Midterms Flashcards
1
Q
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
A
Industrial process
2
Q
Key components of heavy industries
A
Industrial process
3
Q
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
A
Process Industries
4
Q
Characterized by flowing materials or media
A
Production Process
5
Q
examples of process Industries
A
1.food and beverages
2.chemicals
3. Pharmaceuticals
4.Petroleum
5.ceramics
6. Plastic and rubber
7. Tabacco
8.Paper and pulp
9. Etc.
6
Q
Input ➡️ processes➡️ output
In process Industries, example:
A
Raw materials ➡️ Factory ➡️ Manufactured goods
7
Q
Several components can define an industrial system
A
1.Raw materials
2. Energy(electricity)
3. Labour(skilled/unskilled)
4. Land
5. Transport
6. Communication links
7. Capital (including government grants)
8
Q
Refers to the **methods, **techniques, and operations carried out to convert input into outputs
A
Processes
9
Q
This encompasses all the products or by products generated by the system
A
Output
10
Q
Would be goods but there might be waste
A
Primary output
11
Q
Give one benefits of industrial processes
A
Contribute to the conversion of a rare and costly material into a commodity cheaper in price.
12
Q
The result of industrial processes
A
May produce a desired product or creates certain unnecessary by products which maybe toxic, hazardous and hard to manage with
13
Q
Types of industrial processes
A
1.General processes
2.Chemical processes
3. Heat processes
4. Physical processes
5.Distillation processes
14
Q
Used by large in almost all the heavy industries
A
General processes
15
Q
Used for easy transportation between one part to the other.
A
Liquefaction
16
Q
Removal of excess liquid
A
Freeze drying or superficial drying
17
Q
Used for removing pollutants from the exhaust gas that is created
A
Scrubber
18
Q
Involve methods that result in the transformation of one set of chemical substances to another.
A
Chemical processes
19
Q
Can be used to modify or produce various materials
A
Chemical processes
20
Q
Chemical processes example; process used to extract a metal from its ore, often involving the use of heat and reducing agents
A
Smelting
21
Q
Refers to the elimination of pathogens and other harmful microorganisms, usually by chemical means
A
Disinfection
22
Q
Process in which heat is used to chemically combine the materials
A
Pyro-processing
23
Q
One of the materials that are combined by means of pyro-processing methods
A
Cement
24
Q
Heat or direct current is used in the production of materials
A
Heat processes
25
Two methods that use heat processes for producing end products
Flash smelting and electrolysis
26
Refinement of the smelting process and is used predominantly for sulphur ores to produce copper,nickel, and lead.
Flash smelting
27
Process in which electricity is used to produce desired effect of plating or separating metals
Electrolysis
28
Metals and materials are reshaped and molded into various products by means of certain procedures like cutting,folding, polishing, etc.
Physical processes
29
Physical cleaning process of a surface by means of sand or other particles
Sandblasting
30
Components like petroleum and hydrocarbon by-products are produced by the industrial process of distillation
Distillation
31
Two terms related to conversion of raw materials into finished products
Manufacturing and production
32
Process of transforming raw materials into ready goods, with the help of machinery
Manufacturing
33
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
34
Series of action that produce something or that lead to a particular result
Process
35
The use of science in industry, engineering, etc, to invent useful things or to solve problems
Technology
36
It is the machines, equipment, and devices that create and/or deliver products and services
Process technology
37
process technology and transformed resources (3) types
1.Material-processing technologies
2.Information-processing technologies
3.Customer-processing technology
38
It is any technology that shapes, transports,stores,or in a way changes physical objects
Material-processing technology
39
It is any device which collects, manipulates, stores, or distributes information
Information-processing technology
40
It is a machine that simplifies the process being done by human
Customer -processing technology
41
3 categories of customer-processing technology
1.Active
2.Passive
3.One-way monitoring
42
Customers use the technology **to create the service**
Active
43
Processes and controls the customer by restraining the customers action in some way
Passive
44
Tracks customers movements or transactions in an obstrusive way
One-way monitoring
45
Classification of industries
1.Primary industry
2.Genetic industry
3.Extractive industry
4.Manufacturing industry
5.Construction industry
6.Service industry
46
Is concerned with production of goods with the help of nature.It is a nature oriented industry which requires little human effort
Primary industry
47
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
48
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
49
Engaged in transforming raw material into finished product with the **help of machines and manpower**
Manufacturing industries
50
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
51
In modern times service sector plays an important role in the development of the nation
Service industry
52
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
53
Production system involves..
