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| | كتاب Basic Manufacturing |  |
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| كاتب الموضوع | رسالة |
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Admin
مدير المنتدى
عدد المساهمات : 18996
التقييم : 35494
تاريخ التسجيل : 01/07/2009
الدولة : مصر
العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
 | | موضوع: كتاب Basic Manufacturing الجمعة 21 يونيو 2013, 1:52 pm | |
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تذكير بمساهمة فاتح الموضوع : أخوانى فى الله
أحضرت لكم كتاب
Basic Manufacturing
Third Edition
Roger Timings
و المحتوى كما يلي :
Contents
Preface vii
Acknowledgements viii
Chapter 1 The manufacturing industry 1
1.1 What is manufacturing 1
1.2 The main UK manufacturing sectors 3
1.3 The chemical industry 4
1.4 The engineering industry 7
1.5 The food, drink and tobacco products industry 16
1.6 Paper and board manufacture 21
1.7 Textiles, clothing and footwear 23
1.8 The importance of the main manufacturing sectors
to the UK economy 26
1.9 Industry and its location 29
1.10 Key stages of production (example) 31
1.11 Key stages of production (general) 33
1.12 Scales of production 36
Assessment activities 43
Chapter 2 Design and graphical communication 44
2.1 Product design specification 44
2.2 Materials used in manufacture 53
2.3 Properties of materials 73
2.4 Physical properties 78
2.5 Production details and constraints 83
2.6 Quality standards 85
2.7 Generating proposals to meet a design brief 96
2.8 Graphical communication 108
2.9 Technical drawings 114
2.10 Patterns, samples and swatches 120
2.11 From design brief to finished product 124
2.12 Calculating the cost of a product 127
Assessment activities 133
Chapter 3 Manufacturing products 134
3.1 Production planning and the schedule for manufacture 134
3.2 Teamwork 149
3.3 The preparation of materials and components 149
3.4 Machinery, tools and equipment in the working
environment 150
3.5 The preparation of tools and equipment 155
3.6 Processing methods 168
3.7 Handling and storage of materials 1843.8 Combining and assembling components 188
3.9 Assembly of components and subassemblies to
specification and quality standards 202
3.10 Quality and production control 209
3.11 Safety equipment, health and safety procedures
and systems 215
3.12 Safe working practices 228
Assessment activities 231
Chapter 4 Applications of technology 232
4.1 The use of information and communication
technology 232
Case study 4.1: The Internet and the World Wide Web 234
Case study 4.2: Databases 236
Case study 4.3: Spreadsheets 238
Case study 4.4: Computer-aided engineering 240
Case study 4.5: Rapid prototyping 245
Case study 4.6: Reverse engineering 247
Case study 4.7: A simple milling program 253
Case study 4.8: A simple turning program 254
4.2 Control technology and robotics 256
Case study 4.9: Programmable logic controllers 257
Case study 4.10: Pick and place robot 264
Case study 4.11: Wood machining 266
4.3 Smart materials, modern materials and
components 267
Case study 4.12: Coated and smart fabrics 269
Case study 4.13: Specialized adhesives 270
Case study 4.14: The microprocessor 274
Case study 4.15: Microprocessor systems 275
4.4 Impact of modern technology 278
4.5 The advantages and disadvantages of the
use of modern technology 280
Case study 4.16: The impact of modern technology
on the global environment and sustainability 281
4.6 The stages in manufacturing a product 284
4.7 Investigating products 292
Case study 4.17: Investigating a compact disc (CD) 292
Assessment activities 295
Index
Abrasives 162
Acceptance sampling and testing 89
Acrylics 62
Acrylic rubber 60
Added value 2
Adhesives 201
natural 201
thermoplastic 201
thermosetting 201
elastomeric 201
Adhesives, super 270
