Module 2

Question 1

what is manufacturing?

Answer 1

the application of physical and/or chemical processes to alter the geometry, properties, or appearance of materials

Question 2

what is production?

Answer 2

the process of transforming tangible inputs and intangible inputs into products of service

Question 3

what is marketing?

Answer 3

the action of selling and promoting products/services

Question 4

what is an industry?

Answer 4

enterprises/organizations that produce or supply goods and/or services

Question 5

Primary industries ___:

Answer 5

cultivate and exploit natural resources

Question 6

Secondary industries ___:

Answer 6

convert outputs of primary industries into products

Question 7

Tertiary industries ___:

Answer 7

service sector of the economy

Question 8

the three types of production operations are:

Answer 8

1. Continuous production
2. Batch Production
3. Job Production

Question 9

Identical products are produced using assembly lines are with what type of production operation

Answer 9

continuous production

Question 10

output is uninterrupted with no breaks in production in what production operation

Answer 10

continuous production

Question 11

in discrete manufacturing industries…

Answer 11

• equipment is 100% dedicated to one part of the product
• no downtime for product changeovers
• units of production are individually identifiable

Question 12

what is Special Case: Industry 4.0

Answer 12

it represents the fourth revolution, integrating digital technologies into manufacturing and industrial processes

Question 13

Cyber-Physical Systems (CPS) is:

Answer 13

• Physical machines are embedded with sensors and software.
• These systems collect data and interact with the physical
  environment

Question 14

Internet of Things (IoT):

Answer 14

• Devices are interconnected and communicate via the internet.
• Enables real-time data exchange across machines and systems.

Question 15

Cloud Computing:

Answer 15

• Centralized storage and computing power for data access anytime,
  anywhere.
• Scales with demand, ensuring efficiency and collaboration

Question 16

Big Data and Analytics:

Answer 16

• Massive volumes of data are analyzed for patterns, trends, and
  insights.
• Drives process optimization and strategic decisions

Question 17

Artificial Intelligence (AI) & Machine Learning (ML):

Answer 17

• Systems learn from data to predict outcomes and automate tasks.
• Enables smart automation and adaptive systems.

Question 18

Digital Twins

Answer 18

Virtual replicas of physical assets used to simulate, predict, and
improve performance

Question 19

The Special Case: Process Production is used for what?

Answer 19

the extraction of underground/hard to get items (ex. oil/cement)

Question 20

Production of similar products in ‘batches’ is called what?

Answer 20

Batch Production

Question 21

In Batch Production…

Answer 21

• Materials are processed in finite amounts or quantities, called a
  batch
• Production is discontinuous due to interruptions between batches

Question 22

In process industries (batch production)

Answer 22

• Starting materials often in liquid or bulk form.
• Processed together as one unit (e.g., brewing beer, producing
  pharmaceutical drugs, baking bread)

Question 23

In discrete manufacturing industries (batch production)

Answer 23

• Batch = specific number of work units.
• Units may be processed sequentially (one at a time) or simultaneously (all at
  once).
• Batch size can range from 1 to thousands of units.

Question 24

Advantages of Batch Production are:

Answer 24

• Product cost lower
• Flexibility – the ability to answer specific customer needs (such
  as style, weight, size)

Question 25

Disadvantages of Batch Production are:

Answer 25

* Lost time – Machines may need to be reset after completing each batch * Cash investment – Stock of raw materials need to be bought before hand * Need more space * Higher inventory * Late error detection – Product recalls! * Equipment shutdown and failure * More material in the system – increased chances of loss * Higher system throughput time

Question 26

The production of a single product/service is what?

Answer 26

Job Production

Question 27

Advantages of Job Production include:

Answer 27

* All customer needs are met * High quality product/services * Greater customer satisfaction

Question 28

Disadvantages of Job Production include:

Answer 28

* High cost (Price of Fixing a washing machine = New Washing Machine) * Skilled labor needed, therefore, more training (investment)

Question 29

Consumer goods are purchased ___

Answer 29

directly by consumers

Question 30

Capital goods are purchased by who?

Answer 30

companies to produce goods or supply services

Question 31

For a plant engaged in making discrete products, the factory activities are:

Answer 31

(1) processing and assembly operations (2) material handling (3) inspection and test (4) coordination and control

Question 32

Processing and Assembly Operations (A)(Manufacturing Operation)

Answer 32

A) Processing Operations - Energy to alter parts physical property - Human role: primarily monitoring, controlling, loading/unloading - Waste and scrap is generated

Question 33

Three general categories of processing operations

Answer 33

- Shaping operations - Property-enhancing operations - Surface processing operations

Question 34

Part shaping operations

Answer 34

- Applying mechanical force, heat, or other forms of energy to change geometry of material - Classification here is based on the state of starting material

Question 35

Four categories of part shaping

Answer 35

- Solidification Process - Particulate processing - Deformation Processes - Material removal processes

Question 36

Solidification Process (four categories of part shaping operations)

Answer 36

- Start with heated liquid - material flows into mold cavity and solidifies, taking shape of cavity

Question 37

Particulate Process (four categories of part shaping operations)

Answer 37

- start with powder - press powder in a die cavity under high pressure - Strengthen: sintering (heated below melting point to bond particles)

Question 38

Deformation Process (four categories of part shaping operations)

Answer 38

- Start with ductile metal - Metal shaped by applying stresses exceeding yield strength - Heating increases ductility before forming - Forging, extrusion, rolling and sheet metal process

Question 39

Material Removal Process (four categories of part shaping operations)

Answer 39

- Starts as a solid - Key processes:

Question 40

What are the three main types of surface processing operations?

Answer 40

cleaning, surface treatments, coating and thin film deposition

Question 41

Assembly operations involve___

Answer 41

joining two or more separate parts to form a new entity

Question 42

Permanent joining processes include:

Answer 42

welding, brazing, soldering, adhesive bonding

Question 43

mechanical assembly methods include:

Answer 43

the use of threaded fasteners, rivets, expansion fits etc.

Question 44

Production quantity ranges for low, medium, and high production are as follows:

Answer 44

low: 1-100 units medium: 100-10,000 units high: 10,000 to 1 million units