Excerpts from this work may be reproduced by instructors for distribution on a not-for-profit basis for testing or instructional purposes only to

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.Chapter 1 INTRODUCTION AND OVERVIEW OF MANUFACTURING Review Questions Answers to questions labeled (A) are immediately available to students.What is Manufacturing?

1.1 (A) Define manufacturing.Answer. The text defines manufacturing in two ways: technologically and economically.Technologically, manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; manufacturing also includes assembly of multiple parts to make products.Economically, manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations. The key point is that manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials.

1.2 What is the difference between consumer goods and capital goods? Give some examples in each category.Answer. Consumer goods are products purchased directly by consumers, such as cars, personal computers, TVs, tires, and tennis rackets. Capital goods are those purchased by companies to produce goods and/or provide services. Examples of capital goods include aircraft, computers, communication equipment, medical apparatus, trucks and buses, railroad locomotives, machine tools, and construction equipment.

1.3 What is the difference between soft product variety and hard product variety, as these terms are defined in the text?Answer. Soft product variety is when there are only small differences among products, such as the differences among car models made on the same production line. In an assembled product, soft variety is characterized by a high proportion of common parts among the models. Hard product variety is when the products differ substantially, and there are few common parts, if any. The difference between a car and a truck exemplifies hard variety.

1.4 How are product variety and production quantity related when comparing typical factories?Answer. In general, 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.

1.5 One of the dimensions of manufacturing capability is technological processing capability.Define technological processing capability.Answer. The technological processing capability of a plant (or company) is its available set of manufacturing processes. Certain plants perform machining operations, others roll steel billets into sheet stock, and others build automobiles. The underlying feature that distinguishes these plants is the processes they can perform. Technological processing capability includes not only the physical processes, but also the expertise possessed by plant personnel in these processing technologies.(Fundamentals of Modern Manufacturing Materials, Processes, and Systems, 7e Mikell P. Groover) (Solution Manual, For Complete File, Download link at the end of this File) 1 / 4

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.Manufacturing Materials 1.6 (A) What are the four categories of engineering materials used in manufacturing?Answer. The four categories of engineering materials are (1) metals, (2) ceramics, (3) polymers, and (4) composite materials, which consist of non-homogeneous mixtures of the other three types.

1.7 What is the definition of steel?Answer. Steel can be defined as an iron–carbon alloy containing 0.02% to 2.11% carbon.Its composition often includes other alloying elements as well, such as manganese, chromium, nickel, and molybdenum, to enhance the properties of the metal.

1.8 What are some of the typical applications of steel?Answer. Applications of steel include construction (e.g., bridges, I-beams, and nails), transportation (trucks, rails, and rolling stock for railroads), and consumer products (automobiles and appliances).

1.9 (A) What is the difference between a thermoplastic polymer and a thermosetting polymer?Answer. Thermoplastic polymers can be subjected to multiple heating and cooling cycles without substantially altering the molecular structure of the polymer. Thermosetting polymers chemically transform (cure) into a rigid structure on cooling from a heated plastic condition.

1.10 What is the defining characteristic or property of an elastomer?Answer. Elastomers are polymers that exhibit significant elastic behavior.Manufacturing Processes 1.11 Manufacturing processes are usually accomplished as unit operations. Define unit operation.Answer. A unit operation is a single step in the sequence of steps required to transform the starting material into a final product. A unit operation is generally performed on a single piece of equipment that runs independently of other operations in the plant.

1.12 In manufacturing processes, what is the difference between a processing operation and an assembly operation?Answer. A processing operation transforms a work material from one state of completion to a more advanced state that is closer to the final desired product. It changes the geometry, properties, or appearance of the starting material. In general, processing operations are performed on discrete work parts, but certain processing operations are also applicable to assembled items (e.g., painting a spot-welded car body). An assembly operation joins two or more components to create a new entity, called an assembly, subassembly, or some other term that refers to the joining process (e.g., a welded assembly is called a weldment).

1.13 What is the difference between casting and molding?Answer. Casting and molding are both solidification processes. The difference is that casting usually refers to the processing of metals, while molding usually refers to the processing of plastics. 2 / 4

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.

1.14 Particulate processing is generally associated with the processing of which two of the three types of engineering materials?Answer. Metals and ceramics (but not glass ceramics).

1.15 What is the most common reason for heating a metallic workpiece before it is subjected to a deformation process?Answer. To increase its ductility during deformation.

1.16 What is a machining operation?Answer. Machining is a material removal process usually performed on metallic parts, in which excess material is removed from the work part so that what remains is the desired geometry.

1.17 (A) Name the three most important machining operations.Answer. Turning, drilling, and milling.

1.18 What is the most important property-enhancing operation?Answer. Heat treatment.

1.19 Identify the four types of permanent joining processes used in assembly.Answer. The four types are welding, brazing, soldering, and adhesive bonding.

1.20 (A) What is a machine tool?Answer. The term developed during the Industrial Revolution, when it referred to power- driven machines used to operate cutting tools previously operated by hand. Modern machine tools are described by the same basic definition, except that the power is electrical rather than water or steam, and the level of precision and automation is much greater today.Production Systems 1.21 (A) Define batch production and describe why it is often used for medium-quantity production.Answer. Batch production is where groups, lots, or batches of 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 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 to be distributed across a larger number of parts and hence reduce the average operation time per part.

1.22 With which production quantity range is cellular manufacturing most closely associated?Answer. Medium production quantity range.

1.23 Name two departments that are typically classified as manufacturing support departments. 3 / 4

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.Answer. A common organizational structure includes the following three manufacturing support departments: (1) manufacturing engineering, (2) production planning and control, and (3) quality control.Manufacturing Economics 1.24 What is the difference between sequential batch processing and simultaneous batch processing?Answer. In sequential batch processing, the parts in the batch are processed one after the other. In simultaneous batch processing, all of the parts in the batch are processed together at the same time.

1.25 What are overhead costs in a manufacturing company?Answer. Overhead costs consist of all of the expenses of operating the company other than material, direct labor, and equipment.

1.26 Name and define the two categories of overhead costs in a manufacturing company.Answer. The two categories are (1) factory overhead and (2) corporate overhead. Factory overhead consists of the costs of running the factory excluding materials, direct labor, and equipment. This overhead category includes plant supervision, maintenance, insurance, heat and light, and so forth. Corporate overhead consists of company expenses not related to the factory, such as sales, marketing, accounting, legal, engineering, research and development, office space, utilities, and health benefits.

1.27 (A) What is meant by the term availability?Answer. Availability is a reliability term which is simply the proportion uptime of the equipment.Additional Review Questions for Instructor Use 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 Annual production quantities made by a factory can be classified into three ranges. Name the three ranges and the approximate quantities of parts associated with each range.Answer. The three ranges are (1) low production, with quantities in the range 1 to 100 parts; (2) medium production, with quantities in the range 100 to 10,000 parts; and (3) high production, with quantities in the range 10,000 to over a million parts.

1.3 Define plant capacity.Answer. Plant capacity, a.k.a. production capacity, is the maximum rate of production output that a plant can achieve under assumed operating conditions. Operating conditions refer to the number of shifts per week, hours per shift, direct labor manning levels in the plant, and so on.

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