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SOLUTION MANUAL
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,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover
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2010 06-19-09
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1 INTRODUCTION
Review Questions ty
1.1 What are the differences between primary, secondary, and tertiary industries? Give an example
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of each category.
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Answer. A primary industry is one that cultivates and exploits natural resources, such as
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agriculture or mining. A secondary industry takes the outputs of primary industries and
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converts them to consumer and capital goods. Examples of secondary industries are textiles and
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electronics. A tertiary industry is in the service sector of the economy. Examples of tertiary
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industries are banking and education.
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1.2 What is a capital good? Provide an example.
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Answer. Capital goods are those purchased by companies to produce goods or provide services.
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Examples of capital goods are aircraft and construction equipment.
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1.3 How are product variety and production quantity related when comparing typical factories?
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Answer. Generally production quantity is inversely related to product variety. A factory
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that produces a large variety of products will produce a smaller quantity of each. A
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company that produces a single product will produce a large quantity.
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1.4 Define manufacturing capability.
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Answer. Manufacturing capability refers to the technical and physical limitations of a
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manufacturing firm and each of its plants. Three categories of capability mentioned in the text
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are
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(1) technological processing capability, (2) physical size and weight, and (3) production capacity.
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1.5 Name the three basic categories of materials.
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Answer. The three basic categories of engineering materials are (1) metals, (2) ceramics, and
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(3) polymers. A fourth category, composites, is a non-homogeneous mixture of the other types
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and therefore is not a basic category.
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1.6 How does a shaping process differ from a surface processing operation?
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Answer. A shaping process changes the geometry of the work material (machining or forging).
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A surface processing operation does not alter the geometry, but instead alters surface of the
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work (painting or plating).
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1.7 What are two subclasses of assembly processes? Provide an example process for each subclass.
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Answer. The two subclasses of assembly processes are (1) permanent joining and (2)
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mechanical fastening. Examples of permanent joining include welding or adhesive bonding.
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Examples of mechanical fastening include threaded fasteners, such as nuts and bolts, and
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rivets.
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1.8 Define batch production and describe why it is often used for medium-quantity
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production products.
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Answer. Batch production is where groups, lots, or batches or materials or parts are processed
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together through the manufacturing operations. All units in the batch are processed at a given
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station before the group proceeds to the next station. In a medium or low quantity production
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situation, the same machines are used to produce many types of products. Whenever a
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machine switches from one product to another, a changeover occurs. The changeover requires
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Excerpts tyfrom tythis tywork tymay tybe tyreproduced tyby tyinstructors tyfor tydistribution tyon tya tynot-for-profit tybasis tyfor tytesting tyor tyinstructional
typurposes tyonly tyto t y students ty enrolled tyin ty courses tyfor tywhich ty the ty textbook tyhas tybeen ty adopted. t y Any tyother tyreproduction tyor tytranslation tyof
tythis ty work tybeyond tythat typermitted t y by tySections ty107 ty or ty108 ty of tythe ty1976 ty United ty States ty Copyright ty Act ty without tythe typermission ty of tythe
ty copyright tyowner ty is ty unlawful.
1
,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover
ty ty ty ty ty ty ty ty ty ty ty
2010 06-19-09
ty ty
the machine setup to be torn down and set up for the new product. Batch production allows the
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changeover time
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Excerpts tyfrom tythis tywork tymay tybe tyreproduced tyby tyinstructors tyfor tydistribution tyon tya tynot-for-profit tybasis tyfor tytesting tyor tyinstructional
typurposes tyonly tyto t y students ty enrolled tyin ty courses tyfor tywhich ty the ty textbook tyhas tybeen ty adopted. t y Any tyother tyreproduction tyor tytranslation tyof
tythis ty work tybeyond tythat typermitted t y by tySections ty107 ty or ty108 ty of tythe ty1976 ty United ty States ty Copyright ty Act ty without tythe typermission ty of tythe
ty copyright tyowner ty is ty unlawful.
2
, Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover
ty ty ty ty ty ty ty ty ty ty ty
2010 06-19-09
ty ty
to be distributed across a larger number of parts and hence reduce the average operation time
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per part.
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1.9 What is the difference between a process layout and a product layout in a production facility?
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Answer. A process layout is one where the machinery in a plant is arranged based on the
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type of process it performs. To produce a product it must visit the departments in the order
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of the operations that must be performed. This often includes large travel distances within the
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plant. A process layout is often used when the product variety is large the operation
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sequences of products are dissimilar. A product layout is one where the machinery is
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arranged based on the general flow of the products that will be produced. Travel distance is
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reduced because products will generally flow to the next machine in the sequence. A product
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layout works well when all products tend to follow the same sequence of production.
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1.10 Name two departments that are typically classified as manufacturing support departments.
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Answer. A common organizational structure includes the following three manufacturing
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support departments: (1) manufacturing engineering, (2) production planning and control, and
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(3) quality control.
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Multiple Choice Quiz ty ty
There are 18 correct answers in the following multiple choice questions (some questions have multiple
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answers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each
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correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point,
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and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage
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score on the quiz is based on the total number of correct answers.
