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Process Engineering > Midterms > Flashcards

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

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2
Q

Key components of heavy industries

A

Industrial process

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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

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4
Q

Characterized by flowing materials or media

A

Production Process

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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.

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6
Q

Input ➡️ processes➡️ output

In process Industries, example:

A

Raw materials ➡️ Factory ➡️ Manufactured goods

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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)

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8
Q

Refers to the **methods, **techniques, and operations carried out to convert input into outputs

A

Processes

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9
Q

This encompasses all the products or by products generated by the system

A

Output

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10
Q

Would be goods but there might be waste

A

Primary output

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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.

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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

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13
Q

Types of industrial processes

A

1.General processes
2.Chemical processes
3. Heat processes
4. Physical processes
5.Distillation processes

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14
Q

Used by large in almost all the heavy industries

A

General processes

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15
Q

Used for easy transportation between one part to the other.

A

Liquefaction

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16
Q

Removal of excess liquid

A

Freeze drying or superficial drying

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17
Q

Used for removing pollutants from the exhaust gas that is created

A

Scrubber

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18
Q

Involve methods that result in the transformation of one set of chemical substances to another.

A

Chemical processes

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19
Q

Can be used to modify or produce various materials

A

Chemical processes

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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

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21
Q

Refers to the elimination of pathogens and other harmful microorganisms, usually by chemical means

A

Disinfection

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22
Q

Process in which heat is used to chemically combine the materials

A

Pyro-processing

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23
Q

One of the materials that are combined by means of pyro-processing methods

A

Cement

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24
Q

Heat or direct current is used in the production of materials

A

Heat processes

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25
Q

Two methods that use heat processes for producing end products

A

Flash smelting and electrolysis

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26
Q

Refinement of the smelting process and is used predominantly for sulphur ores to produce copper,nickel, and lead.

A

Flash smelting

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27
Q

Process in which electricity is used to produce desired effect of plating or separating metals

A

Electrolysis

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28
Q

Metals and materials are reshaped and molded into various products by means of certain procedures like cutting,folding, polishing, etc.

A

Physical processes

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29
Q

Physical cleaning process of a surface by means of sand or other particles

A

Sandblasting

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30
Q

Components like petroleum and hydrocarbon by-products are produced by the industrial process of distillation

A

Distillation

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31
Q

Two terms related to conversion of raw materials into finished products

A

Manufacturing and production

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32
Q

Process of transforming raw materials into ready goods, with the help of machinery

A

Manufacturing

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33
Q

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

A

Production

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34
Q

Series of action that produce something or that lead to a particular result

A

Process

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35
Q

The use of science in industry, engineering, etc, to invent useful things or to solve problems

A

Technology

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36
Q

It is the machines, equipment, and devices that create and/or deliver products and services

A

Process technology

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37
Q

process technology and transformed resources (3) types

A

1.Material-processing technologies
2.Information-processing technologies
3.Customer-processing technology

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38
Q

It is any technology that shapes, transports,stores,or in a way changes physical objects

A

Material-processing technology

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39
Q

It is any device which collects, manipulates, stores, or distributes information

A

Information-processing technology

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40
Q

It is a machine that simplifies the process being done by human

A

Customer -processing technology

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41
Q

3 categories of customer-processing technology

A

1.Active
2.Passive
3.One-way monitoring

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42
Q

Customers use the technology to create the service

A

Active

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43
Q

Processes and controls the customer by restraining the customers action in some way

A

Passive

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44
Q

Tracks customers movements or transactions in an obstrusive way

A

One-way monitoring

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45
Q

Classification of industries

A

1.Primary industry
2.Genetic industry
3.Extractive industry
4.Manufacturing industry
5.Construction industry
6.Service industry

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46
Q

Is concerned with production of goods with the help of nature.It is a nature oriented industry which requires little human effort

A

Primary industry

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47
Q

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

A

Genetic industries

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48
Q

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

A

Extractive industry

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49
Q

Engaged in transforming raw material into finished product with the help of machines and manpower

A

Manufacturing industries

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50
Q

Take up the work of construction of buildings, bridges,roads,dams,canals,etc.

Can be produced at one place and sold at another place

A

Construction industries

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51
Q

In modern times service sector plays an important role in the development of the nation

A

Service industry

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52
Q

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.

A

Production system

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53
Q

Production system involves..