1. Resources flowing within a define system
2. Combined and transformed
3. Controlled manner
4. Add value
5. Accordance to the policies communicated by management
54
Production processes/system are classified on the basis of
1.Product/output variety
2. Product/operations/output volume
55
Two types of production processes
1. Continuous production process
2. Intermitted production process
56
Under continuous production process
-Process/flow production
-mass production
57
Under intermitted production process
-batch production
-job shop production
-project production
58
Items are completed and placed in stock before receiving a customer order
Made to stock production process(MTS)
59
The end item is completed solely in response to a specific customer order
Made to order production process(MTO)
60
Referred to as repetitive manufacturing systems
Continuous manufacturing system
61
These are mass production facilities that **produce high volumes of the same products**
Continuous manufacturing system
62
Usually make to stock producers
Continuous manufacturing system
63
Manufacturing happens in **automated, special purpose equipments**
Continuous manufacturing system
64
Products **follow the same path**
Continuous manufacturing system
65
Usually the products are **not discrete**
Continuous: Flow shop
66
Also called as process type operations
Continuous flow operations
67
**Standardization** of product and process sequence. Dedicated special purpose machines having **high production** capacities and output tates.
Continuous: mass production
68
With higher rate of production with reduced cycled time and High capacity utilization due to **line balancing**
Continuous: mass production
69
**Less skilled operators** are required and has **low process inventory**
Continuous: mass production
70
Manufacturing **cost per unit is low**
Continuous: mass production
71
In this type of production process the volume of each product is low
Intermitted production process
72
Produces make to order, custom products in accordance with design supplied by the customer
Intermitted production process
73
Products may follow different paths
Intermitted production process
74
a type of manufacturing process in which **small batches of a variety of
custom products **are made.
job shop
75
most of the products
produced require a **UNIQUE SET-UP AND SEQUENCING** of process steps.
job shop process flow
76
used in
– woodworking **shops**,
– metal fabrica**tion** **shops**, et**c**.
job shop production process
77
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
78
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
79
Many **manufacturing** operations fall between
**job shops and repetitive manufacturing.**
Batch Manufacturing
80
means **a single production** run
batch
81
means the **quantity** produced in a **single production run**.
batch size
82
– It may be less than 100 units OR up to a few 1000 units
batch manufacturing
83
makes a **batch** of one product, then may switch over
(set up) the equipment and **make a batch of another item**
batch manufacturing company
84
should be **more flexible than repetitive manufacturing** and it is
**generally less flexible than job shops.**
Production equipment
85
a highly flexible and** low volume type operation**.
project
86
Usually, the item to be produced stays in a fixed place and all the resources come to it.
project
87
At the end of production, resources leave the place.
project
88
project type examples
Examples are
– ship construction,
– bridge construction,
– buildings and
– large machines
89
a system concept that***utilizes instrumentation system*** to perform a certain task or
sequences of operations in an automatic manner or without human intervention.
Automation
90
Is a process or sequence of production activities done in an automatic manner.
AUTOMATED PROCESS
91
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
92
includes the joining of multiple parts to make assembled products.
Manufacturing
93
Exclusively **uses production equipment** for a specific product, ensuring uninterrupted
output.
Continuous Production
94
the **process** is
carried out on a continuous stream of material, **with no interruptions in the output flow**
in process industries ; Continuous Production
95
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
96
Materials are processed in **limited quantities or batches.**
Batch Production
97
Production is intermittent, **with pauses between batches.**
Batch Production
98
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.
