SOLUTIONS MANUAL
,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010
06-19-09
1 INTRODUCTION
Review Questions
1.1 What are the differences between primary, secondary, and tertiary industries? Give an
example of each category.
Answer. A primary industry is one that cultivates and exploits natural resources, such as
agriculture or mining. A secondary industry takes the outputs of primary industries and
converts them to consumer and capital goods. Examples of secondary industries are
textiles and electronics. A tertiary industry is in the service sector of the economy.
Examples of tertiary industries are banking and education.
1.2 What is a capital good? Provide an example.
Answer. Capital goods are those purchased by companies to produce goods or provide
services. Examples of capital goods are aircraft and construction equipment.
1.3 How are product variety and production quantity related when comparing typical factories?
Answer. Generally production quantity is inversely related to product variety. A
factory that produces a large variety of products will produce a smaller quantity of
each. A company that produces a single product will produce a large quantity.
1.4 Define manufacturing capability.
Answer. Manufacturing capability refers to the technical and physical limitations of a
manufacturing firm and each of its plants. Three categories of capability mentioned in
the text are
(1) technological processing capability, (2) physical size and weight, and (3) production
capacity.
1.5 Name the three basic categories of materials.
Answer. The three basic categories of engineering materials are (1) metals, (2) ceramics,
and (3) polymers. A fourth category, composites, is a non-homogeneous mixture of the
other types and therefore is not a basic category.
1.6 How does a shaping process differ from a surface processing operation?
Answer. A shaping process changes the geometry of the work material (machining or
forging). A surface processing operation does not alter the geometry, but instead alters
surface of the work (painting or plating).
1.7 What are two subclasses of assembly processes? Provide an example process for each
subclass.
Answer. The two subclasses of assembly processes are (1) permanent joining and (2)
mechanical fastening. Examples of permanent joining include welding or adhesive bonding.
Examples of mechanical fastening include threaded fasteners, such as nuts and bolts, and
rivets.
1.8 Define batch production and describe why it is often used for medium-quantity
production products.
Answer. Batch production is where groups, lots, or batches or materials or parts are
processed together through the manufacturing operations. All units in the batch are
processed at a given station before the group proceeds to the next station. In a medium or
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner is unlawful.
1
,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010
06-19-09
low quantity production situation, the same machines are used to produce many types of
products. Whenever a machine switches from one product to another, a changeover
occurs. The changeover requires the machine setup to be torn down and set up for the new
product. Batch production allows the changeover time
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner is unlawful.
2
, Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010
06-19-09
to be distributed across a larger number of parts and hence reduce the average operation
time per part.
1.9 What is the difference between a process layout and a product layout in a production facility?
Answer. A process layout is one where the machinery in a plant is arranged based on the
type of process it performs. To produce a product it must visit the departments in the
order of the operations that must be performed. This often includes large travel distances
within the plant. A process layout is often used when the product variety is large the
operation sequences of products are dissimilar. A product layout is one where the
machinery is arranged based on the general flow of the products that will be produced.
Travel distance is reduced because products will generally flow to the next machine in the
sequence. A product layout works well when all products tend to follow the same
sequence of production.
1.10 Name two departments that are typically classified as manufacturing support departments.
Answer. A common organizational structure includes the following three
manufacturing support departments: (1) manufacturing engineering, (2) production
planning and control, and (3) quality control.
Multiple Choice Quiz
There are 18 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.
1.1 Which of the following industries are classified as secondary industries (three correct
answers): (a) beverages (b) financial services, (c) fishing, (d) mining, (e) power utilities, (f)
publishing, and (g) transportation?
Answer. (a), (e), and (f).
1.2 Mining is classified in which one of the following industry categories: (a) agricultural
industry, (b) manufacturing industry, (c) primary industry, (d) secondary industry, (e)
service industry, or (f) tertiary industry?
Answer. (c).
1.3 Inventions of the Industrial Revolution include which one of the following: (a)
automobile, (b) cannon, (c) printing press, (d) steam engine, or (e) sword?
Answer. (d).
1.4 Ferrous metals include which of the following (two correct answers): (a) aluminum, (b) cast
iron,
(c) copper, (d) gold, and (e) steel?
Answer. (c) and (e).
1.5 Which one of the following engineering materials is defined as a compound containing
metallic and nonmetallic elements: (a) ceramic, (b) composite, (c) metal, or (d)
polymer?
Answer. (a).
1.6 Which of the following processes start with a material that is in a fluid or semifluid
state and solidifies the material in a cavity (two best answers): (a) casting, (b) forging,
(c) machining, (d) molding, (e) pressing, and (f) turning?
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner is unlawful.
3
,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010
06-19-09
1 INTRODUCTION
Review Questions
1.1 What are the differences between primary, secondary, and tertiary industries? Give an
example of each category.