A
  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
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54
Q

Production processes/system are classified on the basis of

A

1.Product/output variety
2. Product/operations/output volume

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55
Q

Two types of production processes

A
  1. Continuous production process
  2. Intermitted production process
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56
Q

Under continuous production process

A

-Process/flow production
-mass production

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57
Q

Under intermitted production process

A

-batch production
-job shop production
-project production

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58
Q

Items are completed and placed in stock before receiving a customer order

A

Made to stock production process(MTS)

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59
Q

The end item is completed solely in response to a specific customer order

A

Made to order production process(MTO)

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60
Q

Referred to as repetitive manufacturing systems

A

Continuous manufacturing system

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61
Q

These are mass production facilities that produce high volumes of the same products

A

Continuous manufacturing system

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62
Q

Usually make to stock producers

A

Continuous manufacturing system

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63
Q

Manufacturing happens in automated, special purpose equipments

A

Continuous manufacturing system

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64
Q

Products follow the same path

A

Continuous manufacturing system

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65
Q

Usually the products are not discrete

A

Continuous: Flow shop

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66
Q

Also called as process type operations

A

Continuous flow operations

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67
Q

Standardization of product and process sequence. Dedicated special purpose machines having high production capacities and output tates.

A

Continuous: mass production

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68
Q

With higher rate of production with reduced cycled time and High capacity utilization due to line balancing

A

Continuous: mass production

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69
Q

Less skilled operators are required and has low process inventory

A

Continuous: mass production

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70
Q

Manufacturing cost per unit is low

A

Continuous: mass production

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71
Q

In this type of production process the volume of each product is low

A

Intermitted production process

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72
Q

Produces make to order, custom products in accordance with design supplied by the customer

A

Intermitted production process

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73
Q

Products may follow different paths

A

Intermitted production process

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74
Q

a type of manufacturing process in which **small batches of a variety of
custom products **are made.

A

job shop

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75
Q

most of the products
produced require a UNIQUE SET-UP AND SEQUENCING of process steps.

A

job shop process flow

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76
Q

used in
– woodworking shops,
– metal fabrication shops, etc.

A

job shop production process

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77
Q

Use of general-purpose machines and facilities
: (HL)

A

– Highly Skilled Operators who take up each job as a challenge
– Large inventory of materials tools and par

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78
Q

A large variety of products can be produced with the general-purpose machines(2:)

A

– Operators become more skilled and competent with each job
– Full potential of operators can be utilized

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79
Q

Many manufacturing operations fall between
job shops and repetitive manufacturing.

A

Batch Manufacturing

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80
Q

means a single production run

A

batch

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81
Q

means the quantity produced in a single production run.

A

batch size

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82
Q

– It may be less than 100 units OR up to a few 1000 units

A

batch manufacturing

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83
Q

makes a batch of one product, then may switch over
(set up) the equipment and make a batch of another item

A

batch manufacturing company

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84
Q

should be more flexible than repetitive manufacturing and it is
generally less flexible than job shops.

A

Production equipment

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85
Q

a highly flexible and** low volume type operation**.

A

project

86
Q

Usually, the item to be produced stays in a fixed place and all the resources come to it.

A

project

87
Q

At the end of production, resources leave the place.

A

project

88
Q

project type examples

A

Examples are
– ship construction,
– bridge construction,
– buildings and
– large machines

89
Q

a system concept thatutilizes instrumentation system to perform a certain task or
sequences of operations in an automatic manner or without human intervention.

A

Automation

90
Q

Is a process or sequence of production activities done in an automatic manner.

A

AUTOMATED PROCESS

91
Q

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.

A

Manufacturing

92
Q

includes the joining of multiple parts to make assembled products.

A

Manufacturing

93
Q

Exclusively uses production equipment for a specific product, ensuring uninterrupted
output.

A

Continuous Production

94
Q

the process is
carried out on a continuous stream of material, with no interruptions in the output flow

A

in process industries ; Continuous Production

95
Q

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

A

In the discrete manufacturing industries; Continuous Production

96
Q

Materials are processed in limited quantities or batches.

A

Batch Production

97
Q

Production is intermittent, with pauses between batches.

A

Batch Production

98
Q

Reasons for batch production:(VEE)

A

-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
Q

generally means that the starting
materials are in liquid or bulk form, and they are processed altogether as a unit

A

Batch production in the process industries

100
Q

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.

A

Batch; In the discrete manufacturing industries

101
Q

“manus” means

A

hand

102
Q

“factus” means

A

make

103
Q

“Manufacturing” originates from

A

latin words

104
Q

Goods in those times were crafted by hand, using simple techniques in small
workshops.

A

handicraft

105
Q

is a collection of people, equipment, and procedures organized to
perform the manufacturing operations of a company

A

A production system

106
Q

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.

A

facilities

107
Q

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.

A

Manufacturing support systems.

108
Q

production systems consists of two major
components

A
  • facilities
    -Manufacturing support systems
109
Q

portions of the this are automated
and/or computerized.

A

In modern manufacturing operations; production system

110
Q

People make these systems work.