cured by ambient moisture 272
cured by anaerobic reactions 271
cured by anionic reactions 271
cured by ultraviolet (UV) light 271
cured with activator systems 272
Administration costs 130
Aesthetics 49
Agricultural equipment manufacture 11
Algorithm 113
Amino resins 61
Annealing 174
Anodizing 206
Applied liquid finishes (inorganic) 205
Applied liquid finishes (organic) 204
Assembly 35
Assembling components 188
Assembly of components and sub-assemblies to
specification and quality standards 202
Assembly tools 162, 230
Attributes, see Quality indicators
Automation and control 256
Automated equipment and machinery 170
Axis nomenclature 248
Bakery products manufacturing industry 16
Balance of trade 27
Batch production 37
Bill of materials 288
Biodegradable plastics 272
Blends 72
Blow moulding 178
Bonded webs 71
Brass alloys, properties and applications of 56
Brewing 19
Brittleness 74
Bronze alloys, properties and applications of 57
Buffing 207
Butyl rubber 60
Canned cycles 256
Canning 176
Capital resources 138
Carbonated (fizzy) drinks 19
Carpenter’s saws 157
Carpet manufacture 25
Casting (metals) 179
gravity die-casting 181
pressure die casting 181
sand casting 179
shell moulding 179
Cells of automation 257
Cellulose acetate 62
Ceramic coatings 205
Ceramic materials 58
applications of 59
Cereals 17
Cermets 64
Chemical industry 4
Chemical joining processes 200
solvent welding 200
adhesive (chemical) joining 200
Chemicals, inorganic 4
Chemicals, organic 4
Cider 19
Circuit breakers 227
Circuit breakers with residual current detection
(RCD) 227
Circuit diagrams (electrical) 117
Clothing industry 23, 25
Closed-loop system 249
Client needs, identification of 45
Colour 80
Colouration 208
CNC programming, see Programming
Combining components 188
Complex yarns 67
Component manufacturing industry 11
Components, the preparation of 149
Composite materials 63
cermets 64
glass reinforced plastics (GRP) 64
plywood 63
tufnol 64
wood 63
Composition proportion changes, effects
of 212
Compounds 72
Compression forming 176
Computer aided design (CAD) 117
IndexComputer aided engineering (CAE) 240
Computer numerical control (CNC) 247
Computer technology 273
Conductors 78
Confectionery products 17
Construction equipment manufacturing 12
Consumer durables 9
Contextual 50
Continuous flow and line production 37
Control and adjustment of manual equipment and
machinery 168
Control systems 249
Control technology and robotics 256
automation and control 256
industrial robots 259
programmable logic controllers (PLC) 257
programming methods (robots) 260
Convenience foods 18
Conversion coatings 206
Corduroy 70
Corrosion 81
Costs:
administration 130
direct (materials) 127
general expenses 130
human resources 128
indirect 128
indirect, allocation of 130
management 130
marketing 130
research and development (R&D) 189
service resources 128
cotton 24
Cost of a product, calculation of 127
Critical control points 136
Cutting tools:
abrasive papers and cloths 162
carpenter’s hand saws 157
drills 159
files 157
guillotine shears 157
hacksaw, metal cutting 157
knives 157
scissors 156
scrapers 159
shears 157
Dairy products 17
Databases 236
Defective products and components, dealing
with 213
downgrade 214
investigate causes of 213
recommend solutions 214
rework 214
scrap 214
Defects: 92
causes of 210
Degeneration:
corrosion 81
resistance to 81
weathering 81
Density 79
Dependent demand 287
Design:
client, development of a design brief for a 44
design brief, the 46, 125
design brief to finished product 124
design process, the 46
design proposal 125
design proposal, assessing the feasibility of 99
design proposals for a hand-held portable electric
fan 98
design reviews 101
design, the key role of 45
feedback 126
finished product 126
