,
Solution Manual For
Automation, Production
Systems, And
Computer-Integrated
Manufacturing, 5th
Edition ( Mikell P.
Groover
,
,Mikell P. Groover
Chapter 1 INTROD
UCTION
REVIEWAQUESTIONS
1.1 What Are Some Of The Realities Mentioned At The Beginning Of The Chapter That Modern
Manufacturing Enter Prises Must Cope With? Name Four.
SOLUTION: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, An D (7) The Need For Operational Efficiency.
1.2 What Is A Production System?
SOLUTION:As Defined In The Text, A Production System Is A Collection Of People, Equipment, And
Procedure S 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.
SOLUTION:The Two Categories Given In The Text Are (1) Facilities, Which Consist Of The Factory,
The Equipm Ent In The Factory, And The Way The Equipment Is Organized; And (2) Manufacturing
Support Systems, Whi Ch Is The Set Of Procedures Used By The Company To Manage Production And To
Solve The Technical And L Ogistics 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?
SOLUTION:A Manufacturing System Is A Logical Grouping Of Equipment In The Factory And The
Worker(S) W Ho Operate(S) It. Examples Include Worker-
Machine Systems, Production Lines, And Machine Cells. A Production System Is A Larger System That
Inclu Des A Collection Of Manufacturing Systems And The Support Systems Used To Manage Them. A
Manufacturi Ng System Is A Subset Of The Production System.
1.5 Manufacturing Systems Are Divided Into Three Categories, According To Worker aparticipation.
Name The Three Categories.
SOLUTION: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?
SOLUTION: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 Som E Of Its Features?
SOLUTION:Fixed Automation Is A System In Which The Sequence Of Processing (Or Assembly)
Operations Is F Ixed By The Equipment Configuration. Each Operation In The Sequence Is Usually
Simple, But The Integratio N And Coordination Of Many Such Operations Into One Piece Of Equipment
Makes The System Complex. Ty Pical 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?
SOLUTION:In Programmable Automation, The Production Equipment Is Designed With The Capability
To Chan Ge 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 Pu Rpose 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 Produ Ct Configuration, And (5)
Most Suitable For Batch Production.
1.9 What Is Flexible Automation And What Are Some Of Its Features?
1
, Ch01 Introduction-3e-S 12-15, 16/06, 06/04/07
SOLUTION: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 Alterin G The Physical Setup. Accordingly, The System Can Produce
Various Mixes And Schedules Of Parts Or Prod Ucts Instead Of Requiring That They Be Made In Batches.
The Features Of Flexible Automation Are (1) High I Nvestment For A Custom-
Engineered System, (2) Continuous Production Of Variable Mixtures Of Products, (3) Medium Production R
Ates, And (4) Flexibility To Deal With Product Design Variations
1.10 What Is Computer Integrated Manufacturing?
SOLUTION: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
Functio Ns In One System That Operates Throughout The Enterprise.
1.11 What Are Some Of The Reasons Why Companies Automate Their Operations? Nine Reasons Are
Given In Th E Text. Name Five.
SOLUTION: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 Automatin G.
1.12 Identify Three Situations In Which Manual Labor Is Preferred Over Automation.
SOLUTION:The Five Situations Listed In The Text Are The Following: (1) The Task Is Technologically
Too Diffic Ult 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.
1.13 Human Workers Will Be Needed In Factory Operations, Even In The Most Highly Automated
Operations. Th E Text Identifies At Least Four Types Of Work Forawhich Humans Will Be
Needed. Name Three.
SOLUTION: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.
1.14 What Is The USA Principle? What Does Each Of The Letters Stand For?
SOLUTION:The USA Principle Is A Common Sense Approach To Automation And Process Improvement
Proj Ects. U Means “Understand The Existing Process,” S Stands For “Simplify The Process,” And A
Stands Fora “Automated The Process.”
1.15 The Text Lists Ten Strategies For Automation And Process Improvement. Identify Five Of These Strategies.
SOLUTION:The Ten Strategies Listed In The Text Are (1) Specialization Of Operations, (2) Combined
Operation S, (3) Simultaneous Operations, (4) Integration Of Operations, (5) Increased Flexibility, (6)
Improved Mate Rial Handling And Storage, (7) On-
Line Inspection, (8) Process Control And Optimization, (9) Plant Operations Control, And (10)
Computer- Integrated Manufacturing (CIM).
1.16 What Is An Automation Migration Strategy?
SOLUTION:As Defined In The Text, An Automation Migration Strategy Is A Formalized Plan
Foraevolving The Manufacturing Systems Used To Produce New Products As Demand Grows.
1.17 What Are The Three Phases Of A Typical Automation Migration Strategy?
SOLUTION: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
Mul Ti-
Station Automated System With Serial Operations And Automated Transfer Of Work Units Between Stations.