A

production systems

111
Q

direct labor people

A

blue-collar workers

112
Q

responsible for operating the
facilities

A

direct labor people (blue-collar workers)

113
Q

professional staff people

A

white-collar workers

114
Q

are responsible for the
manufacturing support systems.

A

professional staff people (white-collar workers)

115
Q

can be individual work cells consisting of a single production
machine and a worker assigned to that machine.

A

Manufacturing systems

116
Q

consist of collections of machines and workers

A

More complex manufacturing systems

117
Q

three basic categories of manufacturing systems

A

-manual work system
-worker-machine system
-fully automated system

118
Q

consists of one or more workers performing one or more tasks
without the aid of powered tools.

A

manual work system

119
Q

are common activities in manual work systems

A

Manual material handling tasks

120
Q

commonly require the use of hand tools, such as screwdrivers and
hammers

A

production tasks

121
Q

often employed to grasp the work
part and position it securely for processing.

A

work holder

122
Q

to round the edges of a rectangular part that has just been
milled

A

A machinist using a file

123
Q

to measure the diameter of a shaft

A

A quality control inspector using a micrometer

124
Q

to move cartons in a warehouse

A

A material handling worker using a dolly

125
Q

putting together a piece of machinery using hand tools.

A

A team of assembly workers

126
Q

a human worker operates powered equipment, such as a
machine tool or other production machine

A

a worker-machine system

127
Q

This is one of the most widely used
manufacturing systems

A

a worker-machine system

128
Q

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.

A

Worker-machine systems

129
Q

Examples of worker-machine systems

A

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
Q

one in which a process is performed by a machine without
the direct participation of a human worker.

A

Automated System

131
Q

implemented using a program
of instructions combined with a control system that executes the instructions.

A

automation

132
Q

required to drive the process and to operate the program and control system.

A

power

133
Q

Two levels of automation can be identified:

A

Semiautomated and Fully Automated

134
Q

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.

A

Semi-Automated Machine

135
Q

distinguished from its semiautomated counterpart by its capacity to operate for an extended period of time with no human attention.

A

Fully Automated Machine

136
Q

Examples of automated processes

A

complex chemical processes,
oil refineries, and nuclear power plants.

137
Q

humans or machines?

-sense unexpected stimuli

A

humans

138
Q

humans or machines?

-performs repetitive tasks consistently

A

machine

139
Q

humans or machines?

-store large amounts of data

A

machines

140
Q

humans or machines?

-develop new solutions to problems

A

humans

141
Q

humans or machines?

-cope with abstract problems

A

humans

142
Q

humans or machines?

-adapt to change

A

humans

143
Q

humans or machines?

-generalize from observations

A

humans

144
Q

humans or machines?

-learn from experience

A

humans

145
Q

humans or machines?

-make decisions based on incomplete data

A

humans

146
Q

humans or machines?

-retrieve data from memory reliably

A

machines

147
Q

humans or machines?

-perform multiple tasks simultaneously

A

machines

148
Q

humans or machines?

-apply high forces and power

A

machines

149
Q

humans or machines?

-perform simple computations quickly

A

machines

150
Q

humans or machines?

-make routine decisions quickly

A

machines

151
Q

to design
the processes and equipment, plan and control the production orders, and satisfy
product quality requirements.

A

manufacturing support system

152
Q

manufacturing support system example

A

people and procedures

153
Q

t or f

Most of these support systems do not directly contact the
product, but they plan and control its progress through the factory.

A

true

154
Q

Manufacturing support involves a sequence of activities

The activities consist of FOUR (4) functions that include much information flow and data ..

A

(1) business functions
(2) product design
(3) manufacturing planning
(4) manufacturing control.

155
Q

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.

A

business functions

156
Q

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

A

Automated manufacturing systems

157
Q

why the automated manufacturing system is called automated?

A

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
Q

Three basic types of Automated manufacturing systems

A
  1. Fixed automation
  2. Programmable automation
  3. Flexible automation
159
Q

A manufacturing system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration

A

Fixed Automation

160
Q
  • Suited to high production quantities
  • High initial investment for custom-engineered equipment

Fixed , programmable, or flexible Automation?

A

fixed automation

161
Q
  • High production rates
  • Relatively inflexible in accommodating product variety

Fixed , programmable, or flexible Automation?

A

fixed automation

162
Q

A manufacturing system designed with the capability to change the sequence of
operations to accommodate different product configurations

A

programmable automation

163
Q
  • High investment in general purpose equipment
  • Lower production rates than fixed automation

Fixed , programmable, or flexible Automation?

A

programmable automation

164
Q

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?

A

programmable automation

165
Q

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

A

flexible automation

166
Q
  • High investment for custom-engineered system
  • Continuous production of variable mixes of products

Fixed , programmable, or flexible Automation?

