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by Gordon Mair
Essential Manufacturing
Cover
Preface
Part I: Introduction
1 Introduction
1.1 Wealth and Prosperity
1.2 Manufacturing Industry
1.3 Manufacturing as a Stimulant
1.4 The Supply Chain
1.5 Conclusion
2 Manufacturing History
2.1 Toolmaking Humans
2.2 The New Stone Age
2.3 The Bronze Age
2.4 The Iron Age
2.5 The Industrial Revolution
2.6 The Twentieth Century
2.7 The Twenty‐First Century
3 Typical Manufacturing Industries
3.1 Introduction
3.2 Aerospace Industry
3.3 Automotive Industry
3.4 Shipbuilding and Marine Engineering
3.5 Electronics and Electronic Products
3.6 Household Appliances
3.7 Pharmaceutical Industry
3.8 Food Processing
3.9 Beverage Industry
3.10 Clothing Industry
3.11 Producer Goods
3.12 Materials and Chemicals Production
4 Designing for Manufacture
4.1 Introduction
4.2 Computer Aided Design, Virtual Reality and Augmented Reality
4.3 Design for X
4.4 The Product Life Cycle
4.5 The Design Process
4.6 Identifying the Market Need
4.7 The Product Design Specification
4.8 Concept Design
4.9 Detail Design
4.10 Prototyping
4.11 Production
4.12 Contributors to the Design
4.13 Some Principles of Product Design
4.14 Standardisation and Modularisation
4.15 A Design for Manufacture Example
4.16 Conclusion
5 Manufacturing Concepts
5.1 The Manufacturing System
5.2 Lean Manufacturing and Added Value
5.3 Integrating the Effort
5.4 The Formal Organisation
5.5 Types of Manufacture
5.6 Types of Manufacturing Equipment
Part II: Manufacturing Materials
6 Materials for Manufacture
6.1 Introduction
6.2 The Structure of Metals
6.3 Plastics
6.4 Ceramics
6.5 Composites
6.6 Properties and Testing of Materials
6.7 Conclusion
7 Materials Production
7.1 Introduction
7.2 Ferrous Metals Production
7.3 Non‐Ferrous Metals Production
7.4 Forms of Material Supply
7.5 The Primary Production of Plastics
Part III: Manufacturing Processes
8 Casting
8.1 Introduction
8.2 Ingot Casting
8.3 Continuous Casting
8.4 Sand Casting
8.5 Centrifugal Casting
8.6 Shell Moulding
8.7 Full Mould Process
8.8 Investment Casting
8.9 Die Casting
8.10 Defects in Castings
8.11 Cleaning of Castings
8.12 When to Use Casting
9 Cutting Processes
9.1 Introduction
9.2 Sawing and Filing
9.3 Basic Principles of Machining
9.4 Machine Tools
9.5 Other Cutting Processes
10 Deformation Processes
10.1 Introduction
10.2 Rolling
10.3 Forging
10.4 Extrusion
11 Pressworking
Review Questions
12 Plastics Processing
12.1 Introduction
12.2 Extrusion
12.3 Blow Moulding
12.4 Calendering
12.5 Vacuum Forming
12.6 The Blown Film Process
12.7 Injection Moulding
13 Additive Manufacturing Processes
13.1 Introduction
13.2 Advantages of Additive Manufacturing
13.3 Disadvantages of Additive Manufacturing
13.4 General Types
14 Miscellaneous Metalworking Processes
14.1 Electrodischarge Machining
14.2 Electrochemical Machining
14.3 Chemical Machining
14.4 Ultrasonic Machining
14.5 High Energy Rate Forming
14.6 Powdered Metal Processes
14.7 Pipe and Tube Manufacture
14.8 Metal Finishing Processes
15 Manufacturing Processes in the Electronics Industry
15.1 Introduction
15.2 Semiconductor Component Manufacture
15.3 Clean Rooms
15.4 Printed Circuit Board Manufacture
15.5 Conclusion
16 Assembly and Joining
16.1 Introduction
16.2 Mechanical Fastening
16.3 Soldering
16.4 Brazing
16.5 Welding
16.6 Adhesive Bonding
17 Material and Process Selection
Part IV: Manufacturing Automation
18 Manufacturing Automation – Introduction
18.1 Types of Automation
