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Solution Manual For Automation, Production
Systems, and Computer-Integrated
Manufacturing, 5th edition ( Mikell P. Groover,
2024) All Chapters 1-26| Latest Edition
, Stuvia.com - The Marketplace to Buy and Sell your Study Material
Ch01 Introduction-3e-S 12-15, 16/06, 06/04/07
Chapter 1 Introduction
Review Questions
1 .1 What Are Some Of Therealities Mentioned At Thebeginning Of The Chapter That Modern Manufacturing
Enterprises Must Cope With? Na m e Four.
Ans: The Realities Mentioned In The Text Are (1) Globalization, (2) International Outsourcing, (3) Local
Outsourcing, (4) Contract Manufacturing, (5) Trend Toward The Service Sector, (6) Quality Expectations,
And (7) The Need For Operational Efficiency.
1 .2 What Is A Production System?
Ans: As Defined In The Text, A Production System Is A Collection Of People, Equipment, And
Procedures Organized To Perform The Manufacturing Operations Of A Company (Or Other Organization).
1 .3 Production Systems Can Be Divided Into Two Categories Or Levels. Na m e And Briefly Define The Two Levels.
Ans: The Two Categories Given In The Text Are (1) Facilities, Which Consist Of The Factory, The
Equipment In The Factory, And The Way The Equipment Is Organized; And (2) Manufacturing Support
Systems, Which Is The Set Of Procedures Used By The Company To Manage Production And To Solve
The Technical And Logistics Problems Encountered In Ordering Materials, Moving The Work Through The
Factory, And Ensuring That Products Meet Quality Standards. Product Design And Certain Business
Functions Are Included Among The Manufacturing Support Systems.
1 .4 What Are Manufacturing Systems, And How Are They Distinguished From Production Systems?
Ans: A Manufacturing System Is A Logical Grouping Of Equipment In The Factory And The Worker(S)
Who Operate(S) It. Examples Include Worker-Machine Systems, Production Lines, And Machine Cells. A
Production
System Is A Larger System That Includes A Collection Of Manufacturing Systems And The Support Systems Used
To Manage Them. A Manufacturing System Is A Subset Of The Production System.
1 .5 Manufacturing Systems Are Divided Into Three Categories, According To Worker Participation. Name The
Three Categories.
Ans: The Three Categories Are (1) M a n u a l Work Systems, (2) Worker-Machine Systems, And (3)
Automated Systems.
1 .6 What Are The Four Functions Included Within The Scope Of Manufacturing Support Systems?
Ans: As Identified In The Text, The Four Functions Are (1) Business Functions, (2) Product Design, (3)
Manufacturing Planning, And (4) Manufacturing Control.
1 .7 Three Basic Types Of Automation Are Defined In The Text. What Is Fixed Automation And What Are
Some Of Its Features?
Ans: Fixed Automation Is A System In Which The Sequence Of Processing (Or Assembly) Operations Is
Fixed By The Equipment Configuration. Each Operation In The Sequence Is Usually Simple, But The
Integration And Coordination Of M a ny Such Operations Into One Piece Of Equipment Makes The System
Complex. Typical Features Of Fixed Automation Are (1) High Initial Investment For Custom -Engineered
Equipment, (2) High Production Rates, And (3) Relatively Inflexible In Accommodating Product Variety.
1 .8 What Is Programmable Automation And What Are Some Of Its Features?
Ans: In Programmable Automation, The Production Equipment Is Designed With The Capability To Change The
Sequence Of Operations To Accommodate Different Product Configurations. The Operation Sequence Is
Controlled By A Program, Which Is A Set Of Instructions Coded So That They Can Be Read And
Interpreted By The System. Some Of The Features Of Programmable Automation Are (1) High Investment
In General Purpose Equipment, (2) Lost Production Time Due To Changeovers Of Physical Setup And
Reprogramming, (3) Lower Production Rates Than Fixed Automation, (4) Flexibility To Deal With
Variations And Changes In Product Configuration, And (5) Most Suitable For Batch Production.