Answer. A primary industry is one that cultivates and exploits natural resources, such as
agriculture or mining. A secondary industry takes the outputs of primary industries and
converts them to consumer and capital goods. Examples of secondary industries are
textiles and electronics. A tertiary industry is in the service sector of the economy.
Examples of tertiary industries are banking and education.
1.2 What is a capital good? Provide an example.
Answer. Capital goods are those purchased by companies to produce goods or provide
services. Examples of capital goods are aircraft and construction equipment.
1.3 How are product variety and production quantity related when comparing typical factories?
Answer. Generally production quantity is inversely related to product variety. A
factory that produces a large variety of products will produce a smaller quantity of
each. A company that produces a single product will produce a large quantity.
1.4 Define manufacturing capability.
Answer. Manufacturing capability refers to the technical and physical limitations of a
manufacturing firm and each of its plants. Three categories of capability mentioned in
the text are
(1) technological processing capability, (2) physical size and weight, and (3) production
capacity.
1.5 Name the three basic categories of materials.
Answer. The three basic categories of engineering materials are (1) metals, (2) ceramics,
and (3) polymers. A fourth category, composites, is a non-homogeneous mixture of the
other types and therefore is not a basic category.
1.6 How does a shaping process differ from a surface processing operation?
Answer. A shaping process changes the geometry of the work material (machining or
forging). A surface processing operation does not alter the geometry, but instead alters
surface of the work (painting or plating).
1.7 What are two subclasses of assembly processes? Provide an example process for each
subclass.
Answer. The two subclasses of assembly processes are (1) permanent joining and (2)
mechanical fastening. Examples of permanent joining include welding or adhesive bonding.
Examples of mechanical fastening include threaded fasteners, such as nuts and bolts, and
rivets.
1.8 Define batch production and describe why it is often used for medium-quantity
production products.
Answer. Batch production is where groups, lots, or batches or materials or parts are
processed together through the manufacturing operations. All units in the batch are
processed at a given station before the group proceeds to the next station. In a medium or
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner is unlawful.
1
,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010
06-19-09
low quantity production situation, the same machines are used to produce many types of
products. Whenever a machine switches from one product to another, a changeover
occurs. The changeover requires the machine setup to be torn down and set up for the new
product. Batch production allows the changeover time
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner is unlawful.
2
, Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover 2010
06-19-09
to be distributed across a larger number of parts and hence reduce the average operation
time per part.
1.9 What is the difference between a process layout and a product layout in a production facility?
Answer. A process layout is one where the machinery in a plant is arranged based on the
type of process it performs. To produce a product it must visit the departments in the
order of the operations that must be performed. This often includes large travel distances
within the plant. A process layout is often used when the product variety is large the
operation sequences of products are dissimilar. A product layout is one where the
machinery is arranged based on the general flow of the products that will be produced.
Travel distance is reduced because products will generally flow to the next machine in the
sequence. A product layout works well when all products tend to follow the same
sequence of production.
1.10 Name two departments that are typically classified as manufacturing support departments.
Answer. A common organizational structure includes the following three
manufacturing support departments: (1) manufacturing engineering, (2) production
planning and control, and (3) quality control.
Multiple Choice Quiz
There are 18 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.
1.1 Which of the following industries are classified as secondary industries (three correct
answers): (a) beverages (b) financial services, (c) fishing, (d) mining, (e) power utilities, (f)
publishing, and (g) transportation?
Answer. (a), (e), and (f).
1.2 Mining is classified in which one of the following industry categories: (a) agricultural
industry, (b) manufacturing industry, (c) primary industry, (d) secondary industry, (e)
service industry, or (f) tertiary industry?
Answer. (c).
1.3 Inventions of the Industrial Revolution include which one of the following: (a)
automobile, (b) cannon, (c) printing press, (d) steam engine, or (e) sword?
Answer. (d).
1.4 Ferrous metals include which of the following (two correct answers): (a) aluminum, (b) cast
iron,
(c) copper, (d) gold, and (e) steel?
Answer. (c) and (e).
1.5 Which one of the following engineering materials is defined as a compound containing
metallic and nonmetallic elements: (a) ceramic, (b) composite, (c) metal, or (d)
polymer?
Answer. (a).
1.6 Which of the following processes start with a material that is in a fluid or semifluid
state and solidifies the material in a cavity (two best answers): (a) casting, (b) forging,
(c) machining, (d) molding, (e) pressing, and (f) turning?
Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to
students enrolled in courses for which the textbook has been adopted. Any other reproduction or translation of this work beyond that permitted
by Sections 107 or 108 of the 1976 United States Copyright Act without the permission of the copyright owner is unlawful.
3