18.2 The Advantages of Automation
18.3 Typical Examples of Manufacturing Automation
19 The Building Blocks of Automated Systems
19.1 Cams
19.2 Geneva Mechanism
19.3 Transfer Systems
19.4 Conveyors
19.5 Limit Switches
19.6 Fluid Power Components
19.7 Electric Motors for Actuation
19.8 Feedback Devices
19.9 The Vibratory Bowl Feeder
19.10 Programmable Logic Controllers (PLCs)
19.11 Control of Automated Machines
20 Reprogrammable Automation
20.1 Industrial Robots
20.2 Reprogrammable Equipment Precision
20.3 Computer Numerical Controlled (CNC) Machine Tools
20.4 Automated Guided Vehicles (AGVs)
20.5 Reprogrammable Automation and Industrial Robot Safety
21 Machine Vision
21.1 Areas of Application of Artificial Vision
21.2 Vision System Components
21.3 Lighting
21.4 Some Further Application Examples
21.5 Conclusion
Part V: Manufacturing Operations Management
22 Production Planning
22.1 Introduction
22.2 Plant Location
22.3 Plant Layout
22.4 Project Planning
22.5 Process Planning
23 Production Control
23.1 Introduction
23.2 Elements of Production Control
23.3 Material Requirements Planning
23.4 Manufacturing Resource Planning
23.5 Enterprise Resource Planning
23.6 Recognising Constraints
23.7 Just in Time Manufacture
24 Work Study
24.1 Introduction
24.2 Method Study
24.3 Work Measurement
24.4 Work Study As a Service to Management
25 Manufacturing Economics
25.1 Introduction
25.2 Costs for Decision Making
25.3 Investment Appraisal
25.4 Cost Analysis and Control
25.5 Conclusion
Part VI: Maintaining Manufacturing Quality
26 Quality Defined – Quality Management and Assurance
26.1 Defining Quality
26.2 Quality Management
26.3 Organisation for Quality
26.4 The Cost of Quality
26.5 Conclusion
27 Metrology and Statistical Quality Control
27.1 Introduction
27.2 Metrology
27.3 Factory and Workshop Metrology
27.4 Surface Texture and Measurement
27.5 Statistical Quality Control (SQC)
Part VII: Human Factors in Manufacturing
28 Human Factors in Manufacturing
28.1 Introduction
28.2 Job Satisfaction
28.3 Health and Safety
28.4 Ergonomics
28.5 Conclusion
Part VIII: Conclusion
29 Introduction
29.1 Additive Manufacturing
29.2 Augmented Reality (AR) and Virtual Reality (VR)
29.3 Immersive Telepresence
29.4 Communications Technologies and the IoT
29.5 Cloud Computing
29.6 Big Data Analytics
29.7 Conclusion
Appendix A:
Index
End User License Agreement
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Title Page
Table of Contents
Cover
Preface
Part I: Introduction
1 Introduction
1.1 Wealth and Prosperity
1.2 Manufacturing Industry
1.3 Manufacturing as a Stimulant
1.4 The Supply Chain
1.5 Conclusion
2 Manufacturing History
2.1 Toolmaking Humans
2.2 The New Stone Age
2.3 The Bronze Age
2.4 The Iron Age
2.5 The Industrial Revolution
2.6 The Twentieth Century
2.7 The Twenty‐First Century
3 Typical Manufacturing Industries
3.1 Introduction
3.2 Aerospace Industry
3.3 Automotive Industry
3.4 Shipbuilding and Marine Engineering
3.5 Electronics and Electronic Products
3.6 Household Appliances
3.7 Pharmaceutical Industry
3.8 Food Processing
3.9 Beverage Industry
3.10 Clothing Industry
3.11 Producer Goods
3.12 Materials and Chemicals Production
4 Designing for Manufacture
4.1 Introduction
4.2 Computer Aided Design, Virtual Reality and Augmented Reality
4.3 Design for X
4.4 The Product Life Cycle
4.5 The Design Process
4.6 Identifying the Market Need
4.7 The Product Design Specification
4.8 Concept Design
4.9 Detail Design
4.10 Prototyping
4.11 Production
