Midterms Flashcards
Process and procedures in a large scale that involve chemical or mechanical steps aiding them in manifacture of a specific item or items is known as
Industrial process
Key components of heavy industries
Industrial process
Companies that extract, transport, and process raw materials to manufacture semi-finished or high quality end products by means of physical, mechanical and/or chemical process are classified as
Process Industries
Characterized by flowing materials or media
Production Process
examples of process Industries
1.food and beverages
2.chemicals
3. Pharmaceuticals
4.Petroleum
5.ceramics
6. Plastic and rubber
7. Tabacco
8.Paper and pulp
9. Etc.
Input ➡️ processes➡️ output
In process Industries, example:
Raw materials ➡️ Factory ➡️ Manufactured goods
Several components can define an industrial system
1.Raw materials
2. Energy(electricity)
3. Labour(skilled/unskilled)
4. Land
5. Transport
6. Communication links
7. Capital (including government grants)
Refers to the **methods, **techniques, and operations carried out to convert input into outputs
Processes
This encompasses all the products or by products generated by the system
Output
Would be goods but there might be waste
Primary output
Give one benefits of industrial processes
Contribute to the conversion of a rare and costly material into a commodity cheaper in price.
The result of industrial processes
May produce a desired product or creates certain unnecessary by products which maybe toxic, hazardous and hard to manage with
Types of industrial processes
1.General processes
2.Chemical processes
3. Heat processes
4. Physical processes
5.Distillation processes
Used by large in almost all the heavy industries
General processes
Used for easy transportation between one part to the other.
Liquefaction
Removal of excess liquid
Freeze drying or superficial drying
Used for removing pollutants from the exhaust gas that is created
Scrubber
Involve methods that result in the transformation of one set of chemical substances to another.
Chemical processes
Can be used to modify or produce various materials
Chemical processes
Chemical processes example; process used to extract a metal from its ore, often involving the use of heat and reducing agents
Smelting
Refers to the elimination of pathogens and other harmful microorganisms, usually by chemical means
Disinfection
Process in which heat is used to chemically combine the materials
Pyro-processing
One of the materials that are combined by means of pyro-processing methods
Cement
Heat or direct current is used in the production of materials
Heat processes
Two methods that use heat processes for producing end products
Flash smelting and electrolysis
Refinement of the smelting process and is used predominantly for sulphur ores to produce copper,nickel, and lead.
Flash smelting
Process in which electricity is used to produce desired effect of plating or separating metals
Electrolysis
Metals and materials are reshaped and molded into various products by means of certain procedures like cutting,folding, polishing, etc.
Physical processes
Physical cleaning process of a surface by means of sand or other particles
Sandblasting
Components like petroleum and hydrocarbon by-products are produced by the industrial process of distillation
Distillation
Two terms related to conversion of raw materials into finished products
Manufacturing and production
Process of transforming raw materials into ready goods, with the help of machinery
Manufacturing
Alludes to the processes or methods, that converts inputs like raw material or semi-finished goods, to make finish product or services, which may or may not use machinery
Production
Series of action that produce something or that lead to a particular result
Process
The use of science in industry, engineering, etc, to invent useful things or to solve problems
Technology
It is the machines, equipment, and devices that create and/or deliver products and services
Process technology
process technology and transformed resources (3) types
1.Material-processing technologies
2.Information-processing technologies
3.Customer-processing technology
It is any technology that shapes, transports,stores,or in a way changes physical objects
Material-processing technology
It is any device which collects, manipulates, stores, or distributes information
Information-processing technology
It is a machine that simplifies the process being done by human
Customer -processing technology
3 categories of customer-processing technology
1.Active
2.Passive
3.One-way monitoring
Customers use the technology to create the service
Active
Processes and controls the customer by restraining the customers action in some way
Passive
Tracks customers movements or transactions in an obstrusive way
One-way monitoring
Classification of industries
1.Primary industry
2.Genetic industry
3.Extractive industry
4.Manufacturing industry
5.Construction industry
6.Service industry
Is concerned with production of goods with the help of nature.It is a nature oriented industry which requires little human effort
Primary industry
Are engaged in re-production and multiplication of certain species of plants and animals with the object of sale.The main aim is to earn profit from such sale
Genetic industries
Is concerned with extraction or drawing out goods from the soil, air, or water.Generally, products of extractive industries come in raw form, and they are used by manufacturing and construction industries for producing finished products
Extractive industry
Engaged in transforming raw material into finished product with the help of machines and manpower
Manufacturing industries
Take up the work of construction of buildings, bridges,roads,dams,canals,etc.
