SolutionsManual
for
Automation,
Production Systems, and
Computer Integrated Manufacturing
Third Edition A
Mikell P. Groover A A
Professor of Industrial and Systems Engineering
A A A A A A
Lehigh University A
200 West Packer Avenue Bethlehe
A A A A
m, Pennsylvania 18015
A A
Other contact information:
A A
E-
mail address: or Teleph
A A A A A
one: 610-758-4030
A
Pearson/PRENTICE HALL, Upper Saddle River, New Jersey, 07548
A A A A A A A
,Ch01AIntroduction-3e-SA 12-15,A16/06,A06/04/07
Chapter 1 INTROD
A A
UCTION
REVIEWA QUESTIONS
1.1 WhatAareAsomeAofAtheArealitiesAmentionedAatAtheAbeginningAofAtheAchapterAthatAmodernAmanufacturingAenter
prisesAmustAcopeAwith?ANameAfour.
Answer:ATheArealitiesAmentionedAinAtheAtextAareA(1)Aglobalization,A(2)AinternationalAoutsourcing,A(3)Alocal
Aoutsourcing, A(4) AcontractAmanufacturing, A(5)Atrend Atoward AtheAserviceAsector, A(6) Aquality Aexpectations, Aan
dA(7)AtheAneedAforAoperationalAefficiency.
1.2 WhatAisAaAproductionAsystem?
Answer:AAsAdefinedAinAtheAtext,AaAproductionAsystemAisAaAcollectionAofApeople,Aequipment,AandAprocedure
sAorganizedAtoAperformAtheAmanufacturingAoperationsAofAaAcompanyA(orAotherAorganization).
1.3 ProductionA systemsAcanA beAdividedA intoA twoAcategoriesAorA levels.A NameAandAbrieflyAdefineAtheAtwoA levels.
Answer:ATheAtwoAcategoriesAgivenAinAtheAtextAareA(1)Afacilities,AwhichAconsistAofAtheAfactory,AtheAequipm
entAinAtheAfactory,AandAtheAwayAtheAequipmentAisAorganized;AandA(2)Amanufacturing AsupportAsystems,Awhi
chAisAtheAsetAofAproceduresAusedAbyAtheAcompanyAtoAmanageAproductionAandAtoAsolveAtheAtechnicalAandAl
ogisticsAproblemsAencounteredAinAorderingAmaterials,AmovingAtheAworkAthroughAtheAfactory,AandAensuring
AthatAproductsAmeet Aquality Astandards.AProductAdesign Aand Acertain Abusiness Afunctions AareAincluded Aamong
AtheAmanufacturing AsupportAsystems.
1.4 WhatAareA manufacturingAsystems,AandAhowAareAtheyAdistinguishedAfromAproductionA systems?
Answer:AAAmanufacturing AsystemAisAaAlogicalAgroupingAofAequipmentAinAtheAfactoryAandAtheAworker(s)Aw
hoAoperate(s)Ait.AExamplesAincludeAworker-
machineAsystems,AproductionAlines,AandAmachineAcells.AAAproductionAsystemAisAaAlargerAsystemAthatAinclu
desAaAcollectionAofAmanufacturingAsystemsAandAtheAsupportAsystemsAusedAtoAmanageAthem.AAAmanufacturi
ngAsystemAisAaAsubsetAofAtheAproductionAsystem.
1.5 ManufacturingAsystemsAareAdividedAintoAthreeAcategories,AaccordingAtoAworkerAparticipation.ANameAtheA
threeAcategories.
Answer:ATheAthreeAcategoriesAareA(1)AmanualAworkAsystems,A(2)Aworker-
machineAsystems,AandA(3)AautomatedAsystems.
1.6 WhatAareAtheA fourA functionsAincludedAwithinAtheAscopeAofAmanufacturingAsupportAsystems?
Answer:AAsAidentifiedAinAtheAtext,AtheAfourAfunctionsAareA(1)AbusinessAfunctions,A(2)AproductAdesign,A(3)A
manufacturingAplanning,AandA(4)AmanufacturingAcontrol.
1.7 ThreeAbasicAtypesAofAautomationAareAdefinedAinAtheAtext.AWhatAisAfixedAautomationAandAwhatAareAsom
eAofAitsAfeatures?
