SOLUTION MANUAL
,SolutionsfforfFundamentalsfoffModernfManufacturing,f4/ef(publishedfbyfWiley)ffMPGrooverf2010f06
-19-09
1 INTRODUCTION
ReviewfQuestions
1.1 Whatfarefthefdifferencesfbetweenfprimary,fsecondary,fandftertiaryfindustries?fGivefanfexamplefoffeac
hfcategory.
Answer.fAfprimaryfindustryfisfonefthatfcultivatesfandfexploitsfnaturalfresources,fsuchfasfagriculturefor
fmining.fAfsecondaryfindustryftakesfthefoutputsfoffprimaryfindustriesfandfconvertsfthemftofconsumerfa
ndfcapitalfgoods.fExamplesfoffsecondaryfindustriesfareftextilesfandfelectronics.fAftertiaryfindustryfisfin
fthefservicefsectorfoffthefeconomy.fExamplesfofftertiaryfindustriesfarefbankingfandfeducation.
1.2 Whatfisfafcapitalfgood?fProvidefanfexample.
Answer.fCapitalfgoodsfarefthosefpurchasedfbyfcompaniesftofproducefgoodsforfprovidefservices.fExample
sfoffcapitalfgoodsfarefaircraftfandfconstructionfequipment.
1.3 Howfarefproductfvarietyfandfproductionfquantityfrelatedfwhenfcomparingftypicalffactories?
Answer.fGenerallyfproductionfquantityfisfinverselyfrelatedftofproductfvariety.fAffactoryfthatfpr
oducesfaflargefvarietyfoffproductsfwillfproducefafsmallerfquantityfoffeach.fAfcompanyfthatfprodu
cesfafsinglefproductfwillfproducefaflargefquantity.
1.4 Definefmanufacturingfcapability.
Answer.fManufacturingfcapabilityfrefersftoftheftechnicalfandfphysicalflimitationsfoffafmanufacturin
gffirmfandfeachfoffitsfplants.fThreefcategoriesfoffcapabilityfmentionedfinftheftextfare
(1)ftechnologicalfprocessingfcapability,f(2)fphysicalfsizefandfweight,fandf(3)fproductionfcapacity.
1.5 Namefthefthreefbasicfcategoriesfoffmaterials.
Answer.fThefthreefbasicfcategoriesfoffengineeringfmaterialsfaref(1)fmetals,f(2)fceramics,fandf(3)fpolymer
s.fAffourthfcategory,fcomposites,fisfafnon-
homogeneousfmixturefoffthefotherftypesfandfthereforefisfnotfafbasicfcategory.
1.6 Howfdoesfafshapingfprocessfdifferffromfafsurfacefprocessingfoperation?
Answer.fAfshapingfprocessfchangesfthefgeometryfoffthefworkfmaterialf(machiningforfforging).fAfsurfa
cefprocessingfoperationfdoesfnotfalterfthefgeometry,fbutfinsteadfaltersfsurfacefoffthefworkf(paintingforf
plating).
1.7 Whatfareftwofsubclassesfoffassemblyfprocesses?fProvidefanfexamplefprocessfforfeachfsubclass.
Answer.fTheftwofsubclassesfoffassemblyfprocessesfaref(1)fpermanentfjoiningfandf(2)fmechanicalffasteni
ng.fExamplesfoffpermanentfjoiningfincludefweldingforfadhesivefbonding.fExamplesfoffmechanicalffaste
ningfincludefthreadedffasteners,fsuchfasfnutsfandfbolts,fandfrivets.
1.8 Definefbatchfproductionfandfdescribefwhyfitfisfoftenfusedfforfmedium-
quantityfproductionfproducts.