Can be produced at one place and sold at another place
Construction industries
In modern times service sector plays an important role in the development of the nation
Service industry
Refers to methodolical process used to convert raw materials into finished goods. It encompasses all activities, procedures, inputs, and outputs required ro produce goods and services.
Production system
Production system involves..
- Resources flowing within a define system
- Combined and transformed
- Controlled manner
- Add value
- Accordance to the policies communicated by management
Production processes/system are classified on the basis of
1.Product/output variety
2. Product/operations/output volume
Two types of production processes
- Continuous production process
- Intermitted production process
Under continuous production process
-Process/flow production
-mass production
Under intermitted production process
-batch production
-job shop production
-project production
Items are completed and placed in stock before receiving a customer order
Made to stock production process(MTS)
The end item is completed solely in response to a specific customer order
Made to order production process(MTO)
Referred to as repetitive manufacturing systems
Continuous manufacturing system
These are mass production facilities that produce high volumes of the same products
Continuous manufacturing system
Usually make to stock producers
Continuous manufacturing system
Manufacturing happens in automated, special purpose equipments
Continuous manufacturing system
Products follow the same path
Continuous manufacturing system
Usually the products are not discrete
Continuous: Flow shop
Also called as process type operations
Continuous flow operations
Standardization of product and process sequence. Dedicated special purpose machines having high production capacities and output tates.
Continuous: mass production
With higher rate of production with reduced cycled time and High capacity utilization due to line balancing
Continuous: mass production
Less skilled operators are required and has low process inventory
Continuous: mass production
Manufacturing cost per unit is low
Continuous: mass production
In this type of production process the volume of each product is low
Intermitted production process
Produces make to order, custom products in accordance with design supplied by the customer
Intermitted production process
Products may follow different paths
Intermitted production process
a type of manufacturing process in which **small batches of a variety of
custom products **are made.
job shop
most of the products
produced require a UNIQUE SET-UP AND SEQUENCING of process steps.
job shop process flow
used in
– woodworking shops,
– metal fabrication shops, etc.
job shop production process
Use of general-purpose machines and facilities
: (HL)
– Highly Skilled Operators who take up each job as a challenge
– Large inventory of materials tools and par
A large variety of products can be produced with the general-purpose machines(2:)
– Operators become more skilled and competent with each job
– Full potential of operators can be utilized
Many manufacturing operations fall between
job shops and repetitive manufacturing.
Batch Manufacturing
means a single production run
batch
means the quantity produced in a single production run.
batch size
– It may be less than 100 units OR up to a few 1000 units
batch manufacturing
makes a batch of one product, then may switch over
(set up) the equipment and make a batch of another item
batch manufacturing company
should be more flexible than repetitive manufacturing and it is
generally less flexible than job shops.
Production equipment
a highly flexible and** low volume type operation**.
project
Usually, the item to be produced stays in a fixed place and all the resources come to it.
project
At the end of production, resources leave the place.
project
project type examples
Examples are
– ship construction,
– bridge construction,
– buildings and
– large machines
a system concept thatutilizes instrumentation system to perform a certain task or
sequences of operations in an automatic manner or without human intervention.
Automation
Is a process or sequence of production activities done in an automatic manner.