A

flexible automation

167
Q
  • Medium production rates
  • Flexibility to deal with soft product variety

Fixed , programmable, or flexible Automation?

A

flexible automation

168
Q

three phases of Automation Migration Strategy

A

Phase 1 – Manual production
Phase 2 – Automated production
Phase 3 – Automated integrated production

169
Q

Single-station manned cells working independently

-Advantages: quick to set up, low-cost tooling

A

Phase 1 – Manual production

170
Q

Single-station automated cells operating independently

  • As demand grows and automation can be justified
A

Phase 2 – Automated production

171
Q

Multi-station system with serial operations and automated transfer of work
units between stations

A

Phase 3 – Automated integrated production

172
Q

Manual production using single-station manned cells operating independently

A

Phase 1 – Manual production

172
Q

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.

A

Phase 2 – Automated production

172
Q

using a multi-station automated system with
serial operations and automated transfer of work units between stations.

A

Phase 3 – Automated integrated production

172
Q

Advantages of Automation Migration Strategy

A

-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
Q

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.

A

Simple machines

172
Q

complex machines, also known as

A

compound
machines

173
Q

Machines like trucks, wagons, and bicycles are complex because

A

they have many
moving parts and merge several simple machines, such as levers, pulleys, and gears,
to accomplish tasks.

174
Q

can be any item that is used to achieve a goal

A

a tool

175
Q

Manual tools operated without external power, commonly used to perform
specific mechanical tasks, like wrenches, screwdrivers, and pliers.

A

hand tools

176
Q

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.

A

file

177
Q

a tool used to indicate how parallel (level) or perpendicular (plumb) a surface
is relative to the earth.

A

level

178
Q

Powered Tools rely on…?

A

external power source to operate.

179
Q

They can provide more force or speed
than manual tools and are often used for tasks that require significant power or are
repetitive

A

powered tools

180
Q

-typically large and stationary.

-They are programmed to
perform a specific task or sequence of tasks without human intervention.

A

automated machines

181
Q

Specialized machinery designed for specific tasks within various industries, aiding in the
transformation, storage, or management of materials.

A

process equipment

182
Q

functions of process equipment

A

o Storage
o Flow Control
o Chemical Reaction Containment

183
Q

Types Of Process Equipment

A
  • Fixed/Stationary Equipment

-Rotating/Rotary Equipment

184
Q

Stays in one location during operation.

A

Fixed/Stationary Equipment

184
Q

Contains components that move or rotate during operation

A

Rotating/Rotary Equipment

185
Q

commonly known as “Static Equipment

A

Fixed Equipment

186
Q

refers to stationary
equipment primarily utilized in the oil, gas, and other process industries.

A

Fixed Equipment

187
Q

This type of equipment remains non-moving during its operation.

A

Fixed Equipment

188
Q

Examples of Fixed Equipment

A

-Pressure Vessels
-Heat Exchangers
-Pipelines,
-Storage Tanks
-Valves
-Boilers
-Furnaces

189
Q

pumps, compressors, turbines, electrical equipment, and certain
instrumentation & control components, despite their stationary roles

fixed equipment or not?

A

not fixed equipment

190
Q

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.

A

Rotating Equipment

191
Q

generally refers to any process equipment that moves or rotates

A

Rotating Equipment

192
Q

This type of equipment is most often used to drive process fluids through a system

-it is distinguished by circular movements.

A

Rotating Equipment

193
Q

examples of rotating equipment

A

-Turbines
-pumps
-compressors
-gearboxes
-engines

194
Q

All rotary equipment is made up of…?

A
  • DRIVER,

-CONNECTORS

-DRIVEN EQUIPMENT

195
Q

Reactors, seperators, mixers, and conveyers ar example of..?

A

Process equipment

196
Q

To measure and monitor process parameters

(New card-march 31)

A

Instruments

197
Q

Electric Drills
Angle Grinders
Power Saws
Pneumatic Wrenches

Are examples of..?

New card -march 31

A

Powered tools

198
Q

CNC machines, robots, automated production lines

Are examples of..?

New card -march 31

A

Automated machines

199
Q

Temperature sensors, pressure sensors, flowmeters, level gauges, analyzers, controllers, transmitters, recorders

Are examples of..?

New card-march 31

A

Instruments

200
Q

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.

A

peristaltic

201
Q

Meshing gears

A

gears

202
Q

Rotating lobes

A

lobes

203
Q

Piston moves back and forth

A

piston

204
Q

Flexible diaphragm

A

diaphragm

205
Q

The heat source and receiving medium must be

A

both fluid

206
Q
A

Process Engineering (4 decks)

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