Answer.fBatchfproductionfisfwherefgroups,flots,forfbatchesforfmaterialsforfpartsfarefprocessedftogethe
rfthroughfthefmanufacturingfoperations.fAllfunitsfinfthefbatchfarefprocessedfatfafgivenfstationfbeforefth
efgroupfproceedsftofthefnextfstation.fInfafmediumforflowfquantityfproductionfsituation,fthefsamefmachi
nesfarefusedftofproducefmanyftypesfoffproducts.fWheneverfafmachinefswitchesffromfonefproductftofan
other,fafchangeoverfoccurs.fThefchangeoverfrequiresfthefmachinefsetupftofbeftornfdownfandfsetfupfforft
hefnewfproduct.fBatchfproductionfallowsfthefchangeoverftime
Excerptsffromfthisfworkfmayfbefreproducedfbyfinstructorsfforfdistributionfonfafnot-for-
profitfbasisfforftestingforfinstructionalfpurposesfonlyftof studentsfenrolledfinfcoursesfforfwhichftheftextbookfhasfbeenfadopted.f Anyfotherfreproduc
tionforftranslationfoffthisfworkfbeyondfthatfpermittedf byfSectionsf107forf108foffthef1976fUnitedfStatesfCopyrightfActfwithoutfthefpermissionfoffthef
copyrightfownerfisfunlawful.
1
,SolutionsfforfFundamentalsfoffModernfManufacturing,f4/ef(publishedfbyfWiley)ffMPGrooverf2010f06
-19-09
tofbefdistributedfacrossfaflargerfnumberfoffpartsfandfhencefreducefthefaveragefoperationftimefperfpart.
1.9 Whatfisfthefdifferencefbetweenfafprocessflayoutfandfafproductflayoutfinfafproductionffacility?
Answer.fAfprocessflayoutfisfonefwherefthefmachineryfinfafplantfisfarrangedfbasedfonftheftypefoffproces
sfitfperforms.fTofproducefafproductfitfmustfvisitfthefdepartmentsfinftheforderfoffthefoperationsfthatfmust
fbefperformed.fThisfoftenfincludesflargeftravelfdistancesfwithinfthefplant.fAfprocessflayoutfisfoftenfuse
dfwhenfthefproductfvarietyfisflargefthefoperationfsequencesfoffproductsfarefdissimilar.f Afproductflayou
tfisfonefwherefthefmachineryfisfarrangedfbasedfonfthefgeneralfflowfoffthefproductsfthatfwillfbefproduced
.fTravelfdistancefisfreducedfbecausefproductsfwillfgenerallyfflowftofthefnextfmachinefinfthefsequence.f
Afproductflayoutfworksfwellfwhenfallfproductsftendftoffollowfthefsamefsequencefoffproduction.
1.10 Nameftwofdepartmentsfthatfareftypicallyfclassifiedfasfmanufacturingfsupportfdepartments.
Answer.fAfcommonforganizationalfstructurefincludesftheffollowingfthreefmanufacturingfsupportfde
partments:f(1)fmanufacturingfengineering,f(2)fproductionfplanningfandfcontrol,fandf(3)fqualityfcontr
ol.
MultiplefChoicefQuiz
Therefaref18fcorrectfanswersfinftheffollowingfmultiplefchoicefquestionsf(somefquestionsfhavefmultiplefanswer
sfthatfarefcorrect).fTofattainfafperfectfscorefonfthefquiz,fallfcorrectfanswersfmustfbefgiven.fEachfcorrectfanswerfi
sfworthf1fpoint.fEachfomittedfanswerforfwrongfanswerfreducesfthefscorefbyf1fpoint,fandfeachfadditionalfanswerf
beyondfthefcorrectfnumberfoffanswersfreducesfthefscorefbyf1fpoint.fPercentagefscorefonfthefquizfisfbasedfonftheft
otalfnumberfoffcorrectfanswers.
1.1 Whichfofftheffollowingfindustriesfarefclassifiedfasfsecondaryfindustriesf(threefcorrectfanswers):f(a)fbe
veragesf(b)ffinancialfservices,f(c)ffishing,f(d)fmining,f(e)fpowerfutilities,f(f)fpublishing,fandf(g)ftransp
ortation?
Answer.f(a),f(e),fandf(f).
1.2 Miningfisfclassifiedfinfwhichfonefofftheffollowingfindustryfcategories:f(a)fagriculturalfindustry,f(b)fma
nufacturingfindustry,f(c)fprimaryfindustry,f(d)fsecondaryfindustry,f(e)fservicefindustry,forf(f)ftertiaryfi
ndustry?
Answer.f(c).
1.3 InventionsfoffthefIndustrialfRevolutionfincludefwhichfonefofftheffollowing:f(a)fautomobile,f(b)fca
nnon,f(c)fprintingfpress,f(d)fsteamfengine,forf(e)fsword?