99
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
100
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
101
"manus" means
hand
102
"factus" means
make
103
"Manufacturing" originates from
latin words
104
Goods in those times were crafted by hand, using simple techniques in small
workshops.
handicraft
105
is a **collection of people, equipment, and procedures organized** to
perform the manufacturing operations of a company
A production system
106
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
107
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.
108
production systems consists of two major
components
- facilities
-Manufacturing support systems
109
portions of the this **are automated
and/or computerized.**
In modern manufacturing operations; production system
110
People make these systems work.
production systems
111
direct labor people
blue-collar workers
112
responsible for operating the
facilities
direct labor people (blue-collar workers)
113
professional staff people
white-collar workers
114
are responsible for the
manufacturing support systems.
professional staff people (white-collar workers)
115
can be **individual work cells consisting of a single production
machine and a worker** assigned to that machine.
Manufacturing systems
116
consist of collections of machines and workers
More complex manufacturing systems
117
three basic categories of manufacturing systems
-manual work system
-worker-machine system
-fully automated system
118
consists of one or more workers performing one or more tasks
without the aid of powered tools.
manual work system
119
are common activities in manual work systems
Manual material handling tasks
120
commonly require the **use of hand tools**, such as screwdrivers and
hammers
production tasks
121
often employed **to grasp the work
part and position it securely** for processing.
work holder
122
**to round the edges** of a rectangular part that has just been
milled
A machinist using a file
123
to measure the diameter of a shaft
A quality control inspector using a micrometer
124
to move cartons in a warehouse
A material handling worker using a dolly
125
putting together a piece of machinery using hand tools.
A team of assembly workers
126
a **human worker operates powered equipment**, such as a
machine tool or other production machine
a worker-machine system
127
This is one of the most widely used
manufacturing systems
a worker-machine system
128
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
129
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
130
one in which a process is performed by a machine without
the direct participation of a human worker.
Automated System
131
implemented using a program
of instructions combined with a control system that executes the instructions.
automation
132
required to drive the process and to operate the program and control system.
power
133
Two levels of automation can be identified:
Semiautomated and Fully Automated
134
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
135
distinguished from its semiautomated counterpart by its capacity to operate for an extended period of time with no human attention.
Fully Automated Machine
136
Examples of automated processes
complex chemical processes,
oil refineries, and nuclear power plants.
137
humans or machines?
-sense unexpected stimuli
humans
138
humans or machines?
-performs repetitive tasks consistently
machine
139
humans or machines?
-store large amounts of data
machines
140
humans or machines?
-develop new solutions to problems
humans
141
humans or machines?
-cope with abstract problems
humans
142
humans or machines?
-adapt to change
humans
143
humans or machines?
-generalize from observations
humans
144
humans or machines?
-learn from experience
humans
145
humans or machines?
-make decisions based on incomplete data
humans
146
humans or machines?
-retrieve data from memory reliably
machines
147
humans or machines?
-perform multiple tasks simultaneously
machines
148
humans or machines?
-apply high forces and power
machines
149
humans or machines?
-perform simple computations quickly
machines
150
humans or machines?
-make routine decisions quickly
machines
151
to design
the processes and equipment, plan and control the production orders, and satisfy
product quality requirements.
manufacturing support system
152
manufacturing support system example
people and procedures
153
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
154
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.
155
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
156
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
157
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..
