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4.1 Production Processes Practice Questions

Question 1

13 marks

Text 2 — Grimsett Cycles Ltd

Grimsett Cycles Ltd builds bicycles in a workshop in Sheffield. It employs 18 skilled frame builders. At present every bicycle is made to order: the customer chooses the frame size, the paint colour and the components, and one builder completes the whole bicycle before starting the next one.

Orders have risen every year since the business opened, and some customers now wait eleven weeks for their bicycle. The owner, Agnes Pilling, is considering introducing a standard range of three models — the Fell, the Moor and the Trail — which would be made in batches of 50. New machinery would cut and weld the frames for each batch. Custom bicycles would still be built to order for customers who want them.

Agnes is concerned that the average cost of building each bicycle has risen every year.

Table 1 Bicycles produced by Grimsett Cycles Ltd and average cost per bicycle, 2022–2025

Year Bicycles produced Average cost per bicycle
2022 640 £410
2023 712 £425
2024 788 £446
2025 864 £472
(a)

Identify two characteristics of job production.

(b)

Using Table 1, calculate the percentage increase in the number of bicycles produced by Grimsett Cycles Ltd between 2022 and 2025.

Answer: ________ %

(c)

Analyse one benefit to Grimsett Cycles Ltd of making its standard range in batches.

(d)

Analyse two disadvantages to Grimsett Cycles Ltd of continuing to use job production for all of its bicycles.

Disadvantage 1:

Disadvantage 2:

Question 2

14 marks

Text 2 — Hollowgate Ceramics Ltd

Hollowgate Ceramics Ltd makes ceramic mugs, plates and bowls at a factory in Staffordshire. It employs 85 staff. Most of its output is made in batches: a batch of 2000 plain white mugs may be followed by a batch of patterned mugs ordered by a hotel chain. The business also accepts one-off commissions, such as a complete dinner service designed for a single restaurant, which are made by hand by two skilled potters.

In 2023 the owner, Rosalind Teague, installed four robotic arms that apply glaze to the products, together with a computer system that controls the temperature of the kilns. The robotic arms can keep running overnight. Several members of staff needed a number of weeks of training before the new equipment could be run at full speed.

Table 1 Units produced and units rejected at Hollowgate Ceramics Ltd

Year Units produced Units rejected
2022 640 000 25 600
2023 712 000 21 360
(a)

Identify two characteristics of flow production.

(b)

Using Table 1, calculate the percentage increase in units produced at Hollowgate Ceramics Ltd between 2022 and 2023.

Answer: ............................ %

(c)

Analyse one advantage to Hollowgate Ceramics Ltd of making most of its output using batch production.

(d)

Analyse two ways in which installing the robotic arms and the computer system may affect production at Hollowgate Ceramics Ltd.

Way 1:

Way 2:

Question 3

6 marks
(a)

Which business is most likely to use job production?

  • A A business assembling identical televisions on a production line
  • B A business bottling 10 000 bottles of spring water each hour
  • C A business making a one-off sculpture for a town centre
  • D A business packing frozen pizzas for supermarkets
(b)

Which is a feature of flow production?

  • A Each product is finished before work on the next one begins
  • B Each product is made to the individual requirements of a customer
  • C Workers each complete every stage of the product themselves
  • D Products move continuously from one stage of production to the next
(c)

Identify two ways in which a business could improve the efficiency of its production.

(d)

A factory makes garden planters using flow production. Table 1 shows information about one week's production.

Table 1

Production data for one week
Number of planters produced 12 000
Total fixed costs £18 000
Variable cost per planter £2.50

Calculate the average cost of producing one planter.

Answer: £ ______

Question 4

5 marks
(a)

Which is an example of batch production?

  • A A bakery making 500 white loaves and then 500 wholemeal loaves
  • B A factory assembly line continuously producing identical bottles of cola
  • C A shipyard building one cruise ship to a customer's own design
  • D A tailor making a suit measured for one customer
(b)

Which is a disadvantage of batch production?

  • A Every product must be made to a customer's individual design
  • B Machinery must be reset between batches, so production stops for a time
  • C Only one product can ever be made on the same equipment
  • D Workers must complete every stage of a product themselves
(c)

A business uses job production. Which is most likely to be true?

  • A It has a low cost per unit
  • B It makes large quantities of identical products
  • C It relies on highly skilled workers
  • D It uses an automated production line
(d)

Explain one advantage to a business of using flow production rather than job production.

Question 5

10 marks

Corran Moulding Ltd

Corran Moulding Ltd makes plastic garden chairs and tables in batches, switching its moulding machines between products and colours several times a week. It employs 40 people, 14 of whom lift finished items out of the moulds by hand and stack them for packing. This work is tiring, and some items are scratched or dropped.

The directors are considering installing robotic arms to remove and stack every item. The robots would cost £220 000, which the company would borrow. They could work through the night, and 6 of the 14 handling jobs would no longer be needed. The supplier has said the arms must be reprogrammed each time the moulds are changed.

Table 1 Average weekly figures

Now With robotic arms (forecast)
Items produced 6 000 8 400
Items scratched or damaged 180 30
(a)

Explain one advantage to a business of using automation in production.

(b)

Calculate the forecast percentage increase in the number of items produced each week if Corran Moulding Ltd installs the robotic arms.

Answer: ______ %

(c)

Analyse one advantage and one disadvantage to Corran Moulding Ltd of installing the robotic arms.

Advantage

Disadvantage