Answer:AFixedAautomationAisAaAsystemAinAwhichAtheAsequenceAofAprocessingA(orAassembly)AoperationsAisAf
ixedAbyAtheAequipmentAconfiguration.AEachAoperationAinAtheAsequenceAisAusuallyAsimple,AbutAtheAintegratio
nAandAcoordination AofAmanyAsuchAoperationsAintoAoneApieceAofAequipmentAmakesAtheAsystemAcomplex.ATy
picalAfeaturesAofAfixedAautomationAareA(1)AhighAinitialAinvestmentAforAcustom-
engineeredAequipment,A(2)AhighAproductionArates,AandA(3)ArelativelyAinflexibleAinAaccommodatingAproductA
variety.
1.8 WhatAisAprogrammableAautomationAandAwhatAareA someAofAitsAfeatures?
Answer:AInAprogrammableAautomation,AtheA productionAequipmentAisAdesignedA withAtheAcapabilityAtoAchan
geA theAsequenceAofAoperationsAtoAaccommodateAdifferentAproductAconfigurations.ATheAoperationAsequenceA
isAcontrolledAbyAaAprogram,AwhichAisAaAsetAofAinstructionsAcodedAsoAthatAtheyAcanAbeAreadAandAinterpreted
AbyAtheAsystem.ASomeAofAtheAfeatures AofAprogrammable Aautomation AareA(1) Ahigh AinvestmentAinAgeneralApu
rposeAequipment,A(2)AlostAproductionAtimeAdueAtoAchangeoversAofAphysicalAsetupAandAreprogramming,A(3)A
lowerAproductionAratesAthanAfixedAautomation,A(4)AflexibilityAtoAdealAwithAvariationsAandAchangesAinAprodu
ctAconfiguration,AandA(5)AmostAsuitableAforAbatchAproduction.
1.9 WhatAisAflexibleAautomationA andAwhatAareAsomeAofAitsAfeatures?
1
,Ch01AIntroduction-3e-SA 12-15,A16/06,A06/04/07
Answer:AFlexibleAautomationAisAanAextensionAofAprogrammableAautomation.AAAflexibleAautomatedAsystemA
isAcapableAofAproducingAaAvarietyAofApartsA(orAproducts)AwithAvirtuallyAnoAtimeAlostAforAchangeoversAfrom
AoneApartAstyleAto AtheAnext.AThereAisAnoAlostAproduction AtimeA whileAreprogramming AtheAsystemAand Aalterin
gAtheAphysicalAsetup.AAccordingly,AtheAsystemAcanAproduceAvariousAmixesAandAschedulesAofApartsAorAprod
uctsAinsteadAofArequiringAthatAtheyAbeAmadeAinAbatches.ATheAfeaturesAofAflexibleAautomationAareA(1)AhighAi
nvestmentAforAaAcustom-
engineeredAsystem,A(2)AcontinuousAproductionAofAvariableAmixturesAofAproducts,A(3)AmediumAproductionAr
ates,AandA(4)AflexibilityAtoAdealAwithAproductAdesignAvariations
1.10 WhatAisAcomputerA integratedA manufacturing?
Answer:AAsAdefinedAinAtheAtext,Acomputer-
integratedAmanufacturing A(CIM)AdenotesAtheApervasiveAuseAofAcomputerAsystemsAtoAdesignAtheAproducts,A
planAtheAproduction,AcontrolAtheAoperations,AandAperformAtheAvariousAinformation-
processingAfunctionsAneededAinAaAmanufacturingAfirm.ATrueACIMAinvolvesAintegratingAallAofAtheseAfunctio
nsAinAoneAsystemAthatAoperatesAthroughoutAtheAenterprise.
1.11 WhatAareAsomeAofAtheAreasonsAwhyAcompaniesAautomateAtheirAoperations?ANineAreasonsAareAgivenAinAth
eAtext.ANameAfive.
Answer:ATheAreasonsAgiveAinAtheAtextAareA(1)AtoAincreaseAlaborAproductivity,A(2)AtoAreduceAlaborAcost,A(3)
AtoAmitigateAtheAeffectsAofAlabor Ashortages, A(4) AtoAreduceAorAeliminateAroutineAmanualAand AclericalAtasks,A
(5)AtoAimproveAworkerAsafety,A(6)AtoAimproveAproductAquality,A(7)AtoAreduceAmanufacturingAleadAtime,A(8)
AtoAaccomplish Aprocesses AthatA cannotAbeAdoneAmanually,Aand A (9)AtoAavoid AtheAhigh AcostAofAnotAautomatin
g.