generating proposals to meet a 96
presentation 126
selecting a preferred 101
specification 46
Detail drawings 116
Direct costs (material) 127
Distilling, spirit 20
Drills 159
Drinks manufacturing industry 18
Ductility 76
Duty of care 95, 126
Dyes 208
Elasticity 75
Elastic limit 75
Elastomers, natural 58
Elastomers, synthetic 59
Electrical and electronic engineering 8
Electrical conductivity 75
Electroplating 206
Emergency stop buttons 227
Energy sources 30
Energy sources, renewable 285
Engineering industry 7
Ergonomics 101
Environment, the working 154
cleanliness 155
floor 154
lighting 154
safety 155
settings (machines and equipment) 155
space 154
tooling 155
Environments, hazardous 227
cold 223
contaminated 223
electrically dangerous 224
hygienically dangerous 224
physically dangerous 223
298 IndexEpoxy resins 61
Exploded drawing 116
Extranets 234
Extrusion moulding 177
Fabrics, non-woven 70
pile 70
warp knitted 71
weft knitted 70
woven 67
Fastenings:
riveted 190
compression joints 190
permanent (mechanical) 189
semi-permanent 188
Feasibility study 46
Feedback:
qualitative judgements 104
quantitative judgements 104
Felts, needle 71
Felts, wool 71
Fibres, natural 65
Fibres synthetic 65
Fibres and yarns 65
Files (engineers’) 157
Finishing 33, 35
Finishing methods 203
anodising 206
applied finishes (organic) 204
applied finishes (inorganic) 205
ceramic coatings 205
colouration 208
conversion coatings 205
electroplating 206
glazing 207
hot-dip galvanizing 205
laminating 207
metallic coatings 205
plastic coatings 206
porcelain enamels 205
vitreous enamels 205
Fire alarms 229
First aid 218
Fish 18
Fitness for purpose 53
Fixing and assembly tools:
hammers and mallets 164
needles 167
riveting tools and guns 167
screw drivers 162
spanners 162
soldering irons 164
Flavours 80
Flexible manufacturing (FMS) cells 39
Flow rate 79
Food and drinks, technology applied to 273
Food industries 16
Food products, miscellaneous 18
Footwear 26
Footwear manufacturing industry 23
Forging (metal) 181
Forming tools 162
Frequency of analysis 210
Fruit 17
Fruit drinks 19
Fuses 227
Galvanizing, hot-dip 205
General arrangement drawings 115
General expenses 130
Gin, see Spirit distilling
Glass fibre reinforced plastics (GRP) 64
Glazing 207
Globalization 2
Graphical communication:
bar charts 109
charts 112
data sheets 114
flow charts 112
Gantt charts 110
graphs 108
pictographs (ideograms) 111
pie charts 109
system flow chart (algorithm) 113
Gravity die-casting 181
Gross domestic product (GDP) 27
Gross national product 27
Guards 225
Guillotine shears 157
Hacksaw 157
Hammers 164
Handling of materials 184
Hard magnetic materials 78
Hardening (metals) 174
cold-working 174
precipitation hardening 174
quench hardening 175
tempering 175
Hardness 77
Hazardous environments, see Environments
Health, safety and hygiene 95
Health and safety at work act 228
Health and safety 215
emergency equipment (fire) 216
emergency equipment (first aid) 218
personal safety clothing and equipment 218
requirements 84
risk assessment 216
Human resources 29, 140
Human resource costs 128
Incentives 29
Independent demand 287
Indirect costs 128
Index 299Indirect costs, allocations of 130
Industrial globalization 2
Industrial revolution 1
Industry, the engineering 7
Information and communication technology (ICT),
the use of 232
Injection moulding 176
Inorganic chemicals 4
Internet 233
Inspection, points of for 87
assembly 89
bought in parts 89
finished products 89
material preparation 89
processing 89
raw materials 89
Inspection and testing:
methods of 93
health, safety and hygiene 95
levels of output during production 93
level of performance 93
product finish, packaging and presentation 95
quality of materials 93
tolerances 94
instrument engineering 10