Answer.f(d).
1.4 Ferrousfmetalsfincludefwhichfofftheffollowingf(twofcorrectfanswers):f(a)faluminum,f(b)fcastfiron,
(c)fcopper,f(d)fgold,fandf(e)fsteel?
Answer.f(c)fandf(e).
1.5 Whichfonefofftheffollowingfengineeringfmaterialsfisfdefinedfasfafcompoundfcontainingfmetallicfan
dfnonmetallicfelements:f(a)fceramic,f(b)fcomposite,f(c)fmetal,forf(d)fpolymer?
Answer.f(a).
1.6 Whichfofftheffollowingfprocessesfstartfwithfafmaterialfthatfisfinfaffluidforfsemifluidfstatefandfsolidif
iesfthefmaterialfinfafcavityf(twofbestfanswers):f(a)fcasting,f(b)fforging,f(c)fmachining,f(d)fmolding,f(
e)fpressing,fandf(f)fturning?
Answer.f(a)fandf(d).
Excerptsffromfthisfworkfmayfbefreproducedfbyfinstructorsfforfdistributionfonfafnot-for-
profitfbasisfforftestingforfinstructionalfpurposesfonlyftof studentsfenrolledfinfcoursesfforfwhichftheftextbookfhasfbeenfadopted.f Anyfotherfreproduc
tionforftranslationfoffthisfworkfbeyondfthatfpermittedf byfSectionsf107forf108foffthef1976fUnitedfStatesfCopyrightfActfwithoutfthefpermissionfoffthef
copyrightfownerfisfunlawful.
2
, SolutionsfforfFundamentalsfoffModernfManufacturing,f4/ef(publishedfbyfWiley)ffMPGrooverf2010f06
-19-09
1.7 Particulatefprocessingfoffmetalsfandfceramicsfinvolvesfwhichfofftheffollowingfstepsf(twofbestfanswer
s):f(a)fadhesivefbonding,f(b)fdeformation,f(c)fforging,f(d)fmaterialfremoval,f(e)fmelting,f(f)fpressing,f
andf(g)fsintering?
Answer.f(f)fandf(g).
1.8 Deformationfprocessesfincludefwhichfofftheffollowingf(twofcorrectfanswers):f(a)fcasting,f(b)fdri
lling,f(c)fextrusion,f(d)fforging,f(e)fmilling,f(f)fpainting,fandf(g)fsintering?
Answer.f(c)fandf(d).
1.9 Whichfonefofftheffollowingfisfafmachinefusedftofperformfextrusion:f(a)fforgefhammer,f(b)fmillingfmac
hine,f(c)frollingfmill,f(d)fpress,f(e)ftorch?
Answer.f(d).
1.10 High-
volumefproductionfoffassembledfproductsfisfmostfcloselyfassociatedfwithfwhichfonefofftheffollowin
gflayoutftypes:f(a)fcellularflayout,f(b)ffixedfpositionflayout,f(c)fprocessflayout,forf(d)fproductflayout
?
Answer.f(d).
1.11 Afproductionfplanningfandfcontrolfdepartmentfaccomplishesfwhichfofftheffollowingffunctionsfinfitsfrol
efoffprovidingfmanufacturingfsupportf(twofbestfanswers):f(a)fdesignsfandfordersfmachineftools,
(b)fdevelopsfcorporatefstrategicfplans,f(c)fordersfmaterialsfandfpurchasedfparts,f(d)fperformsfquali
tyfinspections,fandf(e)fschedulesftheforderfoffproductsfonfafmachine?
Answer.f(c)fandf(e).
Excerptsffromfthisfworkfmayfbefreproducedfbyfinstructorsfforfdistributionfonfafnot-for-
profitfbasisfforftestingforfinstructionalfpurposesfonlyftof studentsfenrolledfinfcoursesfforfwhichftheftextbookfhasfbeenfadopted.f Anyfotherfreproduc
tionforftranslationfoffthisfworkfbeyondfthatfpermittedf byfSectionsf107forf108foffthef1976fUnitedfStatesfCopyrightfActfwithoutfthefpermissionfoffthef
copyrightfownerfisfunlawful.