4.12 Contributors to the Design
4.13 Some Principles of Product Design
4.14 Standardisation and Modularisation
4.15 A Design for Manufacture Example
4.16 Conclusion
5 Manufacturing Concepts
5.1 The Manufacturing System
5.2 Lean Manufacturing and Added Value
5.3 Integrating the Effort
5.4 The Formal Organisation
5.5 Types of Manufacture
5.6 Types of Manufacturing Equipment
Part II: Manufacturing Materials
6 Materials for Manufacture
6.1 Introduction
6.2 The Structure of Metals
6.3 Plastics
6.4 Ceramics
6.5 Composites
6.6 Properties and Testing of Materials
6.7 Conclusion
7 Materials Production
7.1 Introduction
7.2 Ferrous Metals Production
7.3 Non‐Ferrous Metals Production
7.4 Forms of Material Supply
7.5 The Primary Production of Plastics
Part III: Manufacturing Processes
8 Casting
8.1 Introduction
8.2 Ingot Casting
8.3 Continuous Casting
8.4 Sand Casting
8.5 Centrifugal Casting
8.6 Shell Moulding
8.7 Full Mould Process
8.8 Investment Casting
8.9 Die Casting
8.10 Defects in Castings
8.11 Cleaning of Castings
8.12 When to Use Casting
9 Cutting Processes
9.1 Introduction
9.2 Sawing and Filing
9.3 Basic Principles of Machining
9.4 Machine Tools
9.5 Other Cutting Processes
10 Deformation Processes
10.1 Introduction
10.2 Rolling
10.3 Forging
10.4 Extrusion
11 Pressworking
Review Questions
12 Plastics Processing
12.1 Introduction
12.2 Extrusion
12.3 Blow Moulding
12.4 Calendering
12.5 Vacuum Forming
12.6 The Blown Film Process
12.7 Injection Moulding
13 Additive Manufacturing Processes
13.1 Introduction
13.2 Advantages of Additive Manufacturing
13.3 Disadvantages of Additive Manufacturing
13.4 General Types
14 Miscellaneous Metalworking Processes
14.1 Electrodischarge Machining
14.2 Electrochemical Machining
14.3 Chemical Machining
14.4 Ultrasonic Machining
14.5 High Energy Rate Forming
14.6 Powdered Metal Processes
14.7 Pipe and Tube Manufacture
14.8 Metal Finishing Processes
15 Manufacturing Processes in the Electronics Industry
15.1 Introduction
15.2 Semiconductor Component Manufacture
15.3 Clean Rooms
15.4 Printed Circuit Board Manufacture
15.5 Conclusion
16 Assembly and Joining
16.1 Introduction
16.2 Mechanical Fastening
16.3 Soldering
16.4 Brazing
16.5 Welding
16.6 Adhesive Bonding
17 Material and Process Selection
Part IV: Manufacturing Automation
18 Manufacturing Automation – Introduction
18.1 Types of Automation
18.2 The Advantages of Automation
18.3 Typical Examples of Manufacturing Automation
19 The Building Blocks of Automated Systems
19.1 Cams
19.2 Geneva Mechanism
19.3 Transfer Systems
19.4 Conveyors
19.5 Limit Switches
19.6 Fluid Power Components
19.7 Electric Motors for Actuation
19.8 Feedback Devices
19.9 The Vibratory Bowl Feeder
19.10 Programmable Logic Controllers (PLCs)
19.11 Control of Automated Machines
20 Reprogrammable Automation
20.1 Industrial Robots
20.2 Reprogrammable Equipment Precision
20.3 Computer Numerical Controlled (CNC) Machine Tools
20.4 Automated Guided Vehicles (AGVs)
20.5 Reprogrammable Automation and Industrial Robot Safety
21 Machine Vision
21.1 Areas of Application of Artificial Vision
21.2 Vision System Components
21.3 Lighting
21.4 Some Further Application Examples
21.5 Conclusion
Part V: Manufacturing Operations Management
22 Production Planning
22.1 Introduction
22.2 Plant Location
22.3 Plant Layout
22.4 Project Planning
22.5 Process Planning
23 Production Control
23.1 Introduction
23.2 Elements of Production Control
23.3 Material Requirements Planning
23.4 Manufacturing Resource Planning
