,SolutionsjforjFundamentalsjofjModernjManufacturing,j4/ej(publishedjbyjWiley)jjMPGrooverj2010j06-
19-09
1 INTRODUCTION
ReviewjQuestions
1.1 Whatjarejthejdifferencesjbetweenjprimary,jsecondary,jandjtertiaryjindustries?jGivejanjexamplejofjeac
hjcategory.
Answer.jAjprimaryjindustryjisjonejthatjcultivatesjandjexploitsjnaturaljresources,jsuchjasjagriculturejorj
mining.jAjsecondaryjindustryjtakesjthejoutputsjofjprimaryjindustriesjandjconvertsjthemjtojconsumerja
ndjcapitaljgoods.jExamplesjofjsecondaryjindustriesjarejtextilesjandjelectronics.jAjtertiaryjindustryjisjinj
thejservicejsectorjofjthejeconomy.jExamplesjofjtertiaryjindustriesjarejbankingjandjeducation.
1.2 Whatjisjajcapitaljgood?jProvidejanjexample.
Answer.jCapitaljgoodsjarejthosejpurchasedjbyjcompaniesjtojproducejgoodsjorjprovidejservices.jExample
sjofjcapitaljgoodsjarejaircraftjandjconstructionjequipment.
1.3 Howjarejproductjvarietyjandjproductionjquantityjrelatedjwhenjcomparingjtypicaljfactories?
Answer.jGenerallyjproductionjquantityjisjinverselyjrelatedjtojproductjvariety.jAjfactoryjthatjpro
ducesjajlargejvarietyjofjproductsjwilljproducejajsmallerjquantityjofjeach.jAjcompanyjthatjproduce
sjajsinglejproductjwilljproducejajlargejquantity.
1.4 Definejmanufacturingjcapability.
Answer.jManufacturingjcapabilityjrefersjtojthejtechnicaljandjphysicaljlimitationsjofjajmanufacturingj
firmjandjeachjofjitsjplants.jThreejcategoriesjofjcapabilityjmentionedjinjthejtextjare
(1) technologicaljprocessingjcapability,j(2)jphysicaljsizejandjweight,jandj(3)jproductionjcapacity.
1.5 Namejthejthreejbasicjcategoriesjofjmaterials.
Answer.jThejthreejbasicjcategoriesjofjengineeringjmaterialsjarej(1)jmetals,j(2)jceramics,jandj(3)jpolymer
s.jAjfourthjcategory,jcomposites,jisjajnon-
homogeneousjmixturejofjthejotherjtypesjandjthereforejisjnotjajbasicjcategory.
1.6 Howjdoesjajshapingjprocessjdifferjfromjajsurfacejprocessingjoperation?
Answer.jAjshapingjprocessjchangesjthejgeometryjofjthejworkjmaterialj(machiningjorjforging).jAjsurf
acejprocessingjoperationjdoesjnotjalterjthejgeometry,jbutjinsteadjaltersjsurfacejofjthejworkj(paintingjo
rjplating).
1.7 Whatjarejtwojsubclassesjofjassemblyjprocesses?jProvidejanjexamplejprocessjforjeachjsubclass.
Answer.jThejtwojsubclassesjofjassemblyjprocessesjarej(1)jpermanentjjoiningjandj(2)jmechanicaljfastenin
g.jExamplesjofjpermanentjjoiningjincludejweldingjorjadhesivejbonding.jExamplesjofjmechanicaljfasteni
ngjincludejthreadedjfasteners,jsuchjasjnutsjandjbolts,jandjrivets.
1.8 Definejbatchjproductionjandjdescribejwhyjitjisjoftenjusedjforjmedium-
quantityjproductionjproducts.