3
,SolutionsfforfFundamentalsfoffModernfManufacturing,f4/ef(publishedfbyfWiley)ffMPGrooverf2010f06
-19-09
1 INTRODUCTION
ReviewfQuestions
1.1 Whatfarefthefdifferencesfbetweenfprimary,fsecondary,fandftertiaryfindustries?fGivefanfexamplefoffeac
hfcategory.
Answer.fAfprimaryfindustryfisfonefthatfcultivatesfandfexploitsfnaturalfresources,fsuchfasfagriculturefor
fmining.fAfsecondaryfindustryftakesfthefoutputsfoffprimaryfindustriesfandfconvertsfthemftofconsumerfa
ndfcapitalfgoods.fExamplesfoffsecondaryfindustriesfareftextilesfandfelectronics.fAftertiaryfindustryfisfin
fthefservicefsectorfoffthefeconomy.fExamplesfofftertiaryfindustriesfarefbankingfandfeducation.
1.2 Whatfisfafcapitalfgood?fProvidefanfexample.
Answer.fCapitalfgoodsfarefthosefpurchasedfbyfcompaniesftofproducefgoodsforfprovidefservices.fExample
sfoffcapitalfgoodsfarefaircraftfandfconstructionfequipment.
1.3 Howfarefproductfvarietyfandfproductionfquantityfrelatedfwhenfcomparingftypicalffactories?
Answer.fGenerallyfproductionfquantityfisfinverselyfrelatedftofproductfvariety.fAffactoryfthatfpr
oducesfaflargefvarietyfoffproductsfwillfproducefafsmallerfquantityfoffeach.fAfcompanyfthatfprodu
cesfafsinglefproductfwillfproducefaflargefquantity.
1.4 Definefmanufacturingfcapability.
Answer.fManufacturingfcapabilityfrefersftoftheftechnicalfandfphysicalflimitationsfoffafmanufacturin
gffirmfandfeachfoffitsfplants.fThreefcategoriesfoffcapabilityfmentionedfinftheftextfare
(1)ftechnologicalfprocessingfcapability,f(2)fphysicalfsizefandfweight,fandf(3)fproductionfcapacity.
1.5 Namefthefthreefbasicfcategoriesfoffmaterials.
Answer.fThefthreefbasicfcategoriesfoffengineeringfmaterialsfaref(1)fmetals,f(2)fceramics,fandf(3)fpolymer
s.fAffourthfcategory,fcomposites,fisfafnon-
homogeneousfmixturefoffthefotherftypesfandfthereforefisfnotfafbasicfcategory.
1.6 Howfdoesfafshapingfprocessfdifferffromfafsurfacefprocessingfoperation?
Answer.fAfshapingfprocessfchangesfthefgeometryfoffthefworkfmaterialf(machiningforfforging).fAfsurfa
cefprocessingfoperationfdoesfnotfalterfthefgeometry,fbutfinsteadfaltersfsurfacefoffthefworkf(paintingforf
plating).
1.7 Whatfareftwofsubclassesfoffassemblyfprocesses?fProvidefanfexamplefprocessfforfeachfsubclass.
Answer.fTheftwofsubclassesfoffassemblyfprocessesfaref(1)fpermanentfjoiningfandf(2)fmechanicalffasteni
ng.fExamplesfoffpermanentfjoiningfincludefweldingforfadhesivefbonding.fExamplesfoffmechanicalffaste
ningfincludefthreadedffasteners,fsuchfasfnutsfandfbolts,fandfrivets.
1.8 Definefbatchfproductionfandfdescribefwhyfitfisfoftenfusedfforfmedium-
quantityfproductionfproducts.