158
Three basic types of Automated manufacturing systems
1. Fixed automation
2. Programmable automation
3. Flexible automation
159
A manufacturing system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration
Fixed Automation
160
* Suited to high production quantities
* High initial investment for custom-engineered equipment
Fixed , programmable, or flexible Automation?
fixed automation
161
* High production rates
* Relatively inflexible in accommodating product variety
Fixed , programmable, or flexible Automation?
fixed automation
162
A manufacturing system designed with the capability to change the sequence of
operations to accommodate different product configurations
programmable automation
163
* High investment in general purpose equipment
* Lower production rates than fixed automation
Fixed , programmable, or flexible Automation?
programmable automation
164
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
165
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
166
* High investment for custom-engineered system
* Continuous production of variable mixes of products
Fixed , programmable, or flexible Automation?
flexible automation
167
* Medium production rates
* Flexibility to deal with soft product variety
Fixed , programmable, or flexible Automation?
flexible automation
168
three phases of Automation Migration Strategy
Phase 1 – Manual production
Phase 2 – Automated production
Phase 3 – Automated integrated production
169
Single-station manned cells working independently
-Advantages: quick to set up, low-cost tooling
Phase 1 – Manual production
170
Single-station automated cells operating independently
- As demand grows and automation can be justified
Phase 2 – Automated production
171
Multi-station system with serial operations and automated transfer of work
units between stations
Phase 3 – Automated integrated production
172
Manual production using single-station manned cells operating independently
Phase 1 – Manual production
172
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
172
using a **multi-station automated system with
serial operations** and automated transfer of work units between stations.
Phase 3 – Automated integrated production
172
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.
172
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
172
complex machines, also known as
compound
machines
173
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.
174
can be any item that is used to achieve a goal
a tool
175
Manual tools operated without external power, commonly used to perform
specific mechanical tasks, like wrenches, screwdrivers, and pliers.
hand tools
176
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
177
a tool used to indicate how parallel (level) or perpendicular (plumb) a surface
is relative to the earth.
level
178
Powered Tools rely on...?
external power source to operate.
179
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
180
-typically large and stationary.
-They are programmed to
perform a specific task or sequence of tasks without human intervention.
automated machines
181
**Specialized machinery** designed for specific tasks within various industries, aiding in the
transformation, storage, or management of materials.
process equipment
182
functions of process equipment
o Storage
o Flow Control
o Chemical Reaction Containment
183
Types Of Process Equipment
- Fixed/Stationary Equipment
-Rotating/Rotary Equipment
184
Stays in one location during operation.
Fixed/Stationary Equipment
184
Contains components that move or rotate during operation
Rotating/Rotary Equipment
185
commonly known as "Static Equipment
Fixed Equipment
186
refers to stationary
equipment primarily utilized in the oil, gas, and other process industries.
Fixed Equipment
187
This type of equipment remains non-moving during its operation.
Fixed Equipment
188
Examples of Fixed Equipment
-Pressure Vessels
-Heat Exchangers
-Pipelines,
-Storage Tanks
-Valves
-Boilers
-Furnaces
189
pumps, compressors, turbines, electrical equipment, and certain
instrumentation & control components, despite their stationary roles
fixed equipment or not?
not fixed equipment
190
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
191
generally refers to any process equipment that moves or rotates
Rotating Equipment
192
This type of equipment is most often used to drive process fluids through a system
-it is distinguished by circular movements.
Rotating Equipment
193
examples of rotating equipment
-Turbines
-pumps
-compressors
-gearboxes
-engines
194
All rotary equipment is made up of...?
- DRIVER,
-CONNECTORS
-DRIVEN EQUIPMENT
195
Reactors, seperators, mixers, and conveyers ar example of..?
Process equipment
196
To measure and monitor process parameters
(New card-march 31)
Instruments
197
Electric Drills
Angle Grinders
Power Saws
Pneumatic Wrenches
Are examples of..?
New card -march 31
Powered tools
198
CNC machines, robots, automated production lines
Are examples of..?
New card -march 31
Automated machines
199
Temperature sensors, pressure sensors, flowmeters, level gauges, analyzers, controllers, transmitters, recorders
Are examples of..?
New card-march 31
Instruments
200
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
201
Meshing gears
gears
202
Rotating lobes
lobes
203
Piston moves back and forth
piston
204
Flexible diaphragm
diaphragm
205
The heat source and receiving medium must be
both fluid
206
