,
,Ch01dIntroduction-3e-SId 12-15,d16/06,d06/04/07
Answer:dFlexibledautomationdisdandextensiondofdprogrammabledautomation.dAdflexibledautomateddsystemdisdc
apabledofdproducingdadvarietydofdpartsd(ordproducts)dwithdvirtuallydnodtimedlostdfordchangeoversdfromdoned part
dstyledtodthednext.dTheredisdnodlostdproductiondtimedwhiledreprogrammingdthedsystemdanddalteringdthedphysicald
setup.dAccordingly,dthedsystemdcandproducedvariousdmixesdanddschedulesdofdpartsdordproductsd insteaddofdrequ
iringdthatdtheydbedmadedindbatches.dThedfeaturesdofdflexibledautomationdared(1)dhighdinvestmentdfordadcustom-
engineereddsystem,d(2)dcontinuousdproductiondofdvariabledmixturesdofdproducts,d(3)dmediumdproductiondrates,d
andd(4)dflexibilitydtoddealdwithdproductddesigndvariations
1.10 Whatdisdcomputerdintegrateddmanufacturing?
Answer:dAsddefineddindthedtext,dcomputer-
integrateddmanufacturingd(CIM)ddenotesdthedpervasivedusedofdcomputerdsystemsdtoddesigndthedproducts,dpland
thedproduction,dcontroldthedoperations,danddperformdthedvariousdinformation-
processingdfunctionsdneededdindadmanufacturingdfirm.dTruedCIMdinvolvesdintegratingdalldofdthesedfunctionsdin
donedsystemdthatdoperatesdthroughoutdthedenterprise.
1.11 Whatdaredsomedofdthedreasonsdwhydcompaniesdautomatedtheirdoperations?dNinedreasonsdaredgivendindthedtext.d
Namedfive.
Answer:dThedreasonsdgivedindthedtextdared(1)dtodincreasedlabordproductivity,d(2)dtodreducedlabordcost,d(3)dtodmi
tigatedthedeffectsdofdlabordshortages,d(4)dtodreducedordeliminatedroutinedmanualdanddclericaldtasks,d(5)dtodimpro
vedworkerdsafety,d(6)dtodimprovedproductdquality,d(7)dtodreducedmanufacturingdleaddtime,d(8)dtodaccomplishdpr
ocessesdthatdcannotdbeddonedmanually,dandd(9)dtodavoiddthedhighdcostdofdnotdautomating.
1.12 Identifydthreedsituationsdindwhichdmanualdlabordisdpreferreddoverdautomation.
Answer:dThedfivedsituationsdlisteddindthedtextdaredthedfollowing:d(1)dThedtaskdisdtechnologicallydtooddifficultdtoda
utomate.d(2)dShortdproductdlifedcycle.d(3)dCustomizeddproduct.d(4)dTodcopedwithdupsdandddownsdinddemand.
(5)dTodreducedriskdofdproductdfailure.
1.13 Humandworkersdwilldbedneededdindfactorydoperations,devendindthedmostdhighlydautomateddoperations.dThedtext
didentifiesdatdleastdfourdtypes dofdworkdfordwhichdhumansdwilldbedneeded.dNamedthree.
Answer:dThedfourdtypesdofdworkdidentifieddindthedtextdared(1)dequipmentdmaintenance,d(2)dprogrammingdanddco
mputerdoperations,d(3)dengineeringdprojectdwork,dandd(4)dplantdmanagement.
1.14 WhatdisdthedUSAdPrinciple?dWhatddoesdeachdofdthedlettersdstanddfor?
Answer:dThedUSAdPrincipledisdadcommondsensedapproachdtodautomationdanddprocessdimprovementdprojects.d
Udmeansd“understanddthedexistingdprocess,”dSdstandsdford“simplifydthedprocess,”danddAdstandsdford“automatedd
thedprocess.”
1.15 Thedtextdlistsdtendstrategiesdfordautomationdanddprocessdimprovement.dIdentifydfivedofdthesedstrategies.
Answer:dThedtendstrategiesdlisteddindthedtextdared(1)dspecializationdofdoperations,d(2)dcombineddoperations,d(3)
dsimultaneousdoperations,d(4)dintegrationdofdoperations,d(5)dincreaseddflexibility,d(6)dimproved dmaterialdhandli
ngdanddstorage,d(7)don-
linedinspection,d(8)dprocessdcontroldanddoptimization,d(9)dplantdoperationsdcontrol,dandd(10)dcomputer-
integrateddmanufacturingd(CIM).
1.16 Whatdisdandautomationdmigrationdstrategy?
Answer:dAsddefineddindthedtext,dandautomationdmigrationdstrategydisdadformalizeddplandfordevolvingdthedmanufac
turingdsystemsduseddtodproducednewdproductsdasddemanddgrows.
1.17 Whatdaredthedthreedphasesdofdadtypicaldautomationdmigrationdstrategy?
Answer:dAsddefineddindthedtext,dthedthreedtypicaldphasesdaredthedfollowing:dPhased1:dManualdproductiondusingd
single-stationdmanneddcellsdoperatingdindependently.dPhased2:dAutomateddproductiondusingdsingle-
stationdautomateddcellsdoperatingdindependently.dPhased3:dAutomateddintegrateddproductiondusingdadmulti-
stationdautomateddsystemdwithdserialdoperationsdanddautomateddtransferdofdworkdunitsdbetweendstations.
