Unit 1 - Introduction to Manufacturing Technology

Question 1

Production technology subcategory

Answer 1

• Manufacturing technology: production of goods with defined forms
• Process technology: production of formless materials (liquids, pastes)
• Energy technology: energy generation
• Information technology: production and processing of information

Question 2

DIN 8580

Answer 2

Deutsches institut fur Norming 8580 standard describes the processes available within manufacturing technology and classifies them in main groups

Question 3

Main groups of DIN 8580

Answer 3

• Primary shaping
• Forming
• Separating
• Joining
• Coating
• Changing of material properties

Question 4

Primary shaping

Answer 4

Building a solid object from a formless material.
Choesion of particles: created

eg:
- from a liquid state (casting)
- from a plastic state (injection molding)
- from a pastry state (casting of ceramic)

Question 5

Forming

Answer 5

Plastic change in the form of a solid body.
Choesion of particles: preserved

eg:
- pressure forming (rolling, extrusion)
- tensile-compressive forming
- tensile forming (lengthening, widening)
- bending

Question 6

Separating

Answer 6

Changing the shape of a solid object by local dechoesion
Choesion of particles: reduced or eliminated

eg:
- cutting (shearing)
- defined (drilling, milling)
- undefined (grinding, honing)
- removal (thermal separation)
- cleaning (abrasive blast cleaning)

Question 7

Joining

Answer 7

Joining workpieces, can be done by using shapeless materials.
Choesion of particles: increased

eg:
- assembly (insertion)
- filling (pour filling)
- forcing on and into (shrinking)
- joining by welding (fusion welding)
- joining by soldering (brazing)
- adhesive bonding

Question 8

Coating

Answer 8

Adding a choesive coat using a shapeless material.
Choesion of particles: increased

eg:
- from a liquid state (painting)
- from a plastic state (filling in)
- from a pastry state (plastering)
- from glanular or powder state
- by welding (fusion deposition)
- by soldering (soldering deposition)

Question 9

Changing of material properties

Answer 9

Changing of material properties, eg; by diffusion, chemical reaction..
Choesion of particles: n/a

eg:
- hardening by forming (forging)
- heat treatment (annealing, hardening)
- thermomechanical treatment
- magnetizing
- irradiation
- photochemical processes

Question 10

Essential manufacturing result for assessing manufacturing task

Answer 10

quality, quality performance, cost

Question 11

Most significant materials

Answer 11

Most significant are ferrous materials, light metals (alluminium), and plastics.

Steel materials are still the most common construction material in the world

Question 12

Materials types (3)

Answer 12

• ferrous materials (steel, iron castin materials)
• non-ferrous metals and alloys
  > light metals (alluminium, magnesium, titanium)
  > heavy metals (copper, zing, nickel)
• non-metals
  > inorganic (ceramic, glass)
  > plastic (thermoplastic, duroplast)

Question 13

Which are the typical materials in lightweight construction?

Answer 13

Aluminiu
Titanium
Fiber-reinforced plastic

Question 14

Composites

Answer 14

Combining the properties of different materials

Question 15

Composites examples

Answer 15

• Ceramics: high melting point, high thermal stability, high corrosion resistance, wear resistance.
• Polymers: high corrosion resistance, low density
• Metals: high thermal conductivity, high thermal shock resistance, toughness, formability

other eg:
particulate composites, fiber-reinforced compositev, glare..

Question 16

flexibility

Answer 16

A production plant that allows it to process a large number of different components (geometries) and produce a wide range of geometric form elements.

Question 17

Degree of automation

Answer 17

is the extent to which workers are involved in the manufacturing process.

With degree of 100%, the production is automatic.

Question 18

Chart flexibility/degree of automation/cost

Answer 18

Unit costs fall as the degree of automation rises, but flexibility decreases while investments increase.

Question 19

REFA

Answer 19

Is an organization that provides a structure for time planning in manufacturing. Times are determined in the work process.

Question 20

Definition and determining allowed times (REFA)

Answer 20

Time load for the person in the work process or the manufacturing equipment.

Determining allowed times:
- Work factor (WF): determined by totaling individual motion elements.
- Methods time measurement (MTM): motion sequences are analyzed and broken down into individual motion elements.

Question 21

DIN EN ISO 9001

Answer 21

Internationally applied guideline for quality management.

Question 22

Quality definition

Answer 22

Indicates if the product meets the requirements

Question 23

Quality management systems (QMS)

Answer 23

is defined as the improvement in quality on the product and production pprocesses.
Productivity increase, cost reduction, price reduction, increase in market share, higher customer approval.

Question 24

Rule of 10

Answer 24

In quality management states the costs of eliminating a defects depends on the stage of discovery.

To avoid defects in early phase of development an FMEA is used.

Question 25

Product management systems

Answer 25

Those are necessary to control the complex production and to integrate the multitude of suppliers for just-in-time production.

Question 26

Toyota production system (TPS)

Answer 26

much heavier emphasis on the involvment of the customer, employees, and quality in the production process.

Question 27

Lean management

Answer 27

this philosophy has the goal of doing only what the customer value.

Question 28

TPS reduce waste rules

Answer 28

overproduction inventory transport and walking routes laborious processing laborious motion waiting times reworking

Question 29

Principles applied in Lean Management

Answer 29

-only improve what customer values in product -focus on your own strengths -involve employees in continuos improvement process -build personal responsibility, team spirit, and teamwork -ensure employees autonomy and self-determination -build a leadership culture -offer employees continued training -provide a clear and open information policy toward the workforce -discuss with and involve enployees in change processes -estabilish a cultural change towards social structures in the company

Question 30

Principles in TPS and orientation

Answer 30

-customer orientation -employee orientation -process orientation -standards orientation -quality orientation -competitive orientation -customer-supplier orientation Improve in small steps sincronizing process, standardizing process, avoiding errors, improving systems, training workers production at customer peace

Question 31

Kaizen system philosopy

Answer 31

Aims to learn from mistakes > "mistakes are an opportunity to improve"

Question 32

cost elements cost centers cost units

Answer 32

cost elements > which costs have been incurred? > material, wage and energy cost cost centers > where have the costs been incurred? > inventory, planning and milling shop cost units > what have the costs been incurred for? > machine type A, gearbox, motor

Question 33

Age in order

Answer 33

1. stone age 2. bronze age 3. iron age 4. middle age 5. early modern age

Question 34

Stone age

Answer 34

Up to 3000 bce paleolitic era, use of stone tools for processing materials

Question 35

Bronze age

Answer 35

3000-1000 bce bronze for jewlery, tools and weapons

Question 36

Iron age

Answer 36

1000 bce - 0 iron is harder than metals previously used, iron deposits were significantly larger

Question 37

Middle age

Answer 37

500-1500 ad between end of antiquity and beginning of modern age commerce began to take on, increasing significance large share of population lived outside towns

Question 38

Early modern age

Answer 38

1500-1700 ad estabilishment of first pre-industrial structures complex products were manufactured the concept of quality gained significance

Question 39

Industrial age

Answer 39

from 1750 ad industries settled in the cities Main ind innovation: steam engine, mechanical loom, assembly line work, automation and IT

Question 40

Industry 1.0

Answer 40

mechanical production equipment using hydropower and steam power

Question 41

Industry 2.0

Answer 41

mass production based on division of labor and electrical energy

Question 42

Industry 3.0

Answer 42

use of electronic and IT to futher automate production

Question 43

Industry 4.0

Answer 43

based on cyber-physical systems (internet)