Insulators (electrical) 78
Intranet 233
Investigating products 292
Islands of automation 257
Jacquard weave 70
Just-in-time (JIT) philosophy 135, 286
Jobbing production 40
Jute manufacture 25
Key stages of production 137
example 31
general 33
Knives 157
Labour, availability of 83
Laminated plastic (Tufnol) 64
Laminating 207
Limits of size (bilateral) 94
Limits of size (unilateral) 94
Linen 24
Location of industry 29
Machine tool manufacturing 16
Machinery:
accessory manufacture 13
automated 157
manual (non-automated) 150
working environment, in the 150
Magnetic properties 78
Malleability 76
Mallets 164
Manual equipment and machinery, control and
adjustment of 168
Manufactured products, improved characteristics
of 279
Manufacturing:
a definition of 1
importance to UK economy 26
materials used in 53
resource planning (MRP 2) 290
sectors, the 8
schedule for 134
the purpose of 2
Manufacturing a product, stages in 284
Management costs 130
Marketing 280
Markets 30
Master production schedule 288
Material requirement planning (MRP 1) 287
Material substitution 212
Materials:
availability of 54, 83
bill of 288
discolouration 187
contamination of 186
forms of supply 62
handling and storage of 184
hygiene 187
key characteristics of 73
oxidation of 185
preparation of 33, 149
radioactivity in 184
resources 140
sharpness 187
shelf life 183
smart 267
toxicity 184
Materials (non-metals), availability and forms of
supply of 58
Materials, properties of 73
brittleness 74
ductility 76
elasticity 75
flammability 186
hardness 77
malleability 76
perishability 186
plasticity 75
rigidity and stiffness 74
strength 73
toughness 74
Materials, quality of 93
Materials used in manufacturing 54
Meat 18
Mechanical engineering industry 10
Mechanical handling equipment manufacturing 13
Mechanical restraint devices 226
Metallic coatings 205
Metals 54
300 IndexMicroprocessor systems 275
Mineral waters 19
Miscellaneous materials 72
Mission statement 291
Mixtures 77
Modern materials 267
Modern technology:
advantages and disadvantages, the 280
improved characteristics of manufactured
products, influence on the 279
marketing, influence on 280
range, type and availability of products,
influence on the 278
safety and efficiency in manufacturing, influence
on the 279
the impact of 278
workforce, changes in type and size of 280
working environment, changes in the 281
Moulding and forming (plastics)
blow moulding 178
compression moulding 176
extrusion moulding 177
injection moulding 176
vacuum forming 179
Needle felts 71
Neoprene 60
Nitrile rubber 60
Nitro-cellulose 60
Non-woven fabrics 70
Normalizing 174
Office machinery and equipment
manufacturing 14
Open-loop system 249
Organic chemicals 4
Orthographic drawings 115
Over-run devices 226
Packaging 33, 36
Paper and board manufacture 21
Pasteurization 175
Patterns 120
Performance 50
Permanent fastenings (thermal) 193
Perry 19
Personal safety clothing and equipment 218
eye protection 221
gloves 221
hats and caps 222
respirators 221
safety footwear 220
safety helmets (hard hats) 221
Phenolic resins 61
Physical properties:
colour 80
degradation, resistance to 81
density 79
electrical conductivity 78
flavour 80
flow rate 79
texture 80
Pictorial drawings 115
Pigments 208
Pile fabrics 70
Plain weave 68
Plant manufacturing 14
Plastic coating 206
Plastic coatings and adhesives 268
Plasticity 75
Plastics:
thermosetting 61
thermoplastic 62
elastomers 58, 60
Pliofilm 60
Plywood 63
Points of inspection, see Inspection, points of,
Polishing 207
Poultry 18
Polyurethane rubber 60
Polychloroprene rubber 60
Polyester (cross-linked) resins 61
Polyethylene teraphthalate (terylene) 62
Polymethyl methacrylate 62
Polypropylene 62
Polystyrene 62
Polysulphide rubber 60
Polytetrafluoro-ethylene (PTFE) (Teflon) 62