23.5 Enterprise Resource Planning
23.6 Recognising Constraints
23.7 Just in Time Manufacture
24 Work Study
24.1 Introduction
24.2 Method Study
24.3 Work Measurement
24.4 Work Study As a Service to Management
25 Manufacturing Economics
25.1 Introduction
25.2 Costs for Decision Making
25.3 Investment Appraisal
25.4 Cost Analysis and Control
25.5 Conclusion
Part VI: Maintaining Manufacturing Quality
26 Quality Defined – Quality Management and Assurance
26.1 Defining Quality
26.2 Quality Management
26.3 Organisation for Quality
26.4 The Cost of Quality
26.5 Conclusion
27 Metrology and Statistical Quality Control
27.1 Introduction
27.2 Metrology
27.3 Factory and Workshop Metrology
27.4 Surface Texture and Measurement
27.5 Statistical Quality Control (SQC)
Part VII: Human Factors in Manufacturing
28 Human Factors in Manufacturing
28.1 Introduction
28.2 Job Satisfaction
28.3 Health and Safety
28.4 Ergonomics
28.5 Conclusion
Part VIII: Conclusion
29 Introduction
29.1 Additive Manufacturing
29.2 Augmented Reality (AR) and Virtual Reality (VR)
29.3 Immersive Telepresence
29.4 Communications Technologies and the IoT
29.5 Cloud Computing
29.6 Big Data Analytics
29.7 Conclusion
Appendix A:
Index
End User License Agreement
List of Tables
Chapter 17
Table 17.1 Examples of the attributes of some processes and associated materials...
Chapter 25
Table 25.1 Marginal cost of a project (bold terms are for emphasis).
Table 25.2 Effect of increased production on a company's profit.
Table 25.3 Problem with the ‘payback’ method of investment appraisal.
Chapter 28
Table 28.1 Categorising levels of risk severity.
Table 28.2 Listing of hazards, those at risk, risk level, action plan and result...
Table 28.3 Approximate luminance requirements for interior activities.
List of Illustrations
Chapter 1
Figure 1.1 The Airbus A380.
Source
: Reproduced with permission of Pixabay.
Figure 1.2 A simplified supply chain for one component contributing to a finish...
Chapter 2
Figure 2.1 How one of the first stone tools may have been used.
Figure 2.2 Maudsley's all metal screwcutting lathe 1794.
Figure 2.3 Jacquard punch card controlled loom 1804.
Figure 2.4 The pen‐nib slitting room in the Hinks, Wells & Co. factory, Birming...
Figure 2.5 Spencer's automatic lathe 1873.
Figure 2.6 (a) ‘Unimate’; the first industrial robot in 1961. (b) Cincinnati Mi...
Figure 2.7 A modern fully automated area within a factory where industrial robo...
Chapter 3
Figure 3.1 Engineers working on a Rolls Royce jet engine.
Figure 3.2 Car assembly by industrial robots.
Figure 3.3 Queen Elizabeth class aircraft carrier. (a) Hull module, (b) bridge ...
Figure 3.4 A massive oil refinery complex in Texas.
Source
: Reproduced with per...
Chapter 4
Figure 4.1 The Product Life Cycle.
Figure 4.2 The design process.
Figure 4.3 (a) Prototype design for an alternator assembly. (b) Alternator re‐d...
Chapter 5
Figure 5.1 The manufacturing system inputs and outputs.
Figure 5.2 Comparison of lead time from product specification to full productio...
Figure 5.3 Hierarchy of objectives from an individual employee to company level...
Figure 5.4 A traditional organisation chart for a large manufacturing company a...
Figure 5.5 The four classes of production showing the relationship of quantity ...
Chapter 6
Figure 6.1 A simple materials classification.
Figure 6.2 Three main types of crystal structure.
Figure 6.3 Crystal formation and grain growth.
Figure 6.4 Effect on grain structure of cold working and recrystallisation.