AUTOMATED PROCESS
the application of physical and/or chemical processes
to alter the geometry, properties, and/or appearance of a given starting material to make
parts or products.
Manufacturing
includes the joining of multiple parts to make assembled products.
Manufacturing
Exclusively uses production equipment for a specific product, ensuring uninterrupted
output.
Continuous Production
the process is
carried out on a continuous stream of material, with no interruptions in the output flow
in process industries ; Continuous Production
means 100%
dedication of the production equipment to the part or product, with no breaks for
product changeovers. The individual units of production are identifiable
In the discrete manufacturing industries; Continuous Production
Materials are processed in limited quantities or batches.
Batch Production
Production is intermittent, with pauses between batches.
Batch Production
Reasons for batch production:(VEE)
-Variations between batches require method, tool, and equipment
adjustments.
- Equipment capacity restricts the processable amount at once.
- Equipment production rate exceeds demand, allowing its use for various
products.
generally means that the starting
materials are in liquid or bulk form, and they are processed altogether as a unit
Batch production in the process industries
is a certain quantity of work
units, and the work units are usually processed one at a time rather than all
together at once. The number of parts in a batch can range from as few as one to
as many as thousands of units.
Batch; In the discrete manufacturing industries
“manus” means
hand
“factus” means
make
“Manufacturing” originates from
latin words
Goods in those times were crafted by hand, using simple techniques in small
workshops.
handicraft
is a collection of people, equipment, and procedures organized to
perform the manufacturing operations of a company
A production system
The physical facilities of the production system include the equipment, the way the
equipment is laid out, and the factory in which the equipment is located.
facilities
These are the 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 in the manufacturing support systems.
Manufacturing support systems.
production systems consists of two major
components
- facilities
-Manufacturing support systems
portions of the this are automated
and/or computerized.
In modern manufacturing operations; production system
People make these systems work.
production systems
direct labor people
blue-collar workers
responsible for operating the
facilities
direct labor people (blue-collar workers)
professional staff people
white-collar workers
are responsible for the
manufacturing support systems.
professional staff people (white-collar workers)
can be individual work cells consisting of a single production
machine and a worker assigned to that machine.
Manufacturing systems
consist of collections of machines and workers
More complex manufacturing systems
three basic categories of manufacturing systems
-manual work system
-worker-machine system
-fully automated system
consists of one or more workers performing one or more tasks
without the aid of powered tools.
manual work system
are common activities in manual work systems
Manual material handling tasks
commonly require the use of hand tools, such as screwdrivers and
hammers
production tasks
often employed to grasp the work
part and position it securely for processing.
work holder
to round the edges of a rectangular part that has just been
milled
A machinist using a file
to measure the diameter of a shaft
A quality control inspector using a micrometer
to move cartons in a warehouse
A material handling worker using a dolly
putting together a piece of machinery using hand tools.
A team of assembly workers
a human worker operates powered equipment, such as a
machine tool or other production machine
a worker-machine system
This is one of the most widely used
manufacturing systems
a worker-machine system
include combinations of one or more workers and one or
more pieces of equipment. The workers and machines are combined to take advantage
of their relative strengths and attributes.
Worker-machine systems
Examples of worker-machine systems
A machinist operating an engine lathe to fabricate a part for a product
* A fitter and an industrial robot working together in an arc–welding work cell
* A production line in which
the products are moved
by mechanized conveyor and
the workers at some of the stations
use power tools to accomplish their
processing or assembly tasks
one in which a process is performed by a machine without
the direct participation of a human worker.
Automated System
implemented using a program
of instructions combined with a control system that executes the instructions.
automation
required to drive the process and to operate the program and control system.
power
Two levels of automation can be identified:
Semiautomated and Fully Automated
performs a portion of the work cycle under some form of program control, and a human worker tends to the machine for the remainder of the cycle, by loading and unloading it, or by performing some other task each cycle.
Semi-Automated Machine
distinguished from its semiautomated counterpart by its capacity to operate for an extended period of time with no human attention.
