Chapter 1 Questions

1) What are the most things should you concern about when you manufacture any
product?

• A product must fully meet design requirements, product specifications, and

standards.

• A product must be manufactured by the most economical and environmentally

friendly methods.

• Quality must be built into the product at each stage from design to assembly, rather
than tested after the product is completed.

• Production methods must be flexible enough to respond to changes in market

demands, types of products, production rates, production quantities, and on‐time
delivery to customer.

• The manufacturer must work with the customer for timely feedback to continuous
product improvement.

2) What are the goals of concurrent engineering?

• Reduce changes in product’s design and engineering.

• Reduce the time and costs involved in taking the product form its design concept
to its production and its introduction into the marketplace.

3) Mention two computer tools that could be used in prototyping.

• CAD (computer‐aided design).

• CAM (computer‐aided manufacturing).

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4) Design for manufacturing requires a fundamental understanding of:

• The characteristics, capabilities, and limitations of materials, manufacturing

processes, machinery, equipment, and tooling and variability in machine
performance, dimensional accuracy and surface finish of the work piece, processing
time, and the effect of processing methods on product quality.

5) Manufacturing operations generally produce some waste, mention two examples

of waste that could be produced by Manufacturing operations.

• Chips from machining and trimmed materials from sheet forming, casting, and
molding operations.
• Hazardous waste and toxic materials used in various products.
• Liquids from processes such as heat treating and plating.

6) Mention three guidelines for Green Design and Manufacturing.

• Reduce waste of materials.

• Reduce the use of hazardous materials in products and processes.

• Make improvements in methods of recycling, waste treatment, and reuse of

materials.

• Minimize energy use.

7) What are the differences between manufacturing properties and mechanical

properties of any material?
• Include strength, ductility, hardness, toughness, elasticity, fatigue, and creep
resistance.

• Indicate whether a particular material can be cast, formed, machined, joined, and
heat treated with relative ease.

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8) What are the causes of product failure?

• Improper material selection.

• Incompatibility of materials in contact, which produces friction, wear, and
galvanic corrosion.

• Defects in raw materials.

• Defects induced during manufacturing.

• Improper component assembly.

9) What are the causes of the short service life of a product?

• Improper selection of materials.
• Improper selection of production methods.
• Insufficient control of processing variables.

• Poor maintenance.

10) How can you select particular manufacturing process and what are the factors
that you should focus on?
It depends on the geometric features of the parts to be produced, including the
dimensional tolerances and surface texture required, and on numerous factors pertaining
to the particular work piece material and its manufacturing properties.
Factors: part size, shape complexity, and dimensional accuracy and surface finish
required.

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11) What are the dimensions of product quality?

• Performance – relative to customer’s intended use.

• Features – special characteristics.

• Reliability – likelihood of breakdowns, malfunctions.

• Serviceability – speed/cost/convenience of servicing.
• Durability – amount of time/use before repairs.

• Appearance – effects on human senses.

• Customer service – treatment before/during/after sale.
• Safety – user protection before/during/after use.