1.12 IdentifyAthreeA situationsAinAwhichAmanualA laborA isApreferredAoverAautomation.
Answer:ATheAfiveAsituationsAlistedAinAtheAtextAareAtheAfollowing:A(1)ATheAtaskAisAtechnologicallyAtooAdiffic
ultAtoAautomate.A(2)AShortAproductAlifeAcycle.A(3)ACustomizedAproduct.A(4)AToAcopeAwithAupsAandAdownsA
inAdemand.
(5)AToAreduceAriskAofAproductAfailure.
1.13 HumanAworkersAwillAbeAneededAinAfactoryAoperations,AevenAinAtheAmostAhighlyAautomatedAoperations.ATh
eAtextAidentifiesAatAleastAfourAtypesAofAworkAforAwhichAhumansAwillAbeAneeded.ANameAthree.
Answer:ATheAfourAtypesAofAworkAidentifiedAinAtheAtextAareA(1)AequipmentAmaintenance,A(2)AprogrammingA
andAcomputerAoperations,A(3)AengineeringAprojectAwork,AandA(4)AplantAmanagement.
1.14 WhatAisAtheA USAAPrinciple?AWhatAdoesAeachAofA theA lettersAstandAfor?
Answer:ATheAUSAAPrincipleAisAaAcommonAsenseAapproachAtoAautomationAandAprocessAimprovementAproj
ects.AUAmeansA“understandAtheAexistingAprocess,”ASAstandsAforA“simplifyAtheAprocess,”AandAAAstandsAforA
“automatedAtheAprocess.”
1.15 TheAtextAlistsAtenA strategiesAforAautomationAandAprocessAimprovement.AIdentifyAfiveAofA theseA strategies.
Answer:ATheAtenAstrategiesAlistedAinAtheAtextAareA(1)AspecializationAofAoperations,A(2)AcombinedAoperation
s,A(3)AsimultaneousAoperations,A(4)AintegrationAofAoperations,A(5)AincreasedAflexibility,A(6)AimprovedAmate
rialAhandlingAandAstorage,A(7)Aon-
lineAinspection,A(8)AprocessAcontrolAandAoptimization,A(9)AplantAoperationsAcontrol,AandA(10)Acomputer-
integratedAmanufacturing A(CIM).
1.16 WhatAisAanAautomationAmigrationA strategy?
Answer:AAsAdefinedAinAtheAtext,AanAautomationAmigrationAstrategyAisAaAformalizedAplanAforAevolvingAtheA
manufacturingAsystemsAusedAtoAproduceAnewAproductsAasAdemandAgrows.
1.17 WhatAareA theA threeAphasesAofAaA typicalAautomationA migrationAstrategy?
Answer:AAsAdefinedAinAtheAtext,AtheAthreeAtypicalAphasesAareAtheAfollowing:APhaseA1:AManualAproduction
Ausing Asingle-
stationAmannedAcellsAoperatingAindependently.APhaseA2:AAutomatedAproductionAusingAsingle-
stationAautomatedAcellsAoperatingAindependently.APhaseA3:AAutomatedAintegratedAproductionAusingAaAmul
ti-
stationAautomatedAsystemAwithAserialAoperationsAandAautomatedAtransferAofAworkAunitsAbetweenAstations.
2
, MfgAOps-3e-SA 11-
22,A23/06,A06/04/07
Chapter 2 A
MANUFACTURING OPERATIONS A
REVIEWA QUESTIONS
2.1 WhatAisAmanufacturing?
Answer:ATwoAdefinitionsAareAgivenAinAtheAtext,AoneAtechnologicalAandAtheAotherAeconomic.ATheAtechnolog
icalAdefinitionAisAtheAfollowing:AManufacturingAisAtheAapplicationAofAphysicalAandAchemicalAprocessesAtoAa
lterAtheAgeometry,Aproperties,Aand/orAappearanceAofAaAgivenAstartingAmaterialAtoAmakeApartsAorAproducts;Am
anufacturingAalsoAincludesAtheAjoiningAofAmultipleApartsAtoAmakeAassembledAproducts.ATheAeconomicAdefi
nitionAisAtheAfollowing:AManufacturingAisAtheAtransformationAofAmaterialsAintoAitemsAofAgreaterAvalueAbyA
meansAofAoneAorAmoreAprocessingAand/orAassemblyAoperations.