Fully Automated Machine
Examples of automated processes
complex chemical processes,
oil refineries, and nuclear power plants.
humans or machines?
-sense unexpected stimuli
humans
humans or machines?
-performs repetitive tasks consistently
machine
humans or machines?
-store large amounts of data
machines
humans or machines?
-develop new solutions to problems
humans
humans or machines?
-cope with abstract problems
humans
humans or machines?
-adapt to change
humans
humans or machines?
-generalize from observations
humans
humans or machines?
-learn from experience
humans
humans or machines?
-make decisions based on incomplete data
humans
humans or machines?
-retrieve data from memory reliably
machines
humans or machines?
-perform multiple tasks simultaneously
machines
humans or machines?
-apply high forces and power
machines
humans or machines?
-perform simple computations quickly
machines
humans or machines?
-make routine decisions quickly
machines
to design
the processes and equipment, plan and control the production orders, and satisfy
product quality requirements.
manufacturing support system
manufacturing support system example
people and procedures
t or f
Most of these support systems do not directly contact the
product, but they plan and control its progress through the factory.
true
Manufacturing support involves a sequence of activities
The activities consist of FOUR (4) functions that include much information flow and data ..
(1) business functions
(2) product design
(3) manufacturing planning
(4) manufacturing control.
are the principal means by which the company communicates
with the customer. They are, therefore, the beginning and the end of the informationprocessing sequence. Included in this category are sales and marketing, sales
forecasting, order entry, and customer billing.
business functions
operate in the factory on the physical product.
They perform operations such as processing, assembly, inspection, and material
handling, in many cases accomplishing more than one of these operations in the same
system
Automated manufacturing systems
why the automated manufacturing system is called automated?
because they perform their operations with a reduced level of human participation compared with the corresponding manual process.
In some highly automated systems, there is virtually no human participation..
Three basic types of Automated manufacturing systems
- Fixed automation
- Programmable automation
- Flexible automation
A manufacturing system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration
Fixed Automation
- Suited to high production quantities
- High initial investment for custom-engineered equipment
Fixed , programmable, or flexible Automation?
fixed automation
- High production rates
- Relatively inflexible in accommodating product variety
Fixed , programmable, or flexible Automation?
fixed automation
A manufacturing system designed with the capability to change the sequence of
operations to accommodate different product configurations
programmable automation
- High investment in general purpose equipment
- Lower production rates than fixed automation
Fixed , programmable, or flexible Automation?
programmable automation
Flexibility to deal with variations and changes in product configuration
* Most suitable for batch production
* Physical setup and part program must be changed between jobs (batches)
Fixed , programmable, or flexible Automation?
programmable automation
An extension of programmable automation in which the system is capable of
changing over from one job to the next with no lost time between jobs
flexible automation
- High investment for custom-engineered system
- Continuous production of variable mixes of products
Fixed , programmable, or flexible Automation?
flexible automation
- Medium production rates
- Flexibility to deal with soft product variety
Fixed , programmable, or flexible Automation?
flexible automation
three phases of Automation Migration Strategy
Phase 1 – Manual production
Phase 2 – Automated production
Phase 3 – Automated integrated production
Single-station manned cells working independently
-Advantages: quick to set up, low-cost tooling
Phase 1 – Manual production
Single-station automated cells operating independently
- As demand grows and automation can be justified
Phase 2 – Automated production
Multi-station system with serial operations and automated transfer of work
units between stations
Phase 3 – Automated integrated production
Manual production using single-station manned cells operating independently
Phase 1 – Manual production
using single-station automated cells operating
independently. As demand for the product grows, and it becomes clear that automation
can be justified, then the single stations are automated to reduce labor and increase
production rate. Work units are still moved between workstations manually.
Phase 2 – Automated production
using a multi-station automated system with
serial operations and automated transfer of work units between stations.
