Chapter 1

Question 1

Define: manufacturing

Answer 1

Transformation of materials into items of greater value by means of one or more processing and/or assembly operations

Question 2

Compare: Discrete vs. Continuous Process

Answer 2

Discrete: Individual parts and assembled products.

Continuous: Items produced continuously; ex. oil refinery or steel metal coiling.

Question 3

Define: Production Quanity

Answer 3

Low: 1 - 100 units/yr
Medium: 100-10,000 units/yr
High: 10,000 + units/yr

Question 4

Define: Product Variety

Answer 4

Soft: When there are small differences among products; ex. car model differences but same make

Hard: When products differ substantially and there are a few common parts, if any.

Question 5

Define: Capability

Answer 5

Refers to the scope of technical and physical capabilities and limitation of a manufacturing company and each of its plants. Three factors:

1) Technological Processing Capability
2) Physical Size and Weight of Product
3) Production Capacity

Question 6

Define: Shaping Processes

Answer 6

Alter the geometry of the starting work material by various methods including casting, forging, and machining. Four Classifications:

1) Solidification Processes
2) Particulate Processing
3) Deformation Processes
4) Material Removal Processes

Question 7

Define: Surface Processing Operations

Answer 7

Performed to clean, treat, coat, or deposit material onto the exterior surface of the work; includes cleaning, surface treatments, and coating and thin deposition processes.

Question 8

Define: Permanent Joining Processes

Answer 8

Includes: welding, brazing, soldering, and adhesive bonding.

Question 9

Define: Mechanical Fastening

Answer 9

The use of a joint that can be conveniently disassembled; includes screws, bolts, and other threaded fasteners.

Question 10

Define: Assembly Operations

Answer 10

Two or more separate parts are joined to form a new entity

Question 11

Define: Machine Tools

Answer 11

Power-driven machines used to operate cutting tools previously operated by hand

Question 12

Define: Tooling

Answer 12

Equipment used to customize the production machinery for the particular part or product.

Question 13

Define: Job Shop

Answer 13

Generally refers to a low-yield production facility (1-100 units/yr) making small quantities of specialized and customized products

Question 14

Define: Fixed-Position Layout

Answer 14

Layout used for large and heavy products, where typically it remains in a single location during its fabrication or assembly. Workers and processing equipment are brought to the product.

Question 15

Define: Batch Production

Answer 15

Generally used in the medium quantity range (100-10,000 units/yr), this approach will make a batch of one product and once this product is entirely finished, will change over the system to produce a batch of the next product

Question 16

Define: Cellular Manufacturing

Answer 16

The processing or assembly of different parts or products by cells consisting of several workstations or machines; Each cell is designed to produce a limited variety of part configurations

Question 17

Define: Mass Production

Answer 17

The high-quantity range (10,000 + units/yr); Includes quantity production and flow line production

Question 18

Define: Flow Line

Answer 18

Involves Multiple pieces of equipment or workstations arranged in sequence, and the work units are physically moved through the sequence to complete the product.

Question 19

Define: Product Layout

Answer 19

The layout of a flow line; generally consists of one long line or a series of connect line segments. Work is moved between stations using a conveyor; ex. assembly line

Question 20

Define: Lean Production

Answer 20

The use of fewer workers and less equipment to accomplish more production in less time, and yet achieve higher quality in the final product. Centers around eliminating waste.

Question 21

Define: Six Sigma

Answer 21

A Quality focused program aimed to reduce variability in the company’s processes and products, which utilizes worker teams to accomplish projects aimed at improving operational performance.

Question 22

Define: Outsourcing

Answer 22

The use of outside contractors to perform work that was traditionally accomplished in-house.

Question 23

Define: Green Manufacturing

Answer 23

Programs that seek to determine the most efficient use of materials and natural resources in production and minimize the negative consequences on the environment. Include”

1) Design products to minimize carbon footprint
2) Design Environmentally friendly processes

Question 24

Define: Design for Environement (DFE)

Answer 24

Techniques that attempt to consider environmental impact during product design prior to production. Includes considerations such as:

1) selecting materials
2) selecting processes
3) designing parts
4) designing products to be dissassembled
5) designing products that minimize the use of hazardous materials
6) considering disposal techniques

Question 25

Define: Concurrent Engineering

Answer 25

Refers to an approach to product design in which companies attempt to reduce the elapsed time required to bring a new product to market by integrating design engineering, manufacturing engineering, and other functions in the company.

Question 26

Define: Design for Manufacturing

Answer 26

An approach to product design that systematically includes consideration of manufacturability and assemblability in the design.

Question 27

Define: Simultaneous Engineering

Answer 27

Another name for Concurrent Engineering; refers to manufacturing planning while the product design is being developed

Question 28

Define: Life Cycle Design

Answer 28

Refers to the product after it has been manufactured; design decisions that impact that installation, maintenance, repair, spare parts, and future upgrades

Question 29

Explain: General Principles of DFM/A (& Include Examples?)

Answer 29

Design for manufacture and/or assembly requires changes to organizational structure to provide closer interaction and better communication between design and manufacturing personal. Often this accomplished by project teams.

Question 30

What are the Benefits of DFM/A?

Answer 30

1) Shorter Time to Bring the Product to Market
2) Smoother Transition into Production
3) Fewer Components in the Final Product
4) Easier Assembly
5) Lower Costs of Production
6) Higher Product Quality
7) Greater Customer Satisfaction