Answer.fBatchfproductionfisfwherefgroups,flots,forfbatchesforfmaterialsforfpartsfarefprocessedftogethe
rfthroughfthefmanufacturingfoperations.fAllfunitsfinfthefbatchfarefprocessedfatfafgivenfstationfbeforefth
efgroupfproceedsftofthefnextfstation.fInfafmediumforflowfquantityfproductionfsituation,fthefsamefmachi
nesfarefusedftofproducefmanyftypesfoffproducts.fWheneverfafmachinefswitchesffromfonefproductftofan
other,fafchangeoverfoccurs.fThefchangeoverfrequiresfthefmachinefsetupftofbeftornfdownfandfsetfupfforft
hefnewfproduct.fBatchfproductionfallowsfthefchangeoverftime
Excerptsffromfthisfworkfmayfbefreproducedfbyfinstructorsfforfdistributionfonfafnot-for-
profitfbasisfforftestingforfinstructionalfpurposesfonlyftof studentsfenrolledfinfcoursesfforfwhichftheftextbookfhasfbeenfadopted.f Anyfotherfreproduc
tionforftranslationfoffthisfworkfbeyondfthatfpermittedf byfSectionsf107forf108foffthef1976fUnitedfStatesfCopyrightfActfwithoutfthefpermissionfoffthef
copyrightfownerfisfunlawful.
1
,SolutionsfforfFundamentalsfoffModernfManufacturing,f4/ef(publishedfbyfWiley)ffMPGrooverf2010f06
-19-09
tofbefdistributedfacrossfaflargerfnumberfoffpartsfandfhencefreducefthefaveragefoperationftimefperfpart.
1.9 Whatfisfthefdifferencefbetweenfafprocessflayoutfandfafproductflayoutfinfafproductionffacility?
Answer.fAfprocessflayoutfisfonefwherefthefmachineryfinfafplantfisfarrangedfbasedfonftheftypefoffproces
sfitfperforms.fTofproducefafproductfitfmustfvisitfthefdepartmentsfinftheforderfoffthefoperationsfthatfmust
fbefperformed.fThisfoftenfincludesflargeftravelfdistancesfwithinfthefplant.fAfprocessflayoutfisfoftenfuse
dfwhenfthefproductfvarietyfisflargefthefoperationfsequencesfoffproductsfarefdissimilar.f Afproductflayou
tfisfonefwherefthefmachineryfisfarrangedfbasedfonfthefgeneralfflowfoffthefproductsfthatfwillfbefproduced
.fTravelfdistancefisfreducedfbecausefproductsfwillfgenerallyfflowftofthefnextfmachinefinfthefsequence.f
Afproductflayoutfworksfwellfwhenfallfproductsftendftoffollowfthefsamefsequencefoffproduction.
1.10 Nameftwofdepartmentsfthatfareftypicallyfclassifiedfasfmanufacturingfsupportfdepartments.
Answer.fAfcommonforganizationalfstructurefincludesftheffollowingfthreefmanufacturingfsupportfde
partments:f(1)fmanufacturingfengineering,f(2)fproductionfplanningfandfcontrol,fandf(3)fqualityfcontr
ol.
MultiplefChoicefQuiz
Therefaref18fcorrectfanswersfinftheffollowingfmultiplefchoicefquestionsf(somefquestionsfhavefmultiplefanswer
sfthatfarefcorrect).fTofattainfafperfectfscorefonfthefquiz,fallfcorrectfanswersfmustfbefgiven.fEachfcorrectfanswerfi
sfworthf1fpoint.fEachfomittedfanswerforfwrongfanswerfreducesfthefscorefbyf1fpoint,fandfeachfadditionalfanswerf
beyondfthefcorrectfnumberfoffanswersfreducesfthefscorefbyf1fpoint.fPercentagefscorefonfthefquizfisfbasedfonftheft
otalfnumberfoffcorrectfanswers.
1.1 Whichfofftheffollowingfindustriesfarefclassifiedfasfsecondaryfindustriesf(threefcorrectfanswers):f(a)fbe
veragesf(b)ffinancialfservices,f(c)ffishing,f(d)fmining,f(e)fpowerfutilities,f(f)fpublishing,fandf(g)ftransp
ortation?
Answer.f(a),f(e),fandf(f).
1.2 Miningfisfclassifiedfinfwhichfonefofftheffollowingfindustryfcategories:f(a)fagriculturalfindustry,f(b)fma
nufacturingfindustry,f(c)fprimaryfindustry,f(d)fsecondaryfindustry,f(e)fservicefindustry,forf(f)ftertiaryfi
ndustry?
Answer.f(c).
1.3 InventionsfoffthefIndustrialfRevolutionfincludefwhichfonefofftheffollowing:f(a)fautomobile,f(b)fca
nnon,f(c)fprintingfpress,f(d)fsteamfengine,forf(e)fsword?