Figure 6.5 The effect of grain direction on component strength.
Figure 6.6 Organic molecules.
Figure 6.7 Polymer chains: network, linear and branched polymers.
Figure 6.8 Tensile, compressive and shear loading and the resulting strain effe...
Figure 6.9 Stress/strain diagram for a low carbon steel.
Figure 6.10 A tensile test specimen.
Figure 6.11 Rockwell hardness test.
Figure 6.12 Izod impact test.
Chapter 7
Figure 7.1 Blast furnace for making iron.
Figure 7.2 Stages in the basic oxygen steelmaking process.
Figure 7.3 Electric arc furnace for steelmaking.
Figure 7.4 One method of copper production.
Figure 7.5 Electrolytic reduction cell for aluminium production.
Figure 7.6 Primary processes and standard material forms.
Figure 7.7 Schematic of a fractionating column.
Figure 7.8 Manufacture of polystyrene.
Chapter 8
Figure 8.1 Ingot casting and effect of mould orientation on piping.
Figure 8.2 Two methods of continuous casting.
Figure 8.3 Sand casting elements. (a) Required component, (b) upper and lower p...
Figure 8.4 Stages in shell moulding.
Figure 8.5 Investment or ‘lost wax’ casting process.
Figure 8.6 The hot chamber die casting process.
Figure 8.7 The cold chamber die casting process
Chapter 9
Figure 9.1 Two‐dimensional (orthogonal) cutting using single point tool.
Figure 9.2 Single point cutting tool for lathe turning. (a) Crater wear. (b) Th...
Figure 9.3 Indexable insert.
Figure 9.4 Generating a surface.
Figure 9.5 Forming a surface.
Figure 9.6 Some machining operations carried out on a lathe.
Figure 9.7 Basic elements of a centre lathe.
Figure 9.8 Three‐jaw chuck (3 and 4 jaw chucks usually much larger than collets...
Figure 9.9 Round collet for cold rolled or previously machined material (openin...
Figure 9.10 Horizontal and vertical milling.
Figure 9.11 Some milling cutters. (a) Cylinder or slab cutter. (b) End mill. (c...
Figure 9.12 Methods of milling. (a) Conventional or ‘up’ milling, maximum chip ...
Figure 9.13 Hand operated vertical drill press.
Figure 9.14 The twist drill.
Figure 9.15 Some operations that can be carried out on a drilling machine.
Chapter 10
Figure 10.1 Principle of operation of a two high reversing mill for steel roll...
Figure 10.2 Some rolling mill configurations.
Figure 10.3 (a) A friction drop hammer forging press and (b) the lower half of ...
Figure 10.4 The principle of extrusion.
Chapter 11
Figure 11.1 The basic configuration of a gap press
Figure 11.2 Some pressworking operations: (a) cropping, (b), piercing and blank...
Figure 11.3 A simple piercing and blanking tool.
Figure 11.4 A typical small component produced by presswork.
Figure 11.5 A car body panel produced by presswork.
Chapter 12
Figure 12.1 The polymer extrusion process and typical polymer sections.
Figure 12.2 The blow moulding process.
Figure 12.3 Calendering.
Figure 12.4 Vacuum forming.
Figure 12.5 The blown film process.
Figure 12.6 Main elements of an injection moulding machine.
Figure 12.7 A reciprocating screw injection system.
Figure 12.8 A two‐plate mould for injection moulding.
Figure 12.9 A method for creating a hole at right angles to the direction of tr...
Figure 12.10 A method for creating internal screw threads using a rotating core...
Figure 12.11 A sprue, gate and runner system.
Figure 12.12 A runner system design for optimum flow: (a) poor and (b) better.
Figure 12.13 Metal inserts in a moulding, the flanges and the knurled head fix ...
Figure 12.14 Some aspects of plastic component design.
Chapter 13
Figure 13.1 Principal additive manufacturing starting materials and examples o...
Figure 13.2 Stereolithography (SL).
Figure 13.3 This multipart engine model used stereolithography to achieve a det...
Figure 13.4 Fused deposition modelling (FDM).
Figure 13.5 A component produced by FDM that would be difficult to make in one ...