Answer.jBatchjproductionjisjwherejgroups,jlots,jorjbatchesjorjmaterialsjorjpartsjarejprocessedjtogetherjt
hroughjthejmanufacturingjoperations.jAlljunitsjinjthejbatchjarejprocessedjatjajgivenjstationjbeforejthejgr
oupjproceedsjtojthejnextjstation.jInjajmediumjorjlowjquantityjproductionjsituation,jthejsamejmachinesja
rejusedjtojproducejmanyjtypesjofjproducts.jWheneverjajmachinejswitchesjfromjonejproductjtojanother,j
ajchangeoverjoccurs.jThejchangeoverjrequiresjthejmachinejsetupjtojbejtornjdownjandjsetjupjforjthejnewj
product.jBatchjproductionjallowsjthejchangeoverjtime
Excerptsjfromjthisjworkjmayjbejreproducedjbyjinstructorsjforjdistributionjonjajnot-for-
profitjbasisjforjtestingjorjinstructionaljpurposesjonlyjtojstudentsjenrolledjinjcoursesjforjwhichjthejtextbookjhasjbeenjadopted.jAnyjotherjreproductio
njorjtranslationjofjthisjworkjbeyondjthatjpermittedjbyjSectionsj107jorj108jofjthej1976jUnitedjStatesjCopyrightjActjwithoutjthejpermissionjofjthejcopy
rightjownerjisjunlawful.
1
,SolutionsjforjFundamentalsjofjModernjManufacturing,j4/ej(publishedjbyjWiley)jjMPGrooverj2010j06-
19-09
tojbejdistributedjacrossjajlargerjnumberjofjpartsjandjhencejreducejthejaveragejoperationjtimejperjpart.
1.9 Whatjisjthejdifferencejbetweenjajprocessjlayoutjandjajproductjlayoutjinjajproductionjfacility?
Answer.jAjprocessjlayoutjisjonejwherejthejmachineryjinjajplantjisjarrangedjbasedjonjthejtypejofjproces
sjitjperforms.jTojproducejajproductjitjmustjvisitjthejdepartmentsjinjthejorderjofjthejoperationsjthatjmustj
bejperformed.jThisjoftenjincludesjlargejtraveljdistancesjwithinjthejplant.jAjprocessjlayoutjisjoftenjusedj
whenjthejproductjvarietyjisjlargejthejoperationjsequencesjofjproductsjarejdissimilar.jAjproductjlayoutji
sjonejwherejthejmachineryjisjarrangedjbasedjonjthejgeneraljflowjofjthejproductsjthatjwilljbejproduced.jT
raveljdistancejisjreducedjbecausejproductsjwilljgenerallyjflowjtojthejnextjmachinejinjthejsequence.jAjp
roductjlayoutjworksjwelljwhenjalljproductsjtendjtojfollowjthejsamejsequencejofjproduction.
1.10 Namejtwojdepartmentsjthatjarejtypicallyjclassifiedjasjmanufacturingjsupportjdepartments.
Answer.jAjcommonjorganizationaljstructurejincludesjthejfollowingjthreejmanufacturingjsupportjde
partments:j(1)jmanufacturingjengineering,j(2)jproductionjplanningjandjcontrol,jandj(3)jqualityjcontr
ol.
MultiplejChoicejQuiz
Therejarej18jcorrectjanswersjinjthejfollowingjmultiplejchoicejquestionsj(somejquestionsjhavejmultiplejanswersjt
hatjarejcorrect).jTojattainjajperfectjscorejonjthejquiz,jalljcorrectjanswersjmustjbejgiven.jEachjcorrectjanswerjisjwo
rthj1jpoint.jEachjomittedjanswerjorjwrongjanswerjreducesjthejscorejbyj1jpoint,jandjeachjadditionaljanswerjbeyo
ndjthejcorrectjnumberjofjanswersjreducesjthejscorejbyj1jpoint.jPercentagejscorejonjthejquizjisjbasedjonjthejtotaljnu
mberjofjcorrectjanswers.
1.1 Whichjofjthejfollowingjindustriesjarejclassifiedjasjsecondaryjindustriesj(threejcorrectjanswers):j(a)jbev
eragesj(b)jfinancialjservices,j(c)jfishing,j(d)jmining,j(e)jpowerjutilities,j(f)jpublishing,jandj(g)jtransport
ation?
Answer.j(a),j(e),jandj(f).
1.2 Miningjisjclassifiedjinjwhichjonejofjthejfollowingjindustryjcategories:j(a)jagriculturaljindustry,j(b)jman
ufacturingjindustry,j(c)jprimaryjindustry,j(d)jsecondaryjindustry,j(e)jservicejindustry,jorj(f)jtertiaryjind
ustry?
Answer.j(c).
1.3 InventionsjofjthejIndustrialjRevolutionjincludejwhichjonejofjthejfollowing:j(a)jautomobile,j(b)jcan
non,j(c)jprintingjpress,j(d)jsteamjengine,jorj(e)jsword?
