SOLUTION MANUAL FOR
AUTOMATION, PRODUCTION
SYSTEMS, AND COMPUTER-
INTEGRATED MANUFACTURING,
5TH EDITION (MIKELL P. GROOVER,
2025) ALL CHAPTERS 1-26| LATEST
EDITION
1
,TABLE OF CONTENTS
Chapter 1 INTRODUCTION
PART I OVERVIEW OF MANUFACTURING
Chapter 2 MANUFACTURING OPERATIONS
PART II AUTOMATION AND CONTROL TECHNOLOGIES
Chapter 4 INTRODUCTION TO AUTOMATION
Chapter 5 INDUSTRIAL CONTROL SYSTEMS
Chapter 6 HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL
Chapter 7 COMPUTER NUMERICAL CONTROL
Chapter 8 INDUSTRIAL ROBOTICS
Chapter 9 DISCRETE CONTROL AND PROGRAMMABLE LOGIC CONTROLLERS
PART III MATERIAL HANDLING AND IDENTIFICATION
Chapter 10 MATERIAL TRANSPORT SYSTEMS
Chapter 11 STORAGE SYSTEMS
PART IV MANUFACTURING SYSTEMS
Chapter 13 OVERVIEW OF MANUFACTURING SYSTEMS
Chapter 14 SINGLE-STATION MANUFACTURING CELLS
Chapter 15 MULTI-STATION MANUFACTURING SYSTEMS: MANUAL ASSEMBLY LINES
Chapter 16 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED PRODUCTION LINES
Chapter 17 AUTOMATED ASSEMBLY SYSTEMS
Chapter 18 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING
Chapter 19 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED FOR FLEXIBILITY
PART V QUALITY CONTROL SYSTEMS
Chapter 20 QUALITY PROGRAMS FOR MANUFACTURING
Chapter 21 INSPECTION PRINCIPLES AND PRACTICES
Chapter 22 INSPECTION TECHNOLOGIES
PART VI MANUFACTURING SUPPORT SYSTEMS AND COMPUTER-INTEGRATED
MANUFACTURING
Chapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM
Chapter 24 PROCESS PLANNING AND CONCURRENT ENGINEERING
Chapter 25 PRODUCTION PLANNING AND CONTROL SYSTEMS
Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION
2
,Chapter 1 INTRODUCTION
REVIEW QUESTIONS
1.1 What Are Some Of The Realities Mentioned At The Beginning Of The Chapter That Modern Manufacturing
Enterprises Must Cope With? Name Four.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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. Name And Briefly Define The Two Levels.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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.
CORRECT ANSWER: The Three Categories Are (1) Manual 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?
CORRECT ANSWER: 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?
CORRECT ANSWER: 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, B ut The
Integration And Coordination Of Many 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?
CORRECT ANSWER: In Programmable Autom ation, 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 Autom ation 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
Dow nloaded by Orifha Mbedzi ()
, CORRECT ANSWER: 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 Made 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?
CORRECT ANSWER: 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 The Reasons Why Companies Automate Their Operations? Nine Reasons Are Given In The
Text. Name Five.
CORRECT ANSWER: 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 Manual 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 Manual Labor Is Preferred Over Automation.
CORRECT ANSWER: 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. Name Three.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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?
CORRECT ANSWER: As Defined In The Text, The Three Typical Phases Are The Following: Phase 1: Manual
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 ()
Dow nloaded by Orifha Mbedzi
AUTOMATION, PRODUCTION
SYSTEMS, AND COMPUTER-
INTEGRATED MANUFACTURING,
5TH EDITION (MIKELL P. GROOVER,
2025) ALL CHAPTERS 1-26| LATEST
EDITION
1
,TABLE OF CONTENTS
Chapter 1 INTRODUCTION
PART I OVERVIEW OF MANUFACTURING
Chapter 2 MANUFACTURING OPERATIONS
PART II AUTOMATION AND CONTROL TECHNOLOGIES
Chapter 4 INTRODUCTION TO AUTOMATION
Chapter 5 INDUSTRIAL CONTROL SYSTEMS
Chapter 6 HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL
Chapter 7 COMPUTER NUMERICAL CONTROL
Chapter 8 INDUSTRIAL ROBOTICS
Chapter 9 DISCRETE CONTROL AND PROGRAMMABLE LOGIC CONTROLLERS
PART III MATERIAL HANDLING AND IDENTIFICATION
Chapter 10 MATERIAL TRANSPORT SYSTEMS
Chapter 11 STORAGE SYSTEMS
PART IV MANUFACTURING SYSTEMS
Chapter 13 OVERVIEW OF MANUFACTURING SYSTEMS
Chapter 14 SINGLE-STATION MANUFACTURING CELLS
Chapter 15 MULTI-STATION MANUFACTURING SYSTEMS: MANUAL ASSEMBLY LINES
Chapter 16 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED PRODUCTION LINES
Chapter 17 AUTOMATED ASSEMBLY SYSTEMS
Chapter 18 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING
Chapter 19 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED FOR FLEXIBILITY
PART V QUALITY CONTROL SYSTEMS
Chapter 20 QUALITY PROGRAMS FOR MANUFACTURING
Chapter 21 INSPECTION PRINCIPLES AND PRACTICES
Chapter 22 INSPECTION TECHNOLOGIES
PART VI MANUFACTURING SUPPORT SYSTEMS AND COMPUTER-INTEGRATED
MANUFACTURING
Chapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM
Chapter 24 PROCESS PLANNING AND CONCURRENT ENGINEERING
Chapter 25 PRODUCTION PLANNING AND CONTROL SYSTEMS
Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION
2
,Chapter 1 INTRODUCTION
REVIEW QUESTIONS
1.1 What Are Some Of The Realities Mentioned At The Beginning Of The Chapter That Modern Manufacturing
Enterprises Must Cope With? Name Four.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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. Name And Briefly Define The Two Levels.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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.
CORRECT ANSWER: The Three Categories Are (1) Manual 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?
CORRECT ANSWER: 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?
CORRECT ANSWER: 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, B ut The
Integration And Coordination Of Many 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?
CORRECT ANSWER: In Programmable Autom ation, 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 Autom ation 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
Dow nloaded by Orifha Mbedzi ()
, CORRECT ANSWER: 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 Made 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?
CORRECT ANSWER: 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 The Reasons Why Companies Automate Their Operations? Nine Reasons Are Given In The
Text. Name Five.
CORRECT ANSWER: 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 Manual 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 Manual Labor Is Preferred Over Automation.
CORRECT ANSWER: 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. Name Three.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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.
CORRECT ANSWER: 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?
CORRECT ANSWER: 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?
CORRECT ANSWER: As Defined In The Text, The Three Typical Phases Are The Following: Phase 1: Manual
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 ()
Dow nloaded by Orifha Mbedzi
