41 PRODUCTION LINES

Review Questions
41.1 What is a production line? Answer. A production line is a sequence of
workstations at which individual tasks are accomplished on each work unit as it
moves from one station to the next to progressively make the product.
41.2 What is the difference between a batch model production line and a mixed
model production line?
Answer. Both lines are used to make multiple product types. A batch model line
produces the different products in batches, with a setup changeover between the
products. A mixed model line produces different products simultaneously.
41.3 What are the advantages of a mixed model line over a batch model line for
producing different product styles? Answer. Advantages of the mixed model line
include the following: (1) no downtime between the different models due to line
changeovers; (2) production rates can be matched to demand rates for the different
models, and thus (3) inventory fluctuations can be avoided in which there are high
inventories of some models while there are stock-outs of other models.
41.4 What are some of the limitations of a mixed model line compared to a batch
model line? Answer. Limitations of a mixed model line include (1) line balancing
problem is more complex, (2) scheduling the models is more difficult, and (3)
getting the right parts to each workstation is more difficult because more parts are
involved.
41.5 Describe how manual methods are used to move parts between workstations
on a production line.
Answer. The manual methods include (1) the work units are simply passed by hand
along a flat worktable from one station to the next, (2) work units are collected in
boxes and then passed between stations, and (3) the work units are pushed along
an non-powered conveyor between stations.
41.6 Briefly define the three types of mechanized workpart transfer systems used in
production lines.
Answer. The three work transfer systems are (1) continuous transfer, in which parts
move on a conveyor at a steady speed; (2) synchronous transfer, in which parts all
move simultaneously from station-to-station with a stop-and-go action; and (3)
asynchronous transfer, in which parts move independently between stations with a
stop-and-go action.
41.7 Why are parts sometimes fixed to the conveyor in a continuous transfer
system in manual assembly? Answer. Because the parts are big and/or heavy and
cannot be conveniently removed by a human worker.
41.8 Why must a production line be paced at a rate higher than that required to
satisfy the demand for the product? Answer. Because all production lines will suffer
a certain amount of nonproductive time due to reliability problems.

41.9 What are the reasons why the number of workers cannot be determined simply
from the ratio Twc/Tc? Answer. The reasons are (1) line balancing losses and (2)
repositioning losses to move either the work units or the workers.
41.10 Why is the line balancing problem on an automated transfer line not as
difficult as it is on a manual assembly line? Answer. The line balancing problem on
an automated transfer line is not as difficult because the operations performed at
each workstation are usually simpler than tasks performed on a manual assembly
line, and there are often fewer stations on an automated line.
41.11 Repositioning time on a synchronous transfer line is known by a different
name; what is that name? Answer. The repositioning time is called the transfer time;
it is the time to move parts from one station to the next.
41.12 Why are single station assembly cells generally not suited to high production
jobs? Answer. The entire work cycle is performed at one station, so single station
cells usually operate at relatively slow production rates.
41.13 What are some of the reasons for downtime on a machining transfer line?
Answer. Reasons for downtime on a machining transfer line include tool changes,
sudden mechanical and electrical failures, and gradual normal wear and tear on the
equipment.

Multiple Choice Quiz

There is a total of 10 correct answers in the following multiple choice questions
(some questions have
multiple answers that are correct). To attain a perfect score on the quiz, all correct
answers must be given. Each correct answer is worth 1 point. Each omitted answer
or wrong answer reduces the score by 1 point, and each additional answer beyond
the correct number of answers reduces the score by 1 point. Percentage score on
the quiz is based on the total number of correct answers.
41.1 Batch model lines are most suited to which one of the following production
situations: (a) job shop, (b) mass production, or (c) medium production? Answer. (c).
41.2 Manual methods of workpart transfer are closest to which one of the following
mechanized methods of transfer: (a) asynchronous, (b) continuous, or (c)
synchronous? Answer. (a).
41.3 Precedence constraints are best described by which of the following (one best
answer): (a) launching sequence in a mixed model line, (b) limiting value of the sum
of element times that can be assigned to a worker or station, (c) order of
workstations along the line, or (d) sequence in which the work elements must be
done? Answer. (d).
41.4 Which of the following phrases are most appropriate to describe the
characteristics of tasks that are performed at automated workstations (three best
answers): (a) complex, (b) consists of multiple work elements, (c) involves a single
work element, (d) involves straight-line motions, (e) requires sensory capability, and
(f) simple? Answer. (c), (d), and (f).
41.5 The transfer line is most closely associated with which one of the following
types of production operations: (a) assembly, (b) automotive chassis fabrication, (c)
machining, (d) pressworking, or (e) spotwelding? Answer. (c). 41.6 A dial indexing
machine uses which one of the following types of workpart transfer: (a)
asynchronous, (b) continuous, (c) parts passed by hand, or (d) synchronous?
Answer. (d).
41.7 The line efficiency (proportion uptime) on an automated line can be increased
by which of the following approaches (two correct answers): (a) improving the
reliability of each workstation on the line, (b) increasing the number of stations on
the line, (c) reducing the cycle time Tc, and (d) reducing the average downtime Td?
Answer. (a) and (d).