Polythene 62
Polyvinyl chloride (PVC) 62
Porcelain enamels 205
Preferred designs, selecting 101
Preparation of tools and equipment,
the 155
Presentations, support material for 105
overhead projector transparencies 107
slides (35 mm transparencies) 107
reports 105
video recordings 107
visual aids 106
Presentation techniques 102
computerized presentation 103
flipcharts 103
overhead projector (OHP) 102
slides 103
technical vocabulary 104
verbal 102
video recording 103
Preserves 18
Pressure die-casting 181
Printing and publishing 22
Process capability study 101
Process condition change, the effect of 211
Processed food 17, 18
Processing 33, 34
Processing materials 172
Processing methods 168
Index 301Processing methods (heat treatments) 174
annealing 174
canning 176
hardening 174
normalizing 174
pasteurisation 175
solution treatment 174
steam pressing 175
ultra-heat treatment 175
Processing methods (shaping) 176
casting 179
forging 181
moulding and forming 176
sheet metal pressing 181
Procurement 32
Product concept 46
Product design specification 44
key features in a 49
Product finish – packaging and presentation 95
Production:
batch 37
continuous flow and line 37
small batch, prototyping and jobbing 40
Production details and constraints 83
available labour 83
available materials 83
available technology 84
health and safety requirements 84
Production, key stages of:
example 31
general 33
Production parameters 51
Production plan, producing a 146
Production planning 134
critical control points 136
key production stages 137
processing times 141
product specification 135
quality indicators 137
resource requirements 138
Production, prototype 40
Production, scales of 36
Production schedules 143
Production systems 42
Products investigating 292
Programmable logic controllers (PLC) 257
Programming 250
dimensional words 250
management words 250
canned cycles 252
Prototype production 40
Quality and production control 209
Quality assurance 86
Quality control 86
as applied to a typical production system 43
effect of composition and proportion changes
212
control of ‘bought-in’ parts 37
control of design 87
control of manufacture 87
dealing with defective products and components
213
defects and their causes 210
defects, critical 92
defects, incidental 93
defects, major 93
defects, minor 93
frequency of analysis 210
material substitution, the effects of 212
points of inspection 87
process condition changes, the effects of 211
operator errors 210
output, the effect of level of 87
traceability 86
Quality indicators 90, 137, 209
attributes 90
variables 90
Quality manager 86
Quality standards 85
fitness for purpose 85
Rapid prototyping 244
Raw materials 29
Research and development costs 129
Resource requirements:
capital resources 138
human resources 140
material resources, typical 140
service resources 141
tooling resources 189
Reverse engineering 246
Rigidity (stiffness) 74
Risk assessment 126
Riveting tools and guns 167
Robot arm geometry 261
Cartesian co-ordinate robots 261
cylindrical co-ordinate robots 262
revolute co-ordinate robots 262
spherical co-ordinate robots 262
wrist, the 262
end effector, the 263
Robots, industrial 259
Robot programming methods 260
drive through 260
lead through 260
off-line programming 260
Rubber, natural 58
Rubbers, synthetic 57
Safety, see Health and safety
Safety and efficiency in manufacturing 279
Safety equipment and systems 224
circuit breakers 227
circuit breakers with residual current detection
(RCD) 227
302 Indexemergency stop buttons 227
fuses 227
guards 225
mechanical restraint devices 226
over-run devices 226
safety valves 226
simultaneous control devices 226
trip devices 226
visual and audible warning devices 226
Safe working practices 228
assembly tools 229
