The outline of the cam in Figure P7.38 is to be machined in an end milling operation, using a 12.5
mm diameterend mill with two teeth. The part is 7.5 mm thick. Write the complete APT program for
this job, using a feedrate = 80 mm/min and a spindle spe
The table below defines the precedence relationships and element times for a new model toy. (a)
Construct theprecedence diagram for this job. (b) If the ideal cycle time = 1.1 min. repositioning time
= 0.1 min, and uptimeproportion is assumed to be 1.0, w
A product whose work content time = 47.5 min is to be assembled on a manual production line. The
requiredproduction rate is 30 units per hour. From previous experience, it is estimated that the
manning level will be1.25, proportion uptime = 0.95, and repo
Briefly define the two categories of discrete process control?
Answer: Discrete process control can be divided into two categories: (1) logic control, which is
concernedwith event-driven changes in the system; and (2) sequencing, which is concerned
Name the five PLC programming methods identified in the International Standard for Programmable
Controllers (IEC 11313).
Answer: The standard specifies three graphical languages and two text-based languages for
PLCs, respectively: (1) ladder l
What type of production does a job shop perform?
Answer: Low production of specialized and customized products. The products are typically
as space capsules, aircraft, and special machinery.
Flow line production is associated with which on
Show that the two statements of the objective function in single model line balancing in Eq. (15.20)
Solution: nTs in the first expression =
in the second expression, since Ts is a constant
(Ts = Maxcfw_Tsi in Eq. (15.11)
What are the four functions included within the scope of manufacturing support systems?
Answer: As identified in the text, the four functions are (1) business functions, (2) product design,
manufacturing planning, and (4) manufacturing control.
A manual assembly line is to be designed to make a small consumer product. The work elements,
their times,and precedence constraints are given in the table below. The workers will operate the line
for 400 min per dayand must produce 300 products per day.
What is the difference between hard product variety and soft product variety?
Answer: Hard product variety is when the products differ substantially. In an assembled product,
variety is characterized by a low proportion of common parts among the pr
What is the difference between a processing operation and an assembly operation?
Answer: A processing operation transforms a work material from one state of completion to a
advanced state that is closer to the final desired part or product. It adds
Production rate for a certain assembled product is 47.5 units per hour. The assembly work content
time = 32 minof direct manual labor. The line operates at 95% uptime. Ten workstations have two
workers on opposite sidesof the line so that both sides of th
Name the four components of a manufacturing system.
Answer: As listed in the text, the four components are (1) production machines plus tools, fixtures,
and otherrelated hardware, (2) a material handling system, (3) a computer system to coordinate
What are the three classifications of production machines, in terms of worker participation?
Answer: In terms of worker participation, the machines can be classified as (1) manually operated,
or (3) fully automated.
What are the five mat
What are the three capabilities that a manufacturing system must possess in order to be flexible?
Answer: As identified in the text, the three capabilities are (1) identification of the different work
units, (2)quick changeover of operating instructions,
What is a pallet fixture in work transport in a manufacturing system?
Answer: A pallet fixture is a workholder that is designed to be transported by the material handling
system.The part is accurately attached to the fixture on the upper face of the palle
What are the five material handling functions that must be provided in a manufacturing system?
Answer: The five material handling functions that must be provided in a manufacturing system are
(1) loadingwork units at each station, (2) positioning the work
Name the three cases of part or product variety in manufacturing systems. Briefly define each of the
Answer: The three cases of part or product variety in manufacturing systems are (1) single model, (2)
batchmodel, and (3) mixed model. In the
Solve the previous problem using the Kilbridge and Wester method in part (c).
Solution: (a) Precedence diagram same as in Problem 15.11.
(b) Same as in Problem 15.11: n = 5 stations.
(c) Line balancing solution using the Kilbridge & Wester method:
What is flexibility in a manufacturing system?
Answer: Flexibility is the attribute that allows a mixed-model manufacturing system to cope with a
certainlevel of variation in part or product style without interruptions in production for changeovers
Why is manning level inversely correlated with automation level in a manufacturing system?
Answer: Manning level is inversely correlated with automation level in a manufacturing system
because thenumber of workers required to operate the system tends to b
A single model assembly line is being planned to produce a consumer appliance at the rate of
200,000 units peryear. The line will be operated 8 hours per shift, two shifts per day, five days per
week, 50 weeks per year.Work content time = 35.0 min. For pl
A manual assembly line has 17 workstations with one operator per station. Work content time to
assemble theproduct = 28.0 min. Production rate of the line = 30 units per hour. The proportion
uptime = 0.94, andrepositioning time = 6 sec. Determine the bala
Work content time for a product assembled on a manual production line is 45.0 min. Production rate
of the linemust be 50 units/hr. Work units are attached to a moving conveyor whose speed = 8
ft/min. Repositioning timeper worker is 8 sec, line efficiency
The required production rate = 50 units per hour for a certain product whose assembly work content
time = 1.2hours. It is to be produced on a production line that includes four workstations that are
automated. Because theautomated stations are not complet
What is a manufacturing system?
Answer: The definition given in the text is the following: A manufacturing system is a collection of
integratedequipment and human resources, whose function is to perform one or more processing
and/or assemblyoperations on
A computer system is an integral component in a modern manufacturing system. Name four of the
eightfunctions of the computer system listed in the text.
Answer: The eight functions of the computer system identified in the text are (1) communicate
What was the first application of an industrial robot?
Answer: According to Historical Note 8.1, the first application of an industrial robot was in a die
castingoperation at a General Motors plant in 1961.
What are the five joint types used in robotic
A TLR robot has a rotational joint (type R) whose output link is connected to the wrist assembly.
Consideringthe design of this joint only, the output link is 600 mm long, and the total range of
rotation of the joint is 40.The spatial resolution of this j
What are the five joint types used in robotic arms and wrists?
Answer: The five joint types are the following: (1) Linear joint (type L joint), in which the
relativemovementbetween the input link and the output link is a translational sliding motion, w