Phase 3 – Automated integrated production
Advantages of Automation Migration Strategy
-It allows introduction of the new product in the shortest possible time, since production cells based on manual workstations are the easiest to design and implement.
-It allows automation to be introduced gradually (in planned phases), as demand for the product grows, engineering changes in the product are made, and time is provided to do a thorough design job on the automated manufacturing system.
-It avoids the commitment
to a high level of automation
from the start, because
there is always a risk
that demand for the product
will not justify it.
are foundational tools that don’t operate independently. They amplify
or modify the force exerted by an individual. They adeptly transfer force from one location to another, alter its direction, magnify its intensity, or extend its distance or velocity, ensuring enhanced efficiency in accomplishing tasks.
Simple machines
complex machines, also known as
compound
machines
Machines like trucks, wagons, and bicycles are complex because
they have many
moving parts and merge several simple machines, such as levers, pulleys, and gears,
to accomplish tasks.
can be any item that is used to achieve a goal
a tool
Manual tools operated without external power, commonly used to perform
specific mechanical tasks, like wrenches, screwdrivers, and pliers.
hand tools
a tool used to remove fine amounts of material from a workpiece. It is common
in woodworking, metalworking, and other similar trade and hobby tasks.
file
a tool used to indicate how parallel (level) or perpendicular (plumb) a surface
is relative to the earth.
level
Powered Tools rely on…?
external power source to operate.
They can provide more force or speed
than manual tools and are often used for tasks that require significant power or are
repetitive
powered tools
-typically large and stationary.
-They are programmed to
perform a specific task or sequence of tasks without human intervention.
automated machines
Specialized machinery designed for specific tasks within various industries, aiding in the
transformation, storage, or management of materials.
process equipment
functions of process equipment
o Storage
o Flow Control
o Chemical Reaction Containment
Types Of Process Equipment
- Fixed/Stationary Equipment
-Rotating/Rotary Equipment
Stays in one location during operation.
Fixed/Stationary Equipment
Contains components that move or rotate during operation
Rotating/Rotary Equipment
commonly known as “Static Equipment
Fixed Equipment
refers to stationary
equipment primarily utilized in the oil, gas, and other process industries.
Fixed Equipment
This type of equipment remains non-moving during its operation.
Fixed Equipment
Examples of Fixed Equipment
-Pressure Vessels
-Heat Exchangers
-Pipelines,
-Storage Tanks
-Valves
-Boilers
-Furnaces
pumps, compressors, turbines, electrical equipment, and certain
instrumentation & control components, despite their stationary roles
fixed equipment or not?
not fixed equipment
a term generally used in the oil and gas and process industries to describe mechanical components that use kinetic energy to move fluids, gases, and other process materials.
Rotating Equipment
generally refers to any process equipment that moves or rotates
Rotating Equipment
This type of equipment is most often used to drive process fluids through a system
-it is distinguished by circular movements.
Rotating Equipment
examples of rotating equipment
-Turbines
-pumps
-compressors
-gearboxes
-engines
All rotary equipment is made up of…?
- DRIVER,
-CONNECTORS
-DRIVEN EQUIPMENT
Reactors, seperators, mixers, and conveyers ar example of..?
Process equipment
To measure and monitor process parameters
(New card-march 31)
Instruments
Electric Drills
Angle Grinders
Power Saws
Pneumatic Wrenches
Are examples of..?
New card -march 31
Powered tools
CNC machines, robots, automated production lines
Are examples of..?
New card -march 31
Automated machines
Temperature sensors, pressure sensors, flowmeters, level gauges, analyzers, controllers, transmitters, recorders
Are examples of..?
New card-march 31
Instruments
Uses a set of rollers that compress
and release a flexible hose or tube,
creating a suction that draws fluid
in and pushes it forward.
peristaltic
Meshing gears
gears
Rotating lobes
lobes
Piston moves back and forth
piston
Flexible diaphragm
diaphragm
The heat source and receiving medium must be
both fluid