1 .9 What Is Flexible Automation And What Are Some Of Its Features?
1
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Ch01 Introduction-3e-S 12-15, 16/06, 06/04/07
Ans: Flexible Automation Is An Extension Of Programmable Automation. A Flexible Automated System
Is Capable Of Producing A Variety Of Parts (Or Products) With Virtually No Time Lost For Changeovers From
One Part Style To The Next. There Is No Lost Production Time While Reprogramming The System And
Altering The Physical Setup. Accordingly, The System Can Produce Various Mixes And Schedules Of Parts
Or Products Instead Of Requiring That They Be M a de In Batches. The Features Of Flexible Automation
Are (1) High Investment For A Custom-Engineered System, (2) Continuous Production Of Variable Mixtures
Of Products, (3) Medium Production Rates, And (4) Flexibility To Deal With Product Design Variations
1 .1 0 What Is Computer Integrated Manufacturing?
Ans: As Defined In The Text, Computer-Integrated Manufacturing (Cim) Denotes The Pervasive Use Of
Computer Systems To Design The Products, Plan The Production, Control The Operations, And Perform
The Various
Information-Processing Functions Needed In A Manufacturing Firm. True Cim Involves Integrating All Of These
Functions In One System That Operates Throughout The Enterprise.
1 .1 1 What Are Some Of Thereasons Why Companies Automate Their Operations? Nine Reasons Are Given In
The Text. Na m e Five.
Ans: The Reasons Give In The Text Are (1) To Increase Labor Productivity, (2) To Reduce Labor Cost, (3) To
Mitigate The Effects Of Labor Shortages, (4) To Reduce Or Eliminate Routine M a n u a l And Clerical Tasks,
(5) To Improve Worker Safety, (6) To Improve Product Quality, (7) To Reduce Manufacturing Lead Time,
(8) To Accomplish Processes That Cannot Be Done Manually, And (9) To Avoid The High Cost Of Not
Automating.
1 .1 2 Identify Three Situations In Which M a n u a l Labor Is Preferred Over Automation.
Ans: The Five Situations Listed In The Text Are The Following: (1) The Task Is Technologically Too Difficult To
Automate. (2) Short Product Life Cycle. (3) Customized Product. (4) To Cope With Ups And Downs In Demand.
(5) To Reduce Risk Of Product Failure.
1 .1 3 Human Workers Will Be Needed In Factory Operations, Even In The Most Highly Automated Operations.
The Text Identifies At Least Four Types Of Work For Which Humans Will Be Needed. Na m e Three.
Ans: The Four Types Of Work Identified In The Text Are (1) Equipment Maintenance, (2) Programming
And Computer Operations, (3) Engineering Project Work, And (4) Plant Management.
1 .1 4 What Is The Usa Principle? What Does Each Of The Letters Stand For?
Ans: The Usa Principle Is A Common Sense Approach To Automation And Process Improvement Projects. U
Means “Understand The Existing Process,” S Stands For “Simplify The Process,” And A Stands For
“Automated The Process.”
1 .1 5 The Text Lists Ten Strategies For Automation And Process Improvement. Identify Five Of These Strategies.
Ans: The Ten Strategies Listed In The Text Are (1) Specialization Of Operations, (2) Combined
Operations, (3) Simultaneous Operations, (4) Integration Of Operations, (5) Increased Flexibility, (6)
Improved Material
Handling And Storage, (7) On-Line Inspection, (8) Process Control And Optimization, (9) Plant Operations
Control, And (10) Computer-Integrated Manufacturing (Cim).
1 .1 6 What Is An Automation Migration Strategy?
Ans: As Defined In The Text, An Automation Migration Strategy Is A Formalized Plan For Evolving The
Manufacturing Systems Used To Produce New Products As Demand Grows.
1 .1 7 What Are The Three Phases Of A Typical Automation Migration Strategy?