2.2 WhatAareAtheAthreeAbasicAindustryAcategories?
Answer:ATheAthreeAbasicAindustryAcategoriesAareAtheAfollowing:A(1)APrimaryAindustries,AwhichAareAthoseAth
atAcultivateAandAexploitAnaturalAresources,AsuchAasAagricultureAandAmining;A(2)AsecondaryAindustries,Awhic
hAconvertAtheAoutputsAofAtheAprimaryAindustriesAintoAproducts;AtheyAincludeAmanufacturing,Aconstruction,Aa
ndApowerAgeneration;AandA(3)AtertiaryAindustries,AwhichAconstituteAtheAserviceAsectorAofAtheAeconomy,Awh
ichAincludesAbanking,Aretail,Atransportation,Aeducation,Agivernment,AandAsoAon.
2.3 WhatAisAtheA differenceAbetweenAconsumerA goodsAandA capitalAgoods?
Answer:AConsumerAgoodsAareAproductsAthatAareApurchasedAdirectlyAbyAconsumers,AsuchAasAcars,Apersonal
Acomputers,ATVs,Atires,Atoys,Aand AtennisArackets.ACapitalAgoodsAareAproducts Apurchased AbyAother Acompani
esAtoAproduceAgoodsAandAsupplyAservices.AExamplesAincludeAcommercialAaircraft,AmainframeAcomputers,A
machineAtools,ArailroadAequipment,AandAconstructionAmachinery.
2.4 WhatA isAtheA differenceAbetweenAaA processingAoperationAandAanA assemblyAoperation?
Answer:AAAprocessingAoperationAtransformsAaAworkAmaterialAfromAoneAstateAofAcompletionAtoAaAmoreAadv
ancedAstateAthatAisAcloserAtoAtheAfinalAdesiredApartAorAproduct.AItAaddsAvalueAbyAchangingAtheAgeometry,Ap
roperties,AorAappearanceAofAtheAstartingAmaterial.AAnAassemblyAoperationAjoinsAtwoAorAmoreAcomponentsAt
oAcreateAaAnewAentity,AcalledAanAassembly,Asubassembly,AorAsomeAotherAtermAthatArefersAtoAtheAjoiningApr
ocess.
2.5 NameAtheAfourA categoriesAofApart-shapingAoperations,AbasedAonA theA stateAofA theA startingAworkA material.
Answer:ATheAfourAcategoriesAareA(1)AsolidificationAprocesses,A(2)AparticulateAprocessing,A(3)AdeformationApro
cesses,AandA(4)AmaterialAremovalAprocesses.
2.6 AssemblyAoperationsAcanAbeAclassifiedAasApermanentAjoiningAmethodsAandAmechanicalAassembly.AWhatAar
eAtheAfourAtypesAofApermanentAjoiningAmethods?
Answer:ATheAjoiningAprocessesAareA(1)Awelding,A(2)Abrazing,A(3)Asoldering,AandA(4)AadhesiveAbonding.
2.7 WhatA isAtheA differenceAbetweenAhardA productA varietyAandA softAproductAvariety?
Answer:AHardAproductAvarietyAisAwhenAtheAproductsAdifferAsubstantially.AInAanAassembledAproduct,AhardAv
arietyAisAcharacterizedAbyAaAlowAproportionAofAcommonApartsAamongAtheAproducts;AinAmanyAcases,AthereAa
reAnoAcommonAparts.ASoftAproductAvarietyAisAwhenAthereAareAonlyAsmallAdifferencesAbetweenAproducts.ATh
ereAisAaAhighAproportionAofAcommonApartsAamongAassembledAproductsAwhoseAvarietyAisAsoft.
2.8 WhatAtypeAofAproductionAdoesAaAjobAshopAperform?
Answer:ALowAproductionAofAspecializedAandAcustomizedAproducts.ATheAproductsAareAtypicallyAcomplex,Asu
chAasAspaceAcapsules,Aaircraft,AandAspecialAmachinery.
2.9 FlowAlineAproductionAisAassociatedAwithAwhichAoneAofAtheAfollowingAlayoutAtypes:A(a)AcellularAlayout,A(b)
Afixed-Aposition Alayout,A(c) AprocessAlayout,AorA(d)AproductAlayout?
Answer:A(d)AProductAlayout.