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1.1 Which of the following industries are classified as secondary industries (three correct answers):
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(a) beverages (b) financial services, (c) fishing, (d) mining, (e) power utilities, (f) publishing,
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and (g) transportation?
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Answer. (a), (e), and (f). ty ty ty ty
1.2 Mining is classified in which one of the following industry categories: (a) agricultural industry,
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(b) manufacturing industry, (c) primary industry, (d) secondary industry, (e) service industry,
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or (f) tertiary industry?
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Answer. (c). ty
1.3 Inventions of the Industrial Revolution include which one of the following: (a) automobile,
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(b) cannon, (c) printing press, (d) steam engine, or (e) sword?
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Answer. (d). ty
1.4 Ferrous metals include which of the following (two correct answers): (a) aluminum, (b) cast iron,
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(c) copper, (d) gold, and (e) steel?
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Answer. (c) and (e). ty ty ty
1.5 Which one of the following engineering materials is defined as a compound containing
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metallic and nonmetallic elements: (a) ceramic, (b) composite, (c) metal, or (d) polymer?
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Answer. (a). ty
1.6 Which of the following processes start with a material that is in a fluid or semifluid state
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and solidifies the material in a cavity (two best answers): (a) casting, (b) forging, (c)
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machining, (d) molding, (e) pressing, and (f) turning?
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Answer. (a) and (d). ty ty ty
Excerpts tyfrom tythis tywork tymay tybe tyreproduced tyby tyinstructors tyfor tydistribution tyon tya tynot-for-profit tybasis tyfor tytesting tyor tyinstructional
typurposes tyonly tyto t y students ty enrolled tyin ty courses tyfor tywhich ty the ty textbook tyhas tybeen ty adopted. t y Any tyother tyreproduction tyor tytranslation tyof
tythis ty work tybeyond tythat typermitted t y by tySections ty107 ty or ty108 ty of tythe ty1976 ty United ty States ty Copyright ty Act ty without tythe typermission ty of tythe
ty copyright tyowner ty is ty unlawful.
3
ty ty
SOLUTION MANUAL
ty
,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover
ty ty ty ty ty ty ty ty ty ty ty
2010 06-19-09
ty ty
1 INTRODUCTION
Review Questions ty
1.1 What are the differences between primary, secondary, and tertiary industries? Give an example
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of each category.
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Answer. A primary industry is one that cultivates and exploits natural resources, such as
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agriculture or mining. A secondary industry takes the outputs of primary industries and
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converts them to consumer and capital goods. Examples of secondary industries are textiles and
ty ty ty ty ty ty ty ty ty ty ty ty ty ty
electronics. A tertiary industry is in the service sector of the economy. Examples of tertiary
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industries are banking and education.
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1.2 What is a capital good? Provide an example.
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Answer. Capital goods are those purchased by companies to produce goods or provide services.
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Examples of capital goods are aircraft and construction equipment.
ty ty ty ty ty ty ty ty ty
1.3 How are product variety and production quantity related when comparing typical factories?
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Answer. Generally production quantity is inversely related to product variety. A factory
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that produces a large variety of products will produce a smaller quantity of each. A
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
company that produces a single product will produce a large quantity.
ty ty ty ty ty ty ty ty ty ty ty
1.4 Define manufacturing capability.
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Answer. Manufacturing capability refers to the technical and physical limitations of a
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manufacturing firm and each of its plants. Three categories of capability mentioned in the text
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
are
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(1) technological processing capability, (2) physical size and weight, and (3) production capacity.
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1.5 Name the three basic categories of materials.
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Answer. The three basic categories of engineering materials are (1) metals, (2) ceramics, and
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(3) polymers. A fourth category, composites, is a non-homogeneous mixture of the other types
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and therefore is not a basic category.
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1.6 How does a shaping process differ from a surface processing operation?
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Answer. A shaping process changes the geometry of the work material (machining or forging).
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A surface processing operation does not alter the geometry, but instead alters surface of the
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work (painting or plating).
ty ty ty ty
1.7 What are two subclasses of assembly processes? Provide an example process for each subclass.
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Answer. The two subclasses of assembly processes are (1) permanent joining and (2)
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mechanical fastening. Examples of permanent joining include welding or adhesive bonding.
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Examples of mechanical fastening include threaded fasteners, such as nuts and bolts, and
ty ty ty ty ty ty ty ty ty ty ty ty ty
rivets.
ty
1.8 Define batch production and describe why it is often used for medium-quantity
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production products.