2
Solution Manual For
Automation, Production
Systems, And
Computer-Integrated
Manufacturing, 5th
Edition ( Mikell P.
Groover
,
,Mikell P. Groover
Chapter 1 INTROD
UCTION
REVIEWAQUESTIONS
1.1 What Are Some Of The Realities Mentioned At The Beginning Of The Chapter That Modern
Manufacturing Enter Prises Must Cope With? Name Four.
SOLUTION: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, An D (7) The Need For Operational Efficiency.
1.2 What Is A Production System?
SOLUTION:As Defined In The Text, A Production System Is A Collection Of People, Equipment, And
Procedure S 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.
SOLUTION:The Two Categories Given In The Text Are (1) Facilities, Which Consist Of The Factory,
The Equipm Ent In The Factory, And The Way The Equipment Is Organized; And (2) Manufacturing
Support Systems, Whi Ch Is The Set Of Procedures Used By The Company To Manage Production And To
Solve The Technical And L Ogistics 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?
SOLUTION:A Manufacturing System Is A Logical Grouping Of Equipment In The Factory And The
Worker(S) W Ho Operate(S) It. Examples Include Worker-
Machine Systems, Production Lines, And Machine Cells. A Production System Is A Larger System That
Inclu Des A Collection Of Manufacturing Systems And The Support Systems Used To Manage Them. A
Manufacturi Ng System Is A Subset Of The Production System.
1.5 Manufacturing Systems Are Divided Into Three Categories, According To Worker aparticipation.
Name The Three Categories.
SOLUTION: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?
SOLUTION: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 Som E Of Its Features?
SOLUTION:Fixed Automation Is A System In Which The Sequence Of Processing (Or Assembly)
Operations Is F Ixed By The Equipment Configuration. Each Operation In The Sequence Is Usually
Simple, But The Integratio N And Coordination Of Many Such Operations Into One Piece Of Equipment
Makes The System Complex. Ty Pical 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?
SOLUTION:In Programmable Automation, The Production Equipment Is Designed With The Capability
To Chan Ge 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 Pu Rpose 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 Produ Ct Configuration, And (5)
Most Suitable For Batch Production.
1.9 What Is Flexible Automation And What Are Some Of Its Features?
1
, Ch01 Introduction-3e-S 12-15, 16/06, 06/04/07
SOLUTION: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 Alterin G The Physical Setup. Accordingly, The System Can Produce
Various Mixes And Schedules Of Parts Or Prod Ucts Instead Of Requiring That They Be Made In Batches.
The Features Of Flexible Automation Are (1) High I Nvestment For A Custom-
Engineered System, (2) Continuous Production Of Variable Mixtures Of Products, (3) Medium Production R
Ates, And (4) Flexibility To Deal With Product Design Variations
1.10 What Is Computer Integrated Manufacturing?
SOLUTION: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
Functio Ns In One System That Operates Throughout The Enterprise.
1.11 What Are Some Of The Reasons Why Companies Automate Their Operations? Nine Reasons Are
Given In Th E Text. Name Five.
SOLUTION: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 Automatin G.
1.12 Identify Three Situations In Which Manual Labor Is Preferred Over Automation.
SOLUTION:The Five Situations Listed In The Text Are The Following: (1) The Task Is Technologically
Too Diffic Ult 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.
1.13 Human Workers Will Be Needed In Factory Operations, Even In The Most Highly Automated
Operations. Th E Text Identifies At Least Four Types Of Work Forawhich Humans Will Be
Needed. Name Three.
SOLUTION: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.
1.14 What Is The USA Principle? What Does Each Of The Letters Stand For?
SOLUTION:The USA Principle Is A Common Sense Approach To Automation And Process Improvement
Proj Ects. U Means “Understand The Existing Process,” S Stands For “Simplify The Process,” And A
Stands Fora “Automated The Process.”
1.15 The Text Lists Ten Strategies For Automation And Process Improvement. Identify Five Of These Strategies.
SOLUTION:The Ten Strategies Listed In The Text Are (1) Specialization Of Operations, (2) Combined
Operation S, (3) Simultaneous Operations, (4) Integration Of Operations, (5) Increased Flexibility, (6)
Improved Mate Rial Handling And Storage, (7) On-
Line Inspection, (8) Process Control And Optimization, (9) Plant Operations Control, And (10)
Computer- Integrated Manufacturing (CIM).
1.16 What Is An Automation Migration Strategy?
SOLUTION:As Defined In The Text, An Automation Migration Strategy Is A Formalized Plan
Foraevolving The Manufacturing Systems Used To Produce New Products As Demand Grows.
1.17 What Are The Three Phases Of A Typical Automation Migration Strategy?
SOLUTION: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
Mul Ti-
Station Automated System With Serial Operations And Automated Transfer Of Work Units Between Stations.
2