2.10 WhatAisAtheA differenceA betweenA aA single-modelAproductionAlineAandA aAmixed-modelAproductionAline?
3
for
Automation,
Production Systems, and
Computer Integrated Manufacturing
Third Edition A
Mikell P. Groover A A
Professor of Industrial and Systems Engineering
A A A A A A
Lehigh University A
200 West Packer Avenue Bethlehe
A A A A
m, Pennsylvania 18015
A A
Other contact information:
A A
E-
mail address: or Teleph
A A A A A
one: 610-758-4030
A
Pearson/PRENTICE HALL, Upper Saddle River, New Jersey, 07548
A A A A A A A
,Ch01AIntroduction-3e-SA 12-15,A16/06,A06/04/07
Chapter 1 INTROD
A A
UCTION
REVIEWA QUESTIONS
1.1 WhatAareAsomeAofAtheArealitiesAmentionedAatAtheAbeginningAofAtheAchapterAthatAmodernAmanufacturingAenter
prisesAmustAcopeAwith?ANameAfour.
Answer:ATheArealitiesAmentionedAinAtheAtextAareA(1)Aglobalization,A(2)AinternationalAoutsourcing,A(3)Alocal
Aoutsourcing, A(4) AcontractAmanufacturing, A(5)Atrend Atoward AtheAserviceAsector, A(6) Aquality Aexpectations, Aan
dA(7)AtheAneedAforAoperationalAefficiency.
1.2 WhatAisAaAproductionAsystem?
Answer:AAsAdefinedAinAtheAtext,AaAproductionAsystemAisAaAcollectionAofApeople,Aequipment,AandAprocedure
sAorganizedAtoAperformAtheAmanufacturingAoperationsAofAaAcompanyA(orAotherAorganization).
1.3 ProductionA systemsAcanA beAdividedA intoA twoAcategoriesAorA levels.A NameAandAbrieflyAdefineAtheAtwoA levels.
Answer:ATheAtwoAcategoriesAgivenAinAtheAtextAareA(1)Afacilities,AwhichAconsistAofAtheAfactory,AtheAequipm
entAinAtheAfactory,AandAtheAwayAtheAequipmentAisAorganized;AandA(2)Amanufacturing AsupportAsystems,Awhi
chAisAtheAsetAofAproceduresAusedAbyAtheAcompanyAtoAmanageAproductionAandAtoAsolveAtheAtechnicalAandAl
ogisticsAproblemsAencounteredAinAorderingAmaterials,AmovingAtheAworkAthroughAtheAfactory,AandAensuring
AthatAproductsAmeet Aquality Astandards.AProductAdesign Aand Acertain Abusiness Afunctions AareAincluded Aamong
AtheAmanufacturing AsupportAsystems.
1.4 WhatAareA manufacturingAsystems,AandAhowAareAtheyAdistinguishedAfromAproductionA systems?
Answer:AAAmanufacturing AsystemAisAaAlogicalAgroupingAofAequipmentAinAtheAfactoryAandAtheAworker(s)Aw
hoAoperate(s)Ait.AExamplesAincludeAworker-
machineAsystems,AproductionAlines,AandAmachineAcells.AAAproductionAsystemAisAaAlargerAsystemAthatAinclu
desAaAcollectionAofAmanufacturingAsystemsAandAtheAsupportAsystemsAusedAtoAmanageAthem.AAAmanufacturi
ngAsystemAisAaAsubsetAofAtheAproductionAsystem.
1.5 ManufacturingAsystemsAareAdividedAintoAthreeAcategories,AaccordingAtoAworkerAparticipation.ANameAtheA
threeAcategories.
Answer:ATheAthreeAcategoriesAareA(1)AmanualAworkAsystems,A(2)Aworker-
machineAsystems,AandA(3)AautomatedAsystems.
1.6 WhatAareAtheA fourA functionsAincludedAwithinAtheAscopeAofAmanufacturingAsupportAsystems?
Answer:AAsAidentifiedAinAtheAtext,AtheAfourAfunctionsAareA(1)AbusinessAfunctions,A(2)AproductAdesign,A(3)A
manufacturingAplanning,AandA(4)AmanufacturingAcontrol.
1.7 ThreeAbasicAtypesAofAautomationAareAdefinedAinAtheAtext.AWhatAisAfixedAautomationAandAwhatAareAsom
eAofAitsAfeatures?