cutting tools 229
fire alarms 229
maintenance procedures 228
protective clothing 229
safety equipment 224
supervision 229
training 229
Samples 120
Sand casting 129
Satin weave 70
Scales of production 36
Schedule for manufacture 134
Scissors 156
Scrapers 159
Service industries 4
Service resource costs 128
Servomotors 250
Shape memory materials 268
Shaping (forming) tools 162
Shears 157
Sheet metal pressing 181
Shell moulding 179
Silicone rubbers 60
Simultaneous control devices 226
Small batch production 40
Smart materials, modern materials and
components 267
adhesives 270
biodegradable plastics 272
coated and smart fabrics 269
plastic coatings and adhesives 268
shape memory materials 268
Soft drinks 18
Soft magnetic materials 78
Soldering irons 164
Solution treatment 174
Sourcing 32
Sourcing and handling information and data 233
Spinning:
complex and plied yarns 67
woollen and worsted 67
yarns 66
Spirit distilling 20
Spread sheets 238
Squashes 19
Statistical sampling techniques 90
Steam pressing 175
Stepper motor 249
Stiffness (rigidity) 74
Storage of materials 180
Strength 73
Styrene-butadiene rubber (SBR) 60
Swatches 120
Synthetic 24
Teamwork 149
Technical drawing 114
circuit diagrams 117
computer aided design (CAD), see also Computer
aided engineering 117
detail drawing 116
exploded drawing 116
general arrangement drawing 115
orthographic drawing 115
pictorial drawing 115
Technology:
application to food and drinks 273
availability of 84
Teflon 62
Terry-towelling 74
Terylene 62
Textile industry 23
Textile yarns (miscellaneous) 25
Texture 80
Thermal properties 79
conductivity 79
insulation 79
refractoriness 79
stability 79
Thermoplastics 61
Thermosetting plastics 61
Thiokol 60
Timber (wood) products 63
Tobacco industry, the 21
Tolerances 94
Tools and equipment, the preparation of 155
Tools and equipment in the working environment
150
Tooling resources 139
Total quality management (TQM) 85
Toughness 74
Training 229
Transport 30
Transport equipment manufacturing 11
Trip devices 226
Tufnol 64
Twill weave 69
Ultra-heat treatment (UHT) 175
Vacuum forming 179
Variables, see Quality indicators
Vegetables 17
Vinyl plastics 62
Index 303Visual and audible warning 226
Vitreous enamels 225
Warp knitted fabrics 71
Weathering 81
Weave:
Jacquard 70
plain 68
satin 70
twill 69
Webs, bonded 71
Weft knitted fabrics 70
Welding:
electric arc 194
friction 197
oxy-acetylene (gas) 195
resistance (spot and seam) 197
solvent (chemical) 200
ultrasonic 198
Whisky, see Spirit distilling
‘White goods’ 9
Wine 21
Wool 24
Wool felts 71
Woollen spinning systems 67
Workforce, changes in the type and size of the 280
Working environment, changes in the 281
World Wide Web 233
Worsted spinning systems 67
Woven fabrics 67
Yarns 66
304 Index
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عدل سابقا من قبل Admin في السبت 31 أكتوبر 2020, 11:52 pm عدل 2 مرات |
|  | |
| كاتب الموضوع | رسالة |
|---|
Admin
مدير المنتدى
عدد المساهمات : 18996
تاريخ التسجيل : 01/07/2009
| | موضوع: كتاب Basic Manufacturing الجمعة 21 يونيو 2013, 1:52 pm | |
|
أخوانى فى الله
أحضرت لكم كتاب
Basic Manufacturing
Third Edition
Roger Timings
و المحتوى كما يلي :
Contents
Preface vii
Acknowledgements viii
Chapter 1 The manufacturing industry 1
1.1 What is manufacturing 1
1.2 The main UK manufacturing sectors 3
1.3 The chemical industry 4
1.4 The engineering industry 7
1.5 The food, drink and tobacco products industry 16
1.6 Paper and board manufacture 21
1.7 Textiles, clothing and footwear 23
1.8 The importance of the main manufacturing sectors
to the UK economy 26
1.9 Industry and its location 29
1.10 Key stages of production (example) 31
1.11 Key stages of production (general) 33
1.12 Scales of production 36
Assessment activities 43
Chapter 2 Design and graphical communication 44
