Introduction,;to,;DeGarmo’s,;Materials,;and,;Processes,;in,;Manufacturing
Review,;Questions
1. The,;availability,;and,;cost,;of,;manufactured,;products,;are,;an,;important,;part,;of,;our,;cost,;o
f,;living,;and,;the,;real,;wealth,;of,;the,;nation., ; Thus,,;reducing,;the,;cost,;of,;producer,;and,;consu
mer,;goods,;improves,;the,;productivity,;while,;holding,;down,;inflation,,;thereby,;improving,;th
e,;general,;standard,;of,;living.
2. This,;is,;true,;if,;you,;consider,;that,;everyone,;who,;uses,;the,;output,;from,;a,;process,,;inclu
ding,;all,;the,;intermediate,;steps,,;is,;a,;customer., ; The,;operator,;of,;the,;next,;process,;is,;the,;user,;an
d,;customer,;of,;the,;proceeding,;process., ; In,;fact,,;some,;companies,;identify,;two,;customers,,;
the,;external,;customer,;who,;buys,;the,;finished,;product,;and,;the,;internal,;customer,,;who,;buil
ds,;the,;product,;one,;-,;i.e.,,;the,;people,;who,;work,;in,;the,;manufacturing,;system.
3. Job,;shop,;-
,;an,;injection,;mold,;manufacturing ,;shop,,;the,;shop,;at ,;a,;large,;university,;that ,;produces,;researc
h,;equipment,;and,;apparatus., ; Job,;shops,;are,;capable,;of,;producing,;products,;with,;great,;variet
y, ,;typically,;employing,;highly,;skilled,;workers.
Flow,;shop,;–
,;automobile,;assembly. ,;Flow,;shops,;are,;usually,;laid,;out ,;so ,;that ,;specific,;products,;pass ,;thr
ough,;a,;series,;of,;operations,;with,;no,;backflow., ; The,;product,;range,;is,;limited,,;production,;
volume,;is,;large,;and,;labor,;skill,;is,;lower,;than,;in,;job,;shops.
Project,;shop,;–,;diesel-
electric,;locomotive,;production,;facility., ; The,;end,;product,;is,;very,;large,;and,;so,;many,;mac
hines,,;tools,;and,;people,;come,;to,;the,;product,;to,;produce,;it,;at,;a,;relatively,;fixed,;location.
The,;Subway,;sandwich,;shop,;would,;be,;a,;flow,;shop.
4. In,;the,;context,;of,;manufacturing,,;a,;manufacturing,;system,;is,;a,;collection,;of,;men,,;ma
chine,;tools,,;and,;material-
moving,;systems,,;collected,;together,;to,;accomplish,;specific,;manufacturing,;or,;fabrication,;
sequences,,;resulting,;in,;components,;or,;end,;products., ; The,;manufacturing,;system,;is,;back
ed,;up,;by,;and,;supported,;by,;the,;production,;system,,;which,;includes,;functions,;like,;control,;
of,;quality,,;inventory,,;production,,;and,;manpower,,;as,;well,;as,;scheduling,,;planning,;and,;the,;
like., ; Within,;the,;manufacturing,;system,,;there,;will,;be,;machine,;tools,,;which,;can,;perfor
m,;jobs,;or
5. No.,;The,;cutting,;tool,;is,;the,;implement,;that,;does,;the,;cutting., ; It,;contains,;the,;cutting,;e
dge,;and,;is,;used,;in,;the,;machine,;tool., ; The,;machine,;tool,;drives,;the,;cutting,;tool,;through,;th
e,;work,;material.
6. The,;basic,;manufacturing,;processes,;are:,;casting,;or,;molding,,;forming,,;(heat),;t
reating,,;metal,;removal,,;finishing,,;joining,;(welding),,;assembly,,;and,;inspection.
1
,7. Casting,;could,;be,;used,,;provided,;the,;material,;can,;be,;melted,;and,;poured,;in,;the,;appro
priate,;process.,;By,;casting,,;the,;desired,;shaped,;in,;final,;or,;near-
final,;form, ,;could,;be,;obtained.,;This,;greatly,;reduces,;the,;necessity,;for,;machining,;the,;hard-
to-
machine,;metal.,;Less,;machining,;is,;needed,;when,;the,;raw,;material,;shape,;is,;close,;to,;the,;fini
shed,;part,;size,;and,;shape,;(called,;near,;net,;shape,;casting)., ; The,;part,;could,;also,;be,;made,;in,;
simpler,;segments,;and,;assembled,;or,;joined.