Ans: As Defined In The Text, The Three Typical Phases Are The Following: Phase 1: M a n u a l
Production Using Single-Station Manned Cells Operating Independently. Phase 2: Automated Production
Using Single -Station Automated Cells Operating Independently. Phase 3: Automated Integrated
Production Using A Multi-Station Automated System With Serial Operations And Automated Transfer
Of Work Units Between Stations.
2
, Chapter 2
Manufacturing Operations
Review Questions
2 .1 What Is Manufacturing?
Ans: Two Definitions Are Given In The Text, One Technological And The Other Economic. The
Technological Definition Is The Following: Manufacturing Is The Application Of Physical And Chemical
Processes To Alter The Geometry, Properties, And/Or Appearance Of A Given Startingmaterialto Make Parts
Or Products; Manufacturing Also Includes The Joining Of Multiple Parts To M a ke Assembled Products. The
Economic Definition Is The Following: Manufacturing Is The Transformation Of Materials Into Items Of
Greater Value By Means Of One Or More Processing And/Or Assembly Operations.
2 .2 What Are The Three Basic Industry Categories?
Ans: The Three Basic Industry Categories Are The Following: (1) Primary Industries, Which Are Those That
Cultivate And Exploit Natural Resources, Such As Agriculture And Mining; (2) Secondary Industries,
Which Convert The Outputs Of The Primary Industries Into Products; They Include Manufacturing,
Construction, And Power
Generation; And (3) Tertiary Industries, Which Constitute The Service Sector Of The Economy, Which
Includes Banking, Retail, Transportation, Education, Givernment, And So On.
2 .3 What Is The Difference Between Consumer Goods And Capital Goods?
Ans: Consumer Goods Are Products That Are Purchased Directly By Consumers, Such As Cars, Personal
Computers, Tvs, Tires, Toys, And Tennis Rackets. Capital Goods Are Products Purchased By Other
Companies To Produce Goods And Supply Services. Examples Include Commercial Aircraft, Mainframe
Computers, Machine Tools, Railroad Equipment, And Construction Machinery.
2 .4 What Is The Difference Between A Processing Operation And An Assembly Operation?
Ans: A Processing Operation Transforms A Work Materialfrom One State Of Completion To A More
Advanced State That Is Closer To The Final Desired Part Or Product. It Adds Value By Changing The
Geometry, Properties, Or
Appearance Of The Starting Material. 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.
2 .5 Na m e The Four Categories Of Part-Shaping Operations, Based On The State Of The Starting Work Material.
Ans: The Four Categories Are (1) Solidification Processes, (2) Particulate Processing, (3) Deformation
Processes, And (4) Material Removal Processes.
2 .6 Assembly Operations C anbe Classified As Permanent Joiningmethods And Mechanicalassembly. What
Are The Four Types Of Permanent Joining Methods?
Ans: The Joiningprocesses Are (1) Welding, (2) Brazing, (3) Soldering, And (4) Adhesive Bonding.
2 .7 What Is The Difference Between Hard Product Variety And Soft Product Variety?
Ans: Hard Product Variety Is When The Products Differ Substantially. In An Assembled Product, Hard
Variety Is Characterized By A Low Proportion Of Common Parts Among The Products; In M a n y Cases,
There Are No Common Parts. Soft Product Variety Is When There Are Only Small Differences Between
Products. There Is A High Proportion Of Common Parts Among Assembled Products Whose Variety Is Soft.
2 .8 What Type Of Production Does A Job Shop Perform?
Ans: Low Production Of Specialized And Customized Products. The Products Are Typically Complex, Such As
Space Capsules, Aircraft, And Special Machinery.
2 .9 Flow Line Production Is Associated With Which One Of The Following Layout Types: (A) Cellular Layout,
(B) Fixed-Position Layout, (C) Process Layout, Or (D) Product Layout?
Ans: (D) Product Layout.
2 .1 0 What Is The Difference Between A Single-Model Production Line And A Mixed-Model Production Line?