Answer.f(d).
1.4 Ferrousfmetalsfincludefwhichfofftheffollowingf(twofcorrectfanswers):f(a)faluminum,f(b)fcastfiron,
(c)fcopper,f(d)fgold,fandf(e)fsteel?
Answer.f(c)fandf(e).
1.5 Whichfonefofftheffollowingfengineeringfmaterialsfisfdefinedfasfafcompoundfcontainingfmetallicfan
dfnonmetallicfelements:f(a)fceramic,f(b)fcomposite,f(c)fmetal,forf(d)fpolymer?
Answer.f(a).
1.6 Whichfofftheffollowingfprocessesfstartfwithfafmaterialfthatfisfinfaffluidforfsemifluidfstatefandfsolidif
iesfthefmaterialfinfafcavityf(twofbestfanswers):f(a)fcasting,f(b)fforging,f(c)fmachining,f(d)fmolding,f(
e)fpressing,fandf(f)fturning?
Answer.f(a)fandf(d).
Excerptsffromfthisfworkfmayfbefreproducedfbyfinstructorsfforfdistributionfonfafnot-for-
profitfbasisfforftestingforfinstructionalfpurposesfonlyftof studentsfenrolledfinfcoursesfforfwhichftheftextbookfhasfbeenfadopted.f Anyfotherfreproduc
tionforftranslationfoffthisfworkfbeyondfthatfpermittedf byfSectionsf107forf108foffthef1976fUnitedfStatesfCopyrightfActfwithoutfthefpermissionfoffthef
copyrightfownerfisfunlawful.
2
, SolutionsfforfFundamentalsfoffModernfManufacturing,f4/ef(publishedfbyfWiley)ffMPGrooverf2010f06
-19-09
1.7 Particulatefprocessingfoffmetalsfandfceramicsfinvolvesfwhichfofftheffollowingfstepsf(twofbestfanswer
s):f(a)fadhesivefbonding,f(b)fdeformation,f(c)fforging,f(d)fmaterialfremoval,f(e)fmelting,f(f)fpressing,f
andf(g)fsintering?
Answer.f(f)fandf(g).
1.8 Deformationfprocessesfincludefwhichfofftheffollowingf(twofcorrectfanswers):f(a)fcasting,f(b)fdri
lling,f(c)fextrusion,f(d)fforging,f(e)fmilling,f(f)fpainting,fandf(g)fsintering?
Answer.f(c)fandf(d).
1.9 Whichfonefofftheffollowingfisfafmachinefusedftofperformfextrusion:f(a)fforgefhammer,f(b)fmillingfmac
hine,f(c)frollingfmill,f(d)fpress,f(e)ftorch?
Answer.f(d).
1.10 High-
volumefproductionfoffassembledfproductsfisfmostfcloselyfassociatedfwithfwhichfonefofftheffollowin
gflayoutftypes:f(a)fcellularflayout,f(b)ffixedfpositionflayout,f(c)fprocessflayout,forf(d)fproductflayout
?
Answer.f(d).
1.11 Afproductionfplanningfandfcontrolfdepartmentfaccomplishesfwhichfofftheffollowingffunctionsfinfitsfrol
efoffprovidingfmanufacturingfsupportf(twofbestfanswers):f(a)fdesignsfandfordersfmachineftools,
(b)fdevelopsfcorporatefstrategicfplans,f(c)fordersfmaterialsfandfpurchasedfparts,f(d)fperformsfquali
tyfinspections,fandf(e)fschedulesftheforderfoffproductsfonfafmachine?
Answer.f(c)fandf(e).
Excerptsffromfthisfworkfmayfbefreproducedfbyfinstructorsfforfdistributionfonfafnot-for-
profitfbasisfforftestingforfinstructionalfpurposesfonlyftof studentsfenrolledfinfcoursesfforfwhichftheftextbookfhasfbeenfadopted.f Anyfotherfreproduc
tionforftranslationfoffthisfworkfbeyondfthatfpermittedf byfSectionsf107forf108foffthef1976fUnitedfStatesfCopyrightfActfwithoutfthefpermissionfoffthef
copyrightfownerfisfunlawful.
3