8. The,;wax,;pattern,;is,;melted,;and,;removed,;as,;a,;liquid., ; Any,;remaining,;wax,;is,;then,;
vaporized,;when,;the,;mold,;is,;heated,;in,;preparation,;for,;the,;pour.
9. A,;relief-
image,;is,;the,;cavity,;in,;the,;die,;that,;the,;work,;material,;is,;deformed,;into,;when,;the,;die,;is,;pres
sed,;into,;the,;workpiece., ; Material,;on,;the,;workpiece,;moving,;into,;the,;cavity,,;―concave,‖,;of,;t
he,;die,;results,;in,;the,;raised,,;―convex,‖,;part,;of,;the,;medal,;surface.
10. Trains,;stop,;at,;the,;station,;to,;load,;and,;unload,;people,;and,;materials.,;In,;an,;assembly,;line,,;p
roducts,;stop,;at,;stations,;to,;take,;on,;materials,;or,;have,;operations,;performed,;on,;them.
11. False.,;Storage,;is,;very,;expensive,;because,;time,;costs,;the,;company,;money., ; It,;is,;e
xpensive,;to,;keep,;track,;of,;stored,;materials, ,;to,;put,;them,;into,;storage,,;to,;get,;them,;back,;fro
m,;storage,,;to,;damage,;them,;as,;a,;result,;of,;excessive,;handling,,;and,;so,;on., ; More,;impor
tantly, ,;storage,;usually,;adds,;no,;value,;-,;very,;few,;items,;appreciate,;on,;the,;shelf.
12. For,;the,;simple,,;conventional,;paper,;clip,,;forming,;processes,;are,;first,;used,;to,;make,;and,;c
oat,;wire,,;which,;is,;then,;cut,;to,;length,;and,;formed,;in,;three,;bending,;operations.
13. Tools,;are,;used,;to,;hold,,;cut,,;shape,,;or,;form,;the,;unfinished,;product.,;Common,;hand,;to
ols,;include,;the,;saw,,;hammer,,;screwdriver,,;chisel,,;punch,,;sandpaper,,;drill, ,;clamp,,;file,,;tor
ch,,;and,;grindstone., ; Basically,,;machines,;are,;mechanized,;versions,;of,;such,;hand,;tools,;an
d,;are,;called,;cutting,;tools.,;Some,;examples,;of,;tools,;for,;cutting,;are,;drill,;bits,,;reamers,,;sing
le-
point,;turning,;tools,,;milling,;cutters,,;saw,;blades,,;broaches,,;and,;grinding,;wheels.,;Noncutti
ng,;tools,;for,;forming,;include,;extrusion,;dies,,;punches,,;and,;molds.,;Tools,;also,;include,;wor
kholders,,;jigs,,;and,;fixtures.,;These,;tools,;and,;cutting,;tools,;are,;generally,;referred,;to,;as,;the,;
tooling,,;which,;usually,;must,;be,;considered,;(purchased),;separate,;from,;machine,;tools.
14. Inefficient,;is,;a,;relative,;term,;here.,;If,;we,;can,;eliminate,;machining,,;we,;can,;save,;the,;tim
e,;and,;the,;money. , ; Machining,;processes,;are,;generally,;those,;which,;give,;the,;part,;its,;final,;si
ze,,;shape,,;and,;surface,;finish,;and,;add,;value,;to,;the,;part., ; Because,;they,;do,;not,;produce,;the,;s
hape,;and,;size,;in,;bulk,,;but,;rather,;by,;localized,;action,;they,;may,;not,;be,;as,;efficient,;as,;formin
g,;and,;casting,;processes., ; Cutting,;tool,;and,;workholding,;tooling,;expenses,;may,;also,;be,;red
uced,,;since,;the,;same,;tool,;can,;work,;on,;many,;different,;products.
15. Figure,;1-1,;and,;figure,;1-
16,;both,;show,;life,;cycle,;progressions., ; For,;an,;audiocassette,;tape,,;it,;went,;to,;a,;commodit
y,;product,,;and,;is,;now,;in,;decline,;as,;CD‘s,;are,;taking,;over.,;We,;will,;know,;that,;it,;is,;in,;seve
re,;decline,;when,;the,;new,;autos,;no,;longer,;offer,;cassette,;players.