2.1 Product design specification 44
2.2 Materials used in manufacture 53
2.3 Properties of materials 73
2.4 Physical properties 78
2.5 Production details and constraints 83
2.6 Quality standards 85
2.7 Generating proposals to meet a design brief 96
2.8 Graphical communication 108
2.9 Technical drawings 114
2.10 Patterns, samples and swatches 120
2.11 From design brief to finished product 124
2.12 Calculating the cost of a product 127
Assessment activities 133
Chapter 3 Manufacturing products 134
3.1 Production planning and the schedule for manufacture 134
3.2 Teamwork 149
3.3 The preparation of materials and components 149
3.4 Machinery, tools and equipment in the working
environment 150
3.5 The preparation of tools and equipment 155
3.6 Processing methods 168
3.7 Handling and storage of materials 1843.8 Combining and assembling components 188
3.9 Assembly of components and subassemblies to
specification and quality standards 202
3.10 Quality and production control 209
3.11 Safety equipment, health and safety procedures
and systems 215
3.12 Safe working practices 228
Assessment activities 231
Chapter 4 Applications of technology 232
4.1 The use of information and communication
technology 232
Case study 4.1: The Internet and the World Wide Web 234
Case study 4.2: Databases 236
Case study 4.3: Spreadsheets 238
Case study 4.4: Computer-aided engineering 240
Case study 4.5: Rapid prototyping 245
Case study 4.6: Reverse engineering 247
Case study 4.7: A simple milling program 253
Case study 4.8: A simple turning program 254
4.2 Control technology and robotics 256
Case study 4.9: Programmable logic controllers 257
Case study 4.10: Pick and place robot 264
Case study 4.11: Wood machining 266
4.3 Smart materials, modern materials and
components 267
Case study 4.12: Coated and smart fabrics 269
Case study 4.13: Specialized adhesives 270
Case study 4.14: The microprocessor 274
Case study 4.15: Microprocessor systems 275
4.4 Impact of modern technology 278
4.5 The advantages and disadvantages of the
use of modern technology 280
Case study 4.16: The impact of modern technology
on the global environment and sustainability 281
4.6 The stages in manufacturing a product 284
4.7 Investigating products 292
Case study 4.17: Investigating a compact disc (CD) 292
Assessment activities 295
Index
Abrasives 162
Acceptance sampling and testing 89
Acrylics 62
Acrylic rubber 60
Added value 2
Adhesives 201
natural 201
thermoplastic 201
thermosetting 201
elastomeric 201
Adhesives, super 270
cured by ambient moisture 272
cured by anaerobic reactions 271
cured by anionic reactions 271
cured by ultraviolet (UV) light 271
cured with activator systems 272
Administration costs 130
Aesthetics 49
Agricultural equipment manufacture 11
Algorithm 113
Amino resins 61
Annealing 174
Anodizing 206
Applied liquid finishes (inorganic) 205
Applied liquid finishes (organic) 204
Assembly 35
Assembling components 188
Assembly of components and sub-assemblies to
specification and quality standards 202
Assembly tools 162, 230
Attributes, see Quality indicators
Automation and control 256
Automated equipment and machinery 170
Axis nomenclature 248
Bakery products manufacturing industry 16
Balance of trade 27
Batch production 37
Bill of materials 288
Biodegradable plastics 272
Blends 72
Blow moulding 178
Bonded webs 71
Brass alloys, properties and applications of 56
Brewing 19
Brittleness 74
Bronze alloys, properties and applications of 57
Buffing 207
Butyl rubber 60
Canned cycles 256
Canning 176
Capital resources 138
Carbonated (fizzy) drinks 19
Carpenter’s saws 157
Carpet manufacture 25
Casting (metals) 179
gravity die-casting 181
pressure die casting 181
sand casting 179
shell moulding 179
Cells of automation 257
