Chapter 2 - Manufacturing Operations Flashcards
An application of physical and chemical process to alter the geomety, propertis, and/or appearance of a given starting material to make parts or products.
Manufacturing (Technological Definition)
also includes the joining of multiple parts to make assembled products
Manufacturing
Accomplished by a combination of machinery, tools, power, and manual labor.
Manufacturing
Almost always carried out as a sequence of operations
Manufacturing
Transformation of materials into items of greater value by means of one or more processing and/or assembly operations.
Manufacturing (Economic Definition)
Manufacturing adds ___ to the material
value
3 Classification of Industries
- Primary industries
- Secondary industries
- Tertiary industries
cultivate and exploit natural
resources
▪ Examples: agriculture, mining
Primary industries
convert output of primary
industries into products
▪ Examples: manufacturing, power generation,
construction
Secondary industries
service sector
▪ Examples: banking, education, government, legal
services, retail trade, transportation
Tertiary industries
Production operations in the process industries and the discrete product industries can be divided into
Continuous production and
Batch production
Three Categories of Processing Operations
- Shaping operations
- Property-enhancing operations
- Surface processing operations
What are/is the shaping operations?
- Solidification processes
- Particulate processing
- Deformation processes
- Material removal processes
What process(es) is/are the property-enhancing operations?
heat treatments
What are/is the process(es) of surface processing operations?
▪ Cleaning and surface treatments
▪ Coating and thin-film deposition
A(n)_______ joins two or more components tocreate
a new entity which is called an assembly, subassembly,etc.
Assembly operation
What are the joining process?
▪ Welding
▪ Brazing and soldering
▪ Adhesive bonding
What are the mechanical assembly?
▪ Threaded fasteners (e.g., bolts and nuts, screws)
▪ Rivets
▪ Interference fits (e.g., press fitting, shrink fits)
▪ Other
Other Factory Operations
▪ Material handling and storage
▪ Inspection and testing
▪ Coordination and control
A means of moving and storing materials between processing and/or assembly operations
Material Handling
What are the material transport?
▪ Vehicles, e.g., forklift trucks, AGVs, monorails
▪ Conveyors
▪ Hoists and cranes
it is an examination of the product and its components to determine whether they conform to design specifications.
Inspection
observing the product (or part, material, subassembly) during actual operation or under conditions that might occur during operation
Testing
Facilities organised in the most efficient way to serve the particular mission of the plant and depends on what?
▪ Types of products manufactured
▪ Production quantity
▪ Product variety
It is the number of units of a given part or product produced annually by the plant
Production Quantity (Q)
It is the number of different product or part designs or types
Product Variety (P)
products differ greatly
▪ Few common components in an assembly
‘Hard’ product variety
small differences between
products
▪ Many common components in an assembly
‘Soft’ product variety
this shop produces low quantities of specialized and
customized products
Job shops
Plant layouts for Job shop
▪ Fixed position
▪ Process layout
What are the 3 quantity ranges?
- Low production
- Medium production
- High production
a quantity ranges that has 1 to 100 units
Low production
a quantity ranges that has 100 to 10,000 units
Medium production
a quantity ranges that has 10,000 to millions of units
High production
What are the 2 type of production in medium Production Quantities?
- Batch production
2. Cellular manufacturing
It is a hard product variety with a given product is produced, and then the facility is changed over to produce another product
Batch production
It is soft product variety and a mixture of products is made without significant changeover time between products
Cellular manufacturing
What are/is the typical layout for Batch Production?
Process Layout
What are/is the typical layout for Job shop?
▪ Fixed position
▪ Process layout
What are/is the typical layout for Cellular manufacturing?
cellular layout
What are the 2 type of production in High Production Quantities?
- Quantity production
2. Flow line production
Equipment is dedicated to the manufacture of one product
▪ Standard machines tooled for high production (e.g., stamping presses, molding machines
Quantity Production
What are/is the typical layout for Quantity production?
process layout
Multiple workstations arranged in sequence
▪ Product requires multiple processing or assembly steps
Flow line production
What are the common layout for Flow line production?
Product layout
Amount of product currently located in the factory that is either being processed or is in between processing operations
Work In Progress
It is under the costs of manufacturing operations that remain constant for any output level.
Fixed costs
It is under the costs of manufacturing operations that vary in proportion to production output level.
Variable costs
What are the alternative classification of manufacturing costs?
- Direct labor
- Materials
- Overhead
It is an alternative classification of manufacturing costs that refers to wages and benefits paid to workers
Direct Labor
It is an alternative classification of manufacturing costs that refers to costs of raw materials
Materials
It is an alternative classification of manufacturing costs that refers to all of the other expenses associated with running the manufacturing firm.
Overhead
2 categories/classification of overhead
▪ Factory overhead
▪ Corporate overhead