3
Solution Manual For Automation, Production
Systems, and Computer-Integrated
Manufacturing, 5th edition ( Mikell P. Groover,
2024) All Chapters 1-26| Latest Edition
, Stuvia.com - The Marketplace to Buy and Sell your Study Material
Ch01 Introduction-3e-S 12-15, 16/06, 06/04/07
Chapter 1 Introduction
Review Questions
1 .1 What Are Some Of Therealities Mentioned At Thebeginning Of The Chapter That Modern Manufacturing
Enterprises Must Cope With? Na m e Four.
Ans: The Realities Mentioned In The Text Are (1) Globalization, (2) International Outsourcing, (3) Local
Outsourcing, (4) Contract Manufacturing, (5) Trend Toward The Service Sector, (6) Quality Expectations,
And (7) The Need For Operational Efficiency.
1 .2 What Is A Production System?
Ans: As Defined In The Text, A Production System Is A Collection Of People, Equipment, And
Procedures Organized To Perform The Manufacturing Operations Of A Company (Or Other Organization).
1 .3 Production Systems Can Be Divided Into Two Categories Or Levels. Na m e And Briefly Define The Two Levels.
Ans: The Two Categories Given In The Text Are (1) Facilities, Which Consist Of The Factory, The
Equipment In The Factory, And The Way The Equipment Is Organized; And (2) Manufacturing Support
Systems, Which Is The Set Of Procedures Used By The Company To Manage Production And To Solve
The Technical And Logistics Problems Encountered In Ordering Materials, Moving The Work Through The
Factory, And Ensuring That Products Meet Quality Standards. Product Design And Certain Business
Functions Are Included Among The Manufacturing Support Systems.
1 .4 What Are Manufacturing Systems, And How Are They Distinguished From Production Systems?
Ans: A Manufacturing System Is A Logical Grouping Of Equipment In The Factory And The Worker(S)
Who Operate(S) It. Examples Include Worker-Machine Systems, Production Lines, And Machine Cells. A
Production
System Is A Larger System That Includes A Collection Of Manufacturing Systems And The Support Systems Used
To Manage Them. A Manufacturing System Is A Subset Of The Production System.
1 .5 Manufacturing Systems Are Divided Into Three Categories, According To Worker Participation. Name The
Three Categories.
Ans: The Three Categories Are (1) M a n u a l Work Systems, (2) Worker-Machine Systems, And (3)
Automated Systems.
1 .6 What Are The Four Functions Included Within The Scope Of Manufacturing Support Systems?
Ans: As Identified In The Text, The Four Functions Are (1) Business Functions, (2) Product Design, (3)
Manufacturing Planning, And (4) Manufacturing Control.
1 .7 Three Basic Types Of Automation Are Defined In The Text. What Is Fixed Automation And What Are
Some Of Its Features?
Ans: Fixed Automation Is A System In Which The Sequence Of Processing (Or Assembly) Operations Is
Fixed By The Equipment Configuration. Each Operation In The Sequence Is Usually Simple, But The
Integration And Coordination Of M a ny Such Operations Into One Piece Of Equipment Makes The System
Complex. Typical Features Of Fixed Automation Are (1) High Initial Investment For Custom -Engineered
Equipment, (2) High Production Rates, And (3) Relatively Inflexible In Accommodating Product Variety.
1 .8 What Is Programmable Automation And What Are Some Of Its Features?
Ans: In Programmable Automation, The Production Equipment Is Designed With The Capability To Change The
Sequence Of Operations To Accommodate Different Product Configurations. The Operation Sequence Is
Controlled By A Program, Which Is A Set Of Instructions Coded So That They Can Be Read And
Interpreted By The System. Some Of The Features Of Programmable Automation Are (1) High Investment
In General Purpose Equipment, (2) Lost Production Time Due To Changeovers Of Physical Setup And
Reprogramming, (3) Lower Production Rates Than Fixed Automation, (4) Flexibility To Deal With
Variations And Changes In Product Configuration, And (5) Most Suitable For Batch Production.