Answer:AFixedAautomationAisAaAsystemAinAwhichAtheAsequenceAofAprocessingA(orAassembly)AoperationsAisAf
ixedAbyAtheAequipmentAconfiguration.AEachAoperationAinAtheAsequenceAisAusuallyAsimple,AbutAtheAintegratio
nAandAcoordination AofAmanyAsuchAoperationsAintoAoneApieceAofAequipmentAmakesAtheAsystemAcomplex.ATy
picalAfeaturesAofAfixedAautomationAareA(1)AhighAinitialAinvestmentAforAcustom-
engineeredAequipment,A(2)AhighAproductionArates,AandA(3)ArelativelyAinflexibleAinAaccommodatingAproductA
variety.
1.8 WhatAisAprogrammableAautomationAandAwhatAareA someAofAitsAfeatures?
Answer:AInAprogrammableAautomation,AtheA productionAequipmentAisAdesignedA withAtheAcapabilityAtoAchan
geA theAsequenceAofAoperationsAtoAaccommodateAdifferentAproductAconfigurations.ATheAoperationAsequenceA
isAcontrolledAbyAaAprogram,AwhichAisAaAsetAofAinstructionsAcodedAsoAthatAtheyAcanAbeAreadAandAinterpreted
AbyAtheAsystem.ASomeAofAtheAfeatures AofAprogrammable Aautomation AareA(1) Ahigh AinvestmentAinAgeneralApu
rposeAequipment,A(2)AlostAproductionAtimeAdueAtoAchangeoversAofAphysicalAsetupAandAreprogramming,A(3)A
lowerAproductionAratesAthanAfixedAautomation,A(4)AflexibilityAtoAdealAwithAvariationsAandAchangesAinAprodu
ctAconfiguration,AandA(5)AmostAsuitableAforAbatchAproduction.
1.9 WhatAisAflexibleAautomationA andAwhatAareAsomeAofAitsAfeatures?
1
,Ch01AIntroduction-3e-SA 12-15,A16/06,A06/04/07
Answer:AFlexibleAautomationAisAanAextensionAofAprogrammableAautomation.AAAflexibleAautomatedAsystemA
isAcapableAofAproducingAaAvarietyAofApartsA(orAproducts)AwithAvirtuallyAnoAtimeAlostAforAchangeoversAfrom
AoneApartAstyleAto AtheAnext.AThereAisAnoAlostAproduction AtimeA whileAreprogramming AtheAsystemAand Aalterin
gAtheAphysicalAsetup.AAccordingly,AtheAsystemAcanAproduceAvariousAmixesAandAschedulesAofApartsAorAprod
uctsAinsteadAofArequiringAthatAtheyAbeAmadeAinAbatches.ATheAfeaturesAofAflexibleAautomationAareA(1)AhighAi
nvestmentAforAaAcustom-
engineeredAsystem,A(2)AcontinuousAproductionAofAvariableAmixturesAofAproducts,A(3)AmediumAproductionAr
ates,AandA(4)AflexibilityAtoAdealAwithAproductAdesignAvariations
1.10 WhatAisAcomputerA integratedA manufacturing?
Answer:AAsAdefinedAinAtheAtext,Acomputer-
integratedAmanufacturing A(CIM)AdenotesAtheApervasiveAuseAofAcomputerAsystemsAtoAdesignAtheAproducts,A
planAtheAproduction,AcontrolAtheAoperations,AandAperformAtheAvariousAinformation-
processingAfunctionsAneededAinAaAmanufacturingAfirm.ATrueACIMAinvolvesAintegratingAallAofAtheseAfunctio
nsAinAoneAsystemAthatAoperatesAthroughoutAtheAenterprise.
1.11 WhatAareAsomeAofAtheAreasonsAwhyAcompaniesAautomateAtheirAoperations?ANineAreasonsAareAgivenAinAth
eAtext.ANameAfive.
Answer:ATheAreasonsAgiveAinAtheAtextAareA(1)AtoAincreaseAlaborAproductivity,A(2)AtoAreduceAlaborAcost,A(3)
AtoAmitigateAtheAeffectsAofAlabor Ashortages, A(4) AtoAreduceAorAeliminateAroutineAmanualAand AclericalAtasks,A
(5)AtoAimproveAworkerAsafety,A(6)AtoAimproveAproductAquality,A(7)AtoAreduceAmanufacturingAleadAtime,A(8)
AtoAaccomplish Aprocesses AthatA cannotAbeAdoneAmanually,Aand A (9)AtoAavoid AtheAhigh AcostAofAnotAautomatin
g.