Answer.j(d).
1.4 Ferrousjmetalsjincludejwhichjofjthejfollowingj(twojcorrectjanswers):j(a)jaluminum,j(b)jcastjiron,
(c)jcopper,j(d)jgold,jandj(e)jsteel?
Answer.j(c)jandj(e).
1.5 Whichjonejofjthejfollowingjengineeringjmaterialsjisjdefinedjasjajcompoundjcontainingjmetallicjandj
nonmetallicjelements:j(a)jceramic,j(b)jcomposite,j(c)jmetal,jorj(d)jpolymer?
Answer.j(a).
1.6 Whichjofjthejfollowingjprocessesjstartjwithjajmaterialjthatjisjinjajfluidjorjsemifluidjstatejandjsolidifi
esjthejmaterialjinjajcavityj(twojbestjanswers):j(a)jcasting,j(b)jforging,j(c)jmachining,j(d)jmolding,j(e
)jpressing,jandj(f)jturning?
Answer.j(a)jandj(d).
Excerptsjfromjthisjworkjmayjbejreproducedjbyjinstructorsjforjdistributionjonjajnot-for-
profitjbasisjforjtestingjorjinstructionaljpurposesjonlyjtojstudentsjenrolledjinjcoursesjforjwhichjthejtextbookjhasjbeenjadopted.jAnyjotherjreproductio
njorjtranslationjofjthisjworkjbeyondjthatjpermittedjbyjSectionsj107jorj108jofjthej1976jUnitedjStatesjCopyrightjActjwithoutjthejpermissionjofjthejcopy
rightjownerjisjunlawful.
2
, SolutionsjforjFundamentalsjofjModernjManufacturing,j4/ej(publishedjbyjWiley)jjMPGrooverj2010j06-
19-09
1.7 Particulatejprocessingjofjmetalsjandjceramicsjinvolvesjwhichjofjthejfollowingjstepsj(twojbestjanswer
s):j(a)jadhesivejbonding,j(b)jdeformation,j(c)jforging,j(d)jmaterialjremoval,j(e)jmelting,j(f)jpressing,ja
ndj(g)jsintering?
Answer.j(f)jandj(g).
1.8 Deformationjprocessesjincludejwhichjofjthejfollowingj(twojcorrectjanswers):j(a)jcasting,j(b)jdril
ling,j(c)jextrusion,j(d)jforging,j(e)jmilling,j(f)jpainting,jandj(g)jsintering?
Answer.j(c)jandj(d).
1.9 Whichjonejofjthejfollowingjisjajmachinejusedjtojperformjextrusion:j(a)jforgejhammer,j(b)jmillingjmac
hine,j(c)jrollingjmill,j(d)jpress,j(e)jtorch?
Answer.j(d).
1.10 High-
volumejproductionjofjassembledjproductsjisjmostjcloselyjassociatedjwithjwhichjonejofjthejfollowing
jlayoutjtypes:j(a)jcellularjlayout,j(b)jfixedjpositionjlayout,j(c)jprocessjlayout,jorj(d)jproductjlayout?
Answer.j(d).
1.11 Ajproductionjplanningjandjcontroljdepartmentjaccomplishesjwhichjofjthejfollowingjfunctionsjinjitsjrolej
ofjprovidingjmanufacturingjsupportj(twojbestjanswers):j(a)jdesignsjandjordersjmachinejtools,
(b)jdevelopsjcorporatejstrategicjplans,j(c)jordersjmaterialsjandjpurchasedjparts,j(d)jperformsjqualityjins
pections,jandj(e)jschedulesjthejorderjofjproductsjonjajmachine?
Answer.j(c)jandj(e).
Excerptsjfromjthisjworkjmayjbejreproducedjbyjinstructorsjforjdistributionjonjajnot-for-
profitjbasisjforjtestingjorjinstructionaljpurposesjonlyjtojstudentsjenrolledjinjcoursesjforjwhichjthejtextbookjhasjbeenjadopted.jAnyjotherjreproductio
njorjtranslationjofjthisjworkjbeyondjthatjpermittedjbyjSectionsj107jorj108jofjthej1976jUnitedjStatesjCopyrightjActjwithoutjthejpermissionjofjthejcopy
rightjownerjisjunlawful.
3