1 .9 What Is Flexible Automation And What Are Some Of Its Features?
1
Downloaded By Sundaram R ()
, Stuvia.com - The Marketplace to Buy and Sell your Study Material
Ch01 Introduction-3e-S 12-15, 16/06, 06/04/07
Ans: Flexible Automation Is An Extension Of Programmable Automation. A Flexible Automated System
Is Capable Of Producing A Variety Of Parts (Or Products) With Virtually No Time Lost For Changeovers From
One Part Style To The Next. There Is No Lost Production Time While Reprogramming The System And
Altering The Physical Setup. Accordingly, The System Can Produce Various Mixes And Schedules Of Parts
Or Products Instead Of Requiring That They Be M a de In Batches. The Features Of Flexible Automation
Are (1) High Investment For A Custom-Engineered System, (2) Continuous Production Of Variable Mixtures
Of Products, (3) Medium Production Rates, And (4) Flexibility To Deal With Product Design Variations
1 .1 0 What Is Computer Integrated Manufacturing?
Ans: As Defined In The Text, Computer-Integrated Manufacturing (Cim) Denotes The Pervasive Use Of
Computer Systems To Design The Products, Plan The Production, Control The Operations, And Perform
The Various
Information-Processing Functions Needed In A Manufacturing Firm. True Cim Involves Integrating All Of These
Functions In One System That Operates Throughout The Enterprise.
1 .1 1 What Are Some Of Thereasons Why Companies Automate Their Operations? Nine Reasons Are Given In
The Text. Na m e Five.
Ans: The Reasons Give In The Text Are (1) To Increase Labor Productivity, (2) To Reduce Labor Cost, (3) To
Mitigate The Effects Of Labor Shortages, (4) To Reduce Or Eliminate Routine M a n u a l And Clerical Tasks,
(5) To Improve Worker Safety, (6) To Improve Product Quality, (7) To Reduce Manufacturing Lead Time,
(8) To Accomplish Processes That Cannot Be Done Manually, And (9) To Avoid The High Cost Of Not
Automating.
1 .1 2 Identify Three Situations In Which M a n u a l Labor Is Preferred Over Automation.
Ans: The Five Situations Listed In The Text Are The Following: (1) The Task Is Technologically Too Difficult To
Automate. (2) Short Product Life Cycle. (3) Customized Product. (4) To Cope With Ups And Downs In Demand.
(5) To Reduce Risk Of Product Failure.
1 .1 3 Human Workers Will Be Needed In Factory Operations, Even In The Most Highly Automated Operations.
The Text Identifies At Least Four Types Of Work For Which Humans Will Be Needed. Na m e Three.
Ans: The Four Types Of Work Identified In The Text Are (1) Equipment Maintenance, (2) Programming
And Computer Operations, (3) Engineering Project Work, And (4) Plant Management.
1 .1 4 What Is The Usa Principle? What Does Each Of The Letters Stand For?
Ans: The Usa Principle Is A Common Sense Approach To Automation And Process Improvement Projects. U
Means “Understand The Existing Process,” S Stands For “Simplify The Process,” And A Stands For
“Automated The Process.”
1 .1 5 The Text Lists Ten Strategies For Automation And Process Improvement. Identify Five Of These Strategies.
Ans: The Ten Strategies Listed In The Text Are (1) Specialization Of Operations, (2) Combined
Operations, (3) Simultaneous Operations, (4) Integration Of Operations, (5) Increased Flexibility, (6)
Improved Material
Handling And Storage, (7) On-Line Inspection, (8) Process Control And Optimization, (9) Plant Operations
Control, And (10) Computer-Integrated Manufacturing (Cim).
1 .1 6 What Is An Automation Migration Strategy?
Ans: As Defined In The Text, An Automation Migration Strategy Is A Formalized Plan For Evolving The
Manufacturing Systems Used To Produce New Products As Demand Grows.
1 .1 7 What Are The Three Phases Of A Typical Automation Migration Strategy?