Figure 13.6 A Medical model and bicycle helmets produced by droplet 3D printing...
Figure 13.7 Some components produced by binder jet printing.
Figure 13.8 Selective laser sintering (SLS).
Figure 13.9 (a) A physical polymer wire‐frame model created by SLS. (b) A compl...
Figure 13.10 A vane produced by laser metal deposition.
Figure 13.11 Principle of laminated object manufacturing (LOM).
Figure 13.12 Aerofoil section produced from carbon fibre sheets.
Chapter 14
Figure 14.1 Electrodischarge machining.
Figure 14.2 Explosive forming a steel bowl‐shaped product.
Figure 14.3 The pressing or briquetting process in powder metallurgy, two punch...
Figure 14.4 The electroplating process.
Chapter 15
Figure 15.1 A semiconductor diode configuration.
Figure 15.2 An integrated circuit manufacturing sequence.
Figure 15.3 An integrated circuit in a dual in‐line package.
Figure 15.4 Single‐sided PCB manufacturing sequence.
Figure 15.5 Component configurations.
Figure 15.6 Component delivery packages.
Figure 15.7 (a) Preformed axial and radial leads and (b) SMD onsertion using ad...
Chapter 16
Figure 16.1 A chart showing some examples of the range of joining processes us...
Figure 16.2 Mechanical fastening examples.
Figure 16.3 Soldering examples.
Figure 16.4 Typical brazed joints.
Figure 16.5 Some basic welding joints and welds.
Figure 16.6 Fillet weld terminology.
Figure 16.7 Butt weld terminology.
Figure 16.8 (a) Simplified section of an oxyacetylene welding torch. (b) Three ...
Figure 16.9 (a) Basic equipment for shielded metal arc or ‘stick’ welding. (b) ...
Figure 16.10 Flux cored arc welding.
Figure 16.11 Gas metal arc welding.
Figure 16.12 Gas tungsten arc welding.
Figure 16.13 Plasma arc welding: (a) transferred and (b) nontransferred.
Figure 16.14 Submerged arc welding.
Figure 16.15 Resistance spot welding.
Figure 16.16 Resistance projection welding.
Figure 16.17 Explosive welding.
Figure 16.18 Friction welding.
Figure 16.19 Ultrasonic welding.
Figure 16.20 Adhesive bonding. (a) Adhesive joint loading conditions and (b) de...
Chapter 17
Figure 17.1 Material and process selection factors.
Chapter 18
Figure 18.1 The interrelationship between volume and cost per unit for manual ...
Figure 18.2 Area of application and effect of reprogrammable automation systems...
Figure 18.3 Industrial robots spot welding car bodies.
Figure 18.4 Human labour being used for qualitative inspection.
Chapter 19
Figure 19.1 Three types of cam used in dedicated ‘hard’ automation.
Figure 19.2 A Geneva mechanism.
Figure 19.3 A linear transfer system.
Figure 19.4 Conveyor system.
Source
: Reproduced with permission of Pixabay.
Figure 19.5 Some limit switch configurations.
Figure 19.6 Simple pneumatic control valve and piston.
Figure 19.7 Simple pneumatic circuit.
Figure 19.8 Typical electric servomotors used in manufacturing automation.
Figure 19.9 The potentiometer, an analogue device for displacement measurement.
Figure 19.10 The tachogenerator, an analogue device for measuring rotational sp...
Figure 19.11 The optical shaft encoder, a digital device for displacement measu...
Figure 19.12 A vibratory bowl feeder.
Figure 19.13 An example of bowl feeder track design.
Figure 19.14 A programmable logic controller (PLC) elements are shown on the le...
Chapter 20
Figure 20.1 Common industrial robot configurations. Articulated, Delta, and SC...
Figure 20.2 The Panasonic TA1400 articulated robot designed specifically for ar...
Figure 20.3 Block diagram of an industrial robot controller functions.
Figure 20.4 Concepts of accuracy and repeatability. (a) High accuracy, high rep...
Figure 20.5 (a) Multitasking CNC machine. (b) Typical MTM tooling.