2
, 16. The,;cost,;to,;manufacture,;a,;typical,;manufactured,;product,;is,;20%,;-
,;30%,;of,;the ,;selling,;price.,;For,;the,;mass,;produced,;product ,;at ,;the,;lower,;end,;of,;this,;range,;
the,;manufacturing,;cost,;is,;$0.20., ; These,;20,;cents,;includes,;material,;and,;processing,;costs
.,;Processing,;includes,;assembly,;in,;addition,;to,;producing,;the,;components., ; Since,;the,;blade,;
cost,;involves,;forming,;the,;edge,;in,;a,;material,;it,;is,;probably,;the,;highest,;cost,;part,;of,;the,;ra
zor.
So,,;with,;20,;cents,;to,;cover,;materials,,;processing,;and,;assembly,,;and,;the,;blade,;the,;most,;e
xpensive,;individual,;part,;an,;estimate,;of,;2-
3,;cents,;is,;reasonable,;for,;the,;production,;of,;the,;high,;precision,;(in,;terms,;of,;edge),;blade.
The,;same,;kind,;of,;reasoning,;can,;be,;used,;with,;manufacturing,;cost,;being,;40%,;of,;s
elling,;cost,;as,;suggested,;in,;Problems,;1,;and,;2.
17. Packaging,;is,;used,;to,;protect,;the,;product,;from,;the,;environment,,;to,;protect,;the,;product,;d
uring,;shipping,;and,;to,;hold,;fixed,;numbers,;of,;products,;for,;sale.
18. Assembly,;of,;a,;binder,;type,;paper,;clip,;involves,;putting,;the,;formed,;wire,;handles,;in,;to,;t
he,;spring,;steel,;binder,;part,;of,;the,;clip.,;Assembly,;of,;bicycle,;wheels,;involves,;putting,;spok
es,;into,;the,;wheel,;and,;hub.
If,;the,;ingredients,;of,;the,;club,;sandwich,;are,;all,;in,;their,;finished,;state,;then,;they,;can,;be,;as
sembled.,;If,;processing,;is,;necessary,;as,;in,;slicing,;as,;turkey,,;the,;entire,;process,;is,;more,;than,;just,;
assembly.
19. The,;physical,;elements,;of,;a,;manufacturing,;system,;are,;the,;machine,;tools,,;the,;tooling,;l
ike,;workholding,;devices,,;material,;handling,;equipment,,;inspection,;equipment,;and,;peopl
e,;who,;actually,;produce,;the,;products., ; Manufacturing,;systems,;are,;characterized,;by,;meas
urable,;parameters,;(throughput,;time,,;cycle,;time,,;defect,;rates,,;production,;rates,,;number,;o
f,;direct,;laborers,,;annual,;production,;volumes,,;etc.)., ; Machine,;tools,;are,;characterized,;by,;t
he,;size,;of,;the,;workpiece,;that,;can,;be,;processed,;or,;the,;spindle,;speeds,;they,;can,;be,;run,;at.,;T
ools,;like,;dies,;for,;sheet,;metal,;forming,;are,;characterized,;by,;their,;size,;and,;weight., ; Inspect
ion,;devices,;have,;measurement,;resolution,;limits. , ; Measurable,;parameters,;extend,;past,;ma
chine,;specifications,;to,;higher,;level,;(involving,;more,;than,;one,;aspect,;of,;part,;production),;
descriptions,;of,;the,;process,;such,;as,;production,;rates.,;The,;manufacturing,;system,;is,;more,;t
han,;the,;physical,;elements.,;Support,;and,;control,;systems,,;along,;with,;the,;physical,;element
s,,;are,;combined,;in,;the,;manufacturing,;system.
20. The,;manufacturing,;engineer,;is,;responsible,;for,;selecting,;or,;designing,;and,;overseeing,;o
peration,;of,;the,;manufacturing,;processes.,;In,;the,;sense,;of,;immediate,;contact,;with,;processes
,;the,;manufacturing,;engineer,;is,;often,;the,;center,;of,;―making,;the,;product‖. ,;However, ,;the,;dec
isions,;made,;by,;part,;and,;product,;designers,;and,;materials,;engineers,;have,;large,;influences,;o
n,;the,;kind,;of,;processes,;that,;can,;be,;used,;to,;make,;the,;part., ; How,;the,;part,;can,;be,;made,;is,;con
strained,;by,;part,;design,;and,;materials,;used., ; So,,;all,;individuals,;who,;make,;decisions,;that,;d
etermine,;manufacturing,;process,;choice,;should,;be,;involved,;in,;figuring,;out,;how,;to,;make,;th
e,;part.
21. In,;Figure,;1-
8,,;the,;lines,;connecting,;the,;processes,;represent,;possible,;paths,;as,;material,;moves,;through,;t
he,;shop,;–,;from,;machine-to-machine,;or,;operation-to-operation.
3