Cellulose acetate 62
Ceramic coatings 205
Ceramic materials 58
applications of 59
Cereals 17
Cermets 64
Chemical industry 4
Chemical joining processes 200
solvent welding 200
adhesive (chemical) joining 200
Chemicals, inorganic 4
Chemicals, organic 4
Cider 19
Circuit breakers 227
Circuit breakers with residual current detection
(RCD) 227
Circuit diagrams (electrical) 117
Clothing industry 23, 25
Closed-loop system 249
Client needs, identification of 45
Colour 80
Colouration 208
CNC programming, see Programming
Combining components 188
Complex yarns 67
Component manufacturing industry 11
Components, the preparation of 149
Composite materials 63
cermets 64
glass reinforced plastics (GRP) 64
plywood 63
tufnol 64
wood 63
Composition proportion changes, effects
of 212
Compounds 72
Compression forming 176
Computer aided design (CAD) 117
IndexComputer aided engineering (CAE) 240
Computer numerical control (CNC) 247
Computer technology 273
Conductors 78
Confectionery products 17
Construction equipment manufacturing 12
Consumer durables 9
Contextual 50
Continuous flow and line production 37
Control and adjustment of manual equipment and
machinery 168
Control systems 249
Control technology and robotics 256
automation and control 256
industrial robots 259
programmable logic controllers (PLC) 257
programming methods (robots) 260
Convenience foods 18
Conversion coatings 206
Corduroy 70
Corrosion 81
Costs:
administration 130
direct (materials) 127
general expenses 130
human resources 128
indirect 128
indirect, allocation of 130
management 130
marketing 130
research and development (R&D) 189
service resources 128
cotton 24
Cost of a product, calculation of 127
Critical control points 136
Cutting tools:
abrasive papers and cloths 162
carpenter’s hand saws 157
drills 159
files 157
guillotine shears 157
hacksaw, metal cutting 157
knives 157
scissors 156
scrapers 159
shears 157
Dairy products 17
Databases 236
Defective products and components, dealing
with 213
downgrade 214
investigate causes of 213
recommend solutions 214
rework 214
scrap 214
Defects: 92
causes of 210
Degeneration:
corrosion 81
resistance to 81
weathering 81
Density 79
Dependent demand 287
Design:
client, development of a design brief for a 44
design brief, the 46, 125
design brief to finished product 124
design process, the 46
design proposal 125
design proposal, assessing the feasibility of 99
design proposals for a hand-held portable electric
fan 98
design reviews 101
design, the key role of 45
feedback 126
finished product 126
generating proposals to meet a 96
presentation 126
selecting a preferred 101
specification 46
Detail drawings 116
Direct costs (material) 127
Distilling, spirit 20
Drills 159
Drinks manufacturing industry 18
Ductility 76
Duty of care 95, 126
Dyes 208
Elasticity 75
Elastic limit 75
Elastomers, natural 58
Elastomers, synthetic 59
Electrical and electronic engineering 8
Electrical conductivity 75
Electroplating 206
Emergency stop buttons 227
Energy sources 30
Energy sources, renewable 285
Engineering industry 7
Ergonomics 101
Environment, the working 154
cleanliness 155
floor 154
lighting 154
safety 155
settings (machines and equipment) 155
space 154
tooling 155
Environments, hazardous 227
cold 223
contaminated 223
electrically dangerous 224
hygienically dangerous 224
physically dangerous 223
298 IndexEpoxy resins 61
Exploded drawing 116
Extranets 234
Extrusion moulding 177
Fabrics, non-woven 70
pile 70
warp knitted 71
weft knitted 70
woven 67
Fastenings:
riveted 190
compression joints 190
permanent (mechanical) 189
semi-permanent 188
Feasibility study 46
Feedback:
qualitative judgements 104
quantitative judgements 104
Felts, needle 71
Felts, wool 71
Fibres, natural 65
Fibres synthetic 65
Fibres and yarns 65
Files (engineers