____________ is required

fixed position or location

manufacturing unit; the major part of the material remains at a fixed position or at one location, and all accessories, materials, required tools, machinery, and other supporting equipment are brought to this location

project layout

other name for fixed position or location

fixed position or location

manufacturing unit; equipment labor and components are moved here

fixed position or location

manufacturing unit; all facilities are brought and arranged around one work center

fixed position or location

manufacturing unit; this layout is good for extremely large items manufactured in very small quantities and is highly preferable when the cost of moving a major piece of material is high

fixed position or location

manufacturing unit; is used in the boiler manufacturing factory, hydraulic and steam turbines, etc.

fixed position or location

manufacturing unit; used in the manufacture of bulky and heavy products such as locomotives, ships, boilers, generators, flyovers, and dams

fixed position or location

manufacturing unit; used in the construction of buildings, flyovers, and dams

capital

manufacturing unit; fixed position or location layout advantages; less ______________ - saves time and cost

movement

manufacturing unit; fixed position or location layout advantages; less material and worker ____________

cost

manufacturing unit; fixed position or location layout advantages; less production _____________

job design, operation sequence

manufacturing unit; fixed position or location layout advantages; flexible layout as changes in _______________ and ________________ can be easily incorporated

sequence of operations

manufacturing unit; fixed position or location layout advantages; adjustments can be made to meet the shortage of materials or absence of workers by changing the _____________

continuity

manufacturing unit; fixed position or location layout advantages; ensures ______________

production

manufacturing unit; fixed position or location layout disadvantages; ___________ period being very long

capital

manufacturing unit; fixed position or location layout disadvantages; _____________ investment is very heavy

very large

manufacturing unit; fixed position or location layout disadvantages; _____________ space is required to store materials and equipment near the product

confusion, conflicts

manufacturing unit; fixed position or location layout disadvantages; as several operations are often carried out simultaneously, there is possibly ____________ and _____________ among different workgroups

fixtures

manufacturing unit; fixed position or location layout disadvantages; complicated _________________

manpower

manufacturing unit; fixed position or location layout disadvantages; requires highly skilled _________________