Figure 20.6 (a) Very large AGV transporting part of an aircraft fuselage. (b) A...
Figure 20.7 An industrial robot working within a 2 m high safety cage.
Figure 20.8 Principle of light curtain, a vertical linear array of photo sensor...
Figure 20.9 A pressure sensitive mat.
Figure 20.10 An emergency stop button; note the mushroom shape for rapid operat...
Figure 20.11 Recessed start button in close proximity to the protruding stop bu...
Figure 20.12 The humanoid configuration Nextage robot by Kawada Robotics at the...
Chapter 21
Figure 21.1 Vision systems checking bottle fill levels and label integrity.
Figure 21.2 Basic elements of a vision–industrial robot system.
Figure 21.3 Machine vision photocell arrays. (a) Linear photocell array of 2592...
Figure 21.4 Setting a threshold value.
Figure 21.5 (a) A rectangle in the field of view of a very low resolution (32 ×...
Figure 21.6 (a) Light rings and (b) light rings in application.
Figure 21.7 (a) An industrial robot is shown palletising bricks with a vision s...
Figure 21.8 (a) A fruit conveyor system is shown with a vision system inspectin...
Chapter 22
Figure 22.1 Decision matrix for plant location: site E is most desirable.
Figure 22.2 Plant layout patterns: (a) ‘functional’ for batch production, (b) ‘...
Figure 22.3 Example project list of activities and durations.
Figure 22.4 Project Gantt chart.
Figure 22.5 The critical path analysis for the project.
Figure 22.6 The project work schedule chart.
Figure 22.7 An operation layout sheet for a clevis rod.
Chapter 23
Figure 23.1 Bill of Material structure for a toy car.
Figure 23.2 Basic MRP system.
Figure 23.3 Benefits of good material scheduling.
Figure 23.4 Closed loop MRP.
Figure 23.5 JIT manufacturing using the Kanban system.
Chapter 24
Figure 24.1 The fabric of Work Study.
Figure 24.2 Templates, pins and string used to plot the movements of a toolmake...
Figure 24.3 Operator and machine activity chart.
Figure 24.4 Clevis assembly process chart.
Figure 24.5 SIMO (simultaneous motion chart) for the assembly operation in Figu...
Figure 24.6 Therbligs.
Figure 24.7 The build‐up of the ‘Standard Time’ for a work activity.
Chapter 25
Figure 25.1 Distribution of costs for a manufacturing company.
Figure 25.2 ‘Risk’ represented by probability curves. (a) The probability of oc...
Figure 25.3 Fixed and variable costs.
Figure 25.4 Cost‐volume‐profit break‐even chart.
Figure 25.5 Break‐even chart for project selection.
Figure 25.6 Investment appraisal using DCF.
Figure 25.7 Allocation of costs to cost centres (chip and crisp departments) us...
Chapter 26
Figure 26.1 The Quality Environment for a manufacturing company.
Figure 26.2 A quality organisation structure indicating some necessary function...
Figure 26.3 Two views of Quality Costs. (a) Traditional perception of Quality C...
Chapter 27
Figure 27.1 Dimensional tolerancing applied to a bearing and shaft to ensure a...
Figure 27.2 The principle of light interference of monochromatic light.
Figure 27.3 Commercial metrology instruments and typical accuracies.
Source
: Re...
Figure 27.4 Greatly exaggerated machined surface features. This could be part o...
Figure 27.5 (a) A surface texture measuring machine. The stylus can be seen sus...
Figure 27.6 (a) Distribution of part sizes produced by turning. (b) Properties ...
Chapter 28
Figure 28.1 The Maslow Scale of the hierarchy of human needs.
Figure 28.2 Engineering and human sciences contributing to ergonomics.
Figure 28.3 Human‐machine closed loop system for car speed control.
Figure 28.4 Distribution of heights of adult male population.
Figure 28.5 Simple 2D models to assist with lathe design.
Figure 28.6 Typical operator dimensions.
Figure 28.7 Quantitative displays.
Figure 28.8 Parallax error when reading mechanical analogue displays: (a) view ...
Figure 28.9 Controls and display convention.
Figure 28.10 Some Db(A) values of typical sounds.
Guide
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