1.12 IdentifyAthreeA situationsAinAwhichAmanualA laborA isApreferredAoverAautomation.
Answer:ATheAfiveAsituationsAlistedAinAtheAtextAareAtheAfollowing:A(1)ATheAtaskAisAtechnologicallyAtooAdiffic
ultAtoAautomate.A(2)AShortAproductAlifeAcycle.A(3)ACustomizedAproduct.A(4)AToAcopeAwithAupsAandAdownsA
inAdemand.
(5)AToAreduceAriskAofAproductAfailure.
1.13 HumanAworkersAwillAbeAneededAinAfactoryAoperations,AevenAinAtheAmostAhighlyAautomatedAoperations.ATh
eAtextAidentifiesAatAleastAfourAtypesAofAworkAforAwhichAhumansAwillAbeAneeded.ANameAthree.
Answer:ATheAfourAtypesAofAworkAidentifiedAinAtheAtextAareA(1)AequipmentAmaintenance,A(2)AprogrammingA
andAcomputerAoperations,A(3)AengineeringAprojectAwork,AandA(4)AplantAmanagement.
1.14 WhatAisAtheA USAAPrinciple?AWhatAdoesAeachAofA theA lettersAstandAfor?
Answer:ATheAUSAAPrincipleAisAaAcommonAsenseAapproachAtoAautomationAandAprocessAimprovementAproj
ects.AUAmeansA“understandAtheAexistingAprocess,”ASAstandsAforA“simplifyAtheAprocess,”AandAAAstandsAforA
“automatedAtheAprocess.”
1.15 TheAtextAlistsAtenA strategiesAforAautomationAandAprocessAimprovement.AIdentifyAfiveAofA theseA strategies.
Answer:ATheAtenAstrategiesAlistedAinAtheAtextAareA(1)AspecializationAofAoperations,A(2)AcombinedAoperation
s,A(3)AsimultaneousAoperations,A(4)AintegrationAofAoperations,A(5)AincreasedAflexibility,A(6)AimprovedAmate
rialAhandlingAandAstorage,A(7)Aon-
lineAinspection,A(8)AprocessAcontrolAandAoptimization,A(9)AplantAoperationsAcontrol,AandA(10)Acomputer-
integratedAmanufacturing A(CIM).
1.16 WhatAisAanAautomationAmigrationA strategy?
Answer:AAsAdefinedAinAtheAtext,AanAautomationAmigrationAstrategyAisAaAformalizedAplanAforAevolvingAtheA
manufacturingAsystemsAusedAtoAproduceAnewAproductsAasAdemandAgrows.
1.17 WhatAareA theA threeAphasesAofAaA typicalAautomationA migrationAstrategy?
Answer:AAsAdefinedAinAtheAtext,AtheAthreeAtypicalAphasesAareAtheAfollowing:APhaseA1:AManualAproduction
Ausing Asingle-
stationAmannedAcellsAoperatingAindependently.APhaseA2:AAutomatedAproductionAusingAsingle-
stationAautomatedAcellsAoperatingAindependently.APhaseA3:AAutomatedAintegratedAproductionAusingAaAmul
ti-
stationAautomatedAsystemAwithAserialAoperationsAandAautomatedAtransferAofAworkAunitsAbetweenAstations.
2
, MfgAOps-3e-SA 11-
22,A23/06,A06/04/07
Chapter 2 A
MANUFACTURING OPERATIONS A
REVIEWA QUESTIONS
2.1 WhatAisAmanufacturing?
Answer:ATwoAdefinitionsAareAgivenAinAtheAtext,AoneAtechnologicalAandAtheAotherAeconomic.ATheAtechnolog
icalAdefinitionAisAtheAfollowing:AManufacturingAisAtheAapplicationAofAphysicalAandAchemicalAprocessesAtoAa
lterAtheAgeometry,Aproperties,Aand/orAappearanceAofAaAgivenAstartingAmaterialAtoAmakeApartsAorAproducts;Am
anufacturingAalsoAincludesAtheAjoiningAofAmultipleApartsAtoAmakeAassembledAproducts.ATheAeconomicAdefi
nitionAisAtheAfollowing:AManufacturingAisAtheAtransformationAofAmaterialsAintoAitemsAofAgreaterAvalueAbyA
meansAofAoneAorAmoreAprocessingAand/orAassemblyAoperations.