2
,
,Ch01dIntroduction-3e-SId 12-15,d16/06,d06/04/07
Answer:dFlexibledautomationdisdandextensiondofdprogrammabledautomation.dAdflexibledautomateddsystemdisdc
apabledofdproducingdadvarietydofdpartsd(ordproducts)dwithdvirtuallydnodtimedlostdfordchangeoversdfromdoned part
dstyledtodthednext.dTheredisdnodlostdproductiondtimedwhiledreprogrammingdthedsystemdanddalteringdthedphysicald
setup.dAccordingly,dthedsystemdcandproducedvariousdmixesdanddschedulesdofdpartsdordproductsd insteaddofdrequ
iringdthatdtheydbedmadedindbatches.dThedfeaturesdofdflexibledautomationdared(1)dhighdinvestmentdfordadcustom-
engineereddsystem,d(2)dcontinuousdproductiondofdvariabledmixturesdofdproducts,d(3)dmediumdproductiondrates,d
andd(4)dflexibilitydtoddealdwithdproductddesigndvariations
1.10 Whatdisdcomputerdintegrateddmanufacturing?
Answer:dAsddefineddindthedtext,dcomputer-
integrateddmanufacturingd(CIM)ddenotesdthedpervasivedusedofdcomputerdsystemsdtoddesigndthedproducts,dpland
thedproduction,dcontroldthedoperations,danddperformdthedvariousdinformation-
processingdfunctionsdneededdindadmanufacturingdfirm.dTruedCIMdinvolvesdintegratingdalldofdthesedfunctionsdin
donedsystemdthatdoperatesdthroughoutdthedenterprise.
1.11 Whatdaredsomedofdthedreasonsdwhydcompaniesdautomatedtheirdoperations?dNinedreasonsdaredgivendindthedtext.d
Namedfive.
Answer:dThedreasonsdgivedindthedtextdared(1)dtodincreasedlabordproductivity,d(2)dtodreducedlabordcost,d(3)dtodmi
tigatedthedeffectsdofdlabordshortages,d(4)dtodreducedordeliminatedroutinedmanualdanddclericaldtasks,d(5)dtodimpro
vedworkerdsafety,d(6)dtodimprovedproductdquality,d(7)dtodreducedmanufacturingdleaddtime,d(8)dtodaccomplishdpr
ocessesdthatdcannotdbeddonedmanually,dandd(9)dtodavoiddthedhighdcostdofdnotdautomating.
1.12 Identifydthreedsituationsdindwhichdmanualdlabordisdpreferreddoverdautomation.
Answer:dThedfivedsituationsdlisteddindthedtextdaredthedfollowing:d(1)dThedtaskdisdtechnologicallydtooddifficultdtoda
utomate.d(2)dShortdproductdlifedcycle.d(3)dCustomizeddproduct.d(4)dTodcopedwithdupsdandddownsdinddemand.
(5)dTodreducedriskdofdproductdfailure.
1.13 Humandworkersdwilldbedneededdindfactorydoperations,devendindthedmostdhighlydautomateddoperations.dThedtext
didentifiesdatdleastdfourdtypes dofdworkdfordwhichdhumansdwilldbedneeded.dNamedthree.
Answer:dThedfourdtypesdofdworkdidentifieddindthedtextdared(1)dequipmentdmaintenance,d(2)dprogrammingdanddco
mputerdoperations,d(3)dengineeringdprojectdwork,dandd(4)dplantdmanagement.
1.14 WhatdisdthedUSAdPrinciple?dWhatddoesdeachdofdthedlettersdstanddfor?
Answer:dThedUSAdPrincipledisdadcommondsensedapproachdtodautomationdanddprocessdimprovementdprojects.d
Udmeansd“understanddthedexistingdprocess,”dSdstandsdford“simplifydthedprocess,”danddAdstandsdford“automatedd
thedprocess.”
1.15 Thedtextdlistsdtendstrategiesdfordautomationdanddprocessdimprovement.dIdentifydfivedofdthesedstrategies.
Answer:dThedtendstrategiesdlisteddindthedtextdared(1)dspecializationdofdoperations,d(2)dcombineddoperations,d(3)
dsimultaneousdoperations,d(4)dintegrationdofdoperations,d(5)dincreaseddflexibility,d(6)dimproved dmaterialdhandli
ngdanddstorage,d(7)don-
linedinspection,d(8)dprocessdcontroldanddoptimization,d(9)dplantdoperationsdcontrol,dandd(10)dcomputer-
integrateddmanufacturingd(CIM).
1.16 Whatdisdandautomationdmigrationdstrategy?
Answer:dAsddefineddindthedtext,dandautomationdmigrationdstrategydisdadformalizeddplandfordevolvingdthedmanufac
turingdsystemsduseddtodproducednewdproductsdasddemanddgrows.
1.17 Whatdaredthedthreedphasesdofdadtypicaldautomationdmigrationdstrategy?
Answer:dAsddefineddindthedtext,dthedthreedtypicaldphasesdaredthedfollowing:dPhased1:dManualdproductiondusingd
single-stationdmanneddcellsdoperatingdindependently.dPhased2:dAutomateddproductiondusingdsingle-
stationdautomateddcellsdoperatingdindependently.dPhased3:dAutomateddintegrateddproductiondusingdadmulti-
stationdautomateddsystemdwithdserialdoperationsdanddautomateddtransferdofdworkdunitsdbetweendstations.
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