Ans: As Defined In The Text, The Three Typical Phases Are The Following: Phase 1: M a n u a l
Production Using Single-Station Manned Cells Operating Independently. Phase 2: Automated Production
Using Single -Station Automated Cells Operating Independently. Phase 3: Automated Integrated
Production Using A Multi-Station Automated System With Serial Operations And Automated Transfer
Of Work Units Between Stations.
2
, Chapter 2
Manufacturing Operations
Review Questions
2 .1 What Is Manufacturing?
Ans: Two Definitions Are Given In The Text, One Technological And The Other Economic. The
Technological Definition Is The Following: Manufacturing Is The Application Of Physical And Chemical
Processes To Alter The Geometry, Properties, And/Or Appearance Of A Given Startingmaterialto Make Parts
Or Products; Manufacturing Also Includes The Joining Of Multiple Parts To M a ke Assembled Products. The
Economic Definition Is The Following: Manufacturing Is The Transformation Of Materials Into Items Of
Greater Value By Means Of One Or More Processing And/Or Assembly Operations.
2 .2 What Are The Three Basic Industry Categories?
Ans: The Three Basic Industry Categories Are The Following: (1) Primary Industries, Which Are Those That
Cultivate And Exploit Natural Resources, Such As Agriculture And Mining; (2) Secondary Industries,
Which Convert The Outputs Of The Primary Industries Into Products; They Include Manufacturing,
Construction, And Power
Generation; And (3) Tertiary Industries, Which Constitute The Service Sector Of The Economy, Which
Includes Banking, Retail, Transportation, Education, Givernment, And So On.
2 .3 What Is The Difference Between Consumer Goods And Capital Goods?
Ans: Consumer Goods Are Products That Are Purchased Directly By Consumers, Such As Cars, Personal
Computers, Tvs, Tires, Toys, And Tennis Rackets. Capital Goods Are Products Purchased By Other
Companies To Produce Goods And Supply Services. Examples Include Commercial Aircraft, Mainframe
Computers, Machine Tools, Railroad Equipment, And Construction Machinery.
2 .4 What Is The Difference Between A Processing Operation And An Assembly Operation?
Ans: A Processing Operation Transforms A Work Materialfrom One State Of Completion To A More
Advanced State That Is Closer To The Final Desired Part Or Product. It Adds Value By Changing The
Geometry, Properties, Or
Appearance Of The Starting Material. 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.
2 .5 Na m e The Four Categories Of Part-Shaping Operations, Based On The State Of The Starting Work Material.
Ans: The Four Categories Are (1) Solidification Processes, (2) Particulate Processing, (3) Deformation
Processes, And (4) Material Removal Processes.
2 .6 Assembly Operations C anbe Classified As Permanent Joiningmethods And Mechanicalassembly. What
Are The Four Types Of Permanent Joining Methods?
Ans: The Joiningprocesses Are (1) Welding, (2) Brazing, (3) Soldering, And (4) Adhesive Bonding.
2 .7 What Is The Difference Between Hard Product Variety And Soft Product Variety?
Ans: Hard Product Variety Is When The Products Differ Substantially. In An Assembled Product, Hard
Variety Is Characterized By A Low Proportion Of Common Parts Among The Products; In M a n y Cases,
There Are No Common Parts. Soft Product Variety Is When There Are Only Small Differences Between
Products. There Is A High Proportion Of Common Parts Among Assembled Products Whose Variety Is Soft.
2 .8 What Type Of Production Does A Job Shop Perform?
Ans: Low Production Of Specialized And Customized Products. The Products Are Typically Complex, Such As
Space Capsules, Aircraft, And Special Machinery.
2 .9 Flow Line Production Is Associated With Which One Of The Following Layout Types: (A) Cellular Layout,
(B) Fixed-Position Layout, (C) Process Layout, Or (D) Product Layout?
Ans: (D) Product Layout.
2 .1 0 What Is The Difference Between A Single-Model Production Line And A Mixed-Model Production Line?
3