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Answer. Batch production is where groups, lots, or batches or materials or parts are processed
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together through the manufacturing operations. All units in the batch are processed at a given
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
station before the group proceeds to the next station. In a medium or low quantity production
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situation, the same machines are used to produce many types of products. Whenever a
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machine switches from one product to another, a changeover occurs. The changeover requires
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Excerpts tyfrom tythis tywork tymay tybe tyreproduced tyby tyinstructors tyfor tydistribution tyon tya tynot-for-profit tybasis tyfor tytesting tyor tyinstructional
typurposes tyonly tyto t y students ty enrolled tyin ty courses tyfor tywhich ty the ty textbook tyhas tybeen ty adopted. t y Any tyother tyreproduction tyor tytranslation tyof
tythis ty work tybeyond tythat typermitted t y by tySections ty107 ty or ty108 ty of tythe ty1976 ty United ty States ty Copyright ty Act ty without tythe typermission ty of tythe
ty copyright tyowner ty is ty unlawful.
1
,Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover
ty ty ty ty ty ty ty ty ty ty ty
2010 06-19-09
ty ty
the machine setup to be torn down and set up for the new product. Batch production allows the
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changeover time
ty ty
Excerpts tyfrom tythis tywork tymay tybe tyreproduced tyby tyinstructors tyfor tydistribution tyon tya tynot-for-profit tybasis tyfor tytesting tyor tyinstructional
typurposes tyonly tyto t y students ty enrolled tyin ty courses tyfor tywhich ty the ty textbook tyhas tybeen ty adopted. t y Any tyother tyreproduction tyor tytranslation tyof
tythis ty work tybeyond tythat typermitted t y by tySections ty107 ty or ty108 ty of tythe ty1976 ty United ty States ty Copyright ty Act ty without tythe typermission ty of tythe
ty copyright tyowner ty is ty unlawful.
2
, Solutions for Fundamentals of Modern Manufacturing, 4/e (published by Wiley) MPGroover
ty ty ty ty ty ty ty ty ty ty ty
2010 06-19-09
ty ty
to be distributed across a larger number of parts and hence reduce the average operation time
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
per part.
ty ty
1.9 What is the difference between a process layout and a product layout in a production facility?
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Answer. A process layout is one where the machinery in a plant is arranged based on the
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type of process it performs. To produce a product it must visit the departments in the order
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of the operations that must be performed. This often includes large travel distances within the
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plant. A process layout is often used when the product variety is large the operation
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sequences of products are dissimilar. A product layout is one where the machinery is
ty ty ty ty ty t y ty ty ty ty ty ty ty ty
arranged based on the general flow of the products that will be produced. Travel distance is
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
reduced because products will generally flow to the next machine in the sequence. A product
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
layout works well when all products tend to follow the same sequence of production.
ty ty ty ty ty ty ty ty ty ty ty ty ty ty
1.10 Name two departments that are typically classified as manufacturing support departments.
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Answer. A common organizational structure includes the following three manufacturing
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support departments: (1) manufacturing engineering, (2) production planning and control, and
ty ty ty ty ty ty ty ty ty ty ty
(3) quality control.
ty ty ty
Multiple Choice Quiz ty ty
There are 18 correct answers in the following multiple choice questions (some questions have multiple
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answers that are correct). To attain a perfect score on the quiz, all correct answers must be given. Each
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correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point,
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage
ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty ty
score on the quiz is based on the total number of correct answers.
ty ty ty ty ty ty ty ty ty ty ty ty ty
1.1 Which of the following industries are classified as secondary industries (three correct answers):
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(a) beverages (b) financial services, (c) fishing, (d) mining, (e) power utilities, (f) publishing,
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and (g) transportation?
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Answer. (a), (e), and (f). ty ty ty ty
1.2 Mining is classified in which one of the following industry categories: (a) agricultural industry,
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(b) manufacturing industry, (c) primary industry, (d) secondary industry, (e) service industry,
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or (f) tertiary industry?
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Answer. (c). ty
1.3 Inventions of the Industrial Revolution include which one of the following: (a) automobile,
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(b) cannon, (c) printing press, (d) steam engine, or (e) sword?
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Answer. (d). ty
1.4 Ferrous metals include which of the following (two correct answers): (a) aluminum, (b) cast iron,
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(c) copper, (d) gold, and (e) steel?
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Answer. (c) and (e). ty ty ty
1.5 Which one of the following engineering materials is defined as a compound containing
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metallic and nonmetallic elements: (a) ceramic, (b) composite, (c) metal, or (d) polymer?
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Answer. (a). ty
1.6 Which of the following processes start with a material that is in a fluid or semifluid state
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and solidifies the material in a cavity (two best answers): (a) casting, (b) forging, (c)
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machining, (d) molding, (e) pressing, and (f) turning?
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Answer. (a) and (d). ty ty ty
Excerpts tyfrom tythis tywork tymay tybe tyreproduced tyby tyinstructors tyfor tydistribution tyon tya tynot-for-profit tybasis tyfor tytesting tyor tyinstructional
typurposes tyonly tyto t y students ty enrolled tyin ty courses tyfor tywhich ty the ty textbook tyhas tybeen ty adopted. t y Any tyother tyreproduction tyor tytranslation tyof
tythis ty work tybeyond tythat typermitted t y by tySections ty107 ty or ty108 ty of tythe ty1976 ty United ty States ty Copyright ty Act ty without tythe typermission ty of tythe
ty copyright tyowner ty is ty unlawful.
3