2.2 WhatAareAtheAthreeAbasicAindustryAcategories?
Answer:ATheAthreeAbasicAindustryAcategoriesAareAtheAfollowing:A(1)APrimaryAindustries,AwhichAareAthoseAth
atAcultivateAandAexploitAnaturalAresources,AsuchAasAagricultureAandAmining;A(2)AsecondaryAindustries,Awhic
hAconvertAtheAoutputsAofAtheAprimaryAindustriesAintoAproducts;AtheyAincludeAmanufacturing,Aconstruction,Aa
ndApowerAgeneration;AandA(3)AtertiaryAindustries,AwhichAconstituteAtheAserviceAsectorAofAtheAeconomy,Awh
ichAincludesAbanking,Aretail,Atransportation,Aeducation,Agivernment,AandAsoAon.
2.3 WhatAisAtheA differenceAbetweenAconsumerA goodsAandA capitalAgoods?
Answer:AConsumerAgoodsAareAproductsAthatAareApurchasedAdirectlyAbyAconsumers,AsuchAasAcars,Apersonal
Acomputers,ATVs,Atires,Atoys,Aand AtennisArackets.ACapitalAgoodsAareAproducts Apurchased AbyAother Acompani
esAtoAproduceAgoodsAandAsupplyAservices.AExamplesAincludeAcommercialAaircraft,AmainframeAcomputers,A
machineAtools,ArailroadAequipment,AandAconstructionAmachinery.
2.4 WhatA isAtheA differenceAbetweenAaA processingAoperationAandAanA assemblyAoperation?
Answer:AAAprocessingAoperationAtransformsAaAworkAmaterialAfromAoneAstateAofAcompletionAtoAaAmoreAadv
ancedAstateAthatAisAcloserAtoAtheAfinalAdesiredApartAorAproduct.AItAaddsAvalueAbyAchangingAtheAgeometry,Ap
roperties,AorAappearanceAofAtheAstartingAmaterial.AAnAassemblyAoperationAjoinsAtwoAorAmoreAcomponentsAt
oAcreateAaAnewAentity,AcalledAanAassembly,Asubassembly,AorAsomeAotherAtermAthatArefersAtoAtheAjoiningApr
ocess.
2.5 NameAtheAfourA categoriesAofApart-shapingAoperations,AbasedAonA theA stateAofA theA startingAworkA material.
Answer:ATheAfourAcategoriesAareA(1)AsolidificationAprocesses,A(2)AparticulateAprocessing,A(3)AdeformationApro
cesses,AandA(4)AmaterialAremovalAprocesses.
2.6 AssemblyAoperationsAcanAbeAclassifiedAasApermanentAjoiningAmethodsAandAmechanicalAassembly.AWhatAar
eAtheAfourAtypesAofApermanentAjoiningAmethods?
Answer:ATheAjoiningAprocessesAareA(1)Awelding,A(2)Abrazing,A(3)Asoldering,AandA(4)AadhesiveAbonding.
2.7 WhatA isAtheA differenceAbetweenAhardA productA varietyAandA softAproductAvariety?
Answer:AHardAproductAvarietyAisAwhenAtheAproductsAdifferAsubstantially.AInAanAassembledAproduct,AhardAv
arietyAisAcharacterizedAbyAaAlowAproportionAofAcommonApartsAamongAtheAproducts;AinAmanyAcases,AthereAa
reAnoAcommonAparts.ASoftAproductAvarietyAisAwhenAthereAareAonlyAsmallAdifferencesAbetweenAproducts.ATh
ereAisAaAhighAproportionAofAcommonApartsAamongAassembledAproductsAwhoseAvarietyAisAsoft.
2.8 WhatAtypeAofAproductionAdoesAaAjobAshopAperform?
Answer:ALowAproductionAofAspecializedAandAcustomizedAproducts.ATheAproductsAareAtypicallyAcomplex,Asu
chAasAspaceAcapsules,Aaircraft,AandAspecialAmachinery.
2.9 FlowAlineAproductionAisAassociatedAwithAwhichAoneAofAtheAfollowingAlayoutAtypes:A(a)AcellularAlayout,A(b)
Afixed-Aposition Alayout,A(c) AprocessAlayout,AorA(d)AproductAlayout?
Answer:A(d)AProductAlayout.
2.10 WhatAisAtheA differenceA betweenA aA single-modelAproductionAlineAandA aAmixed-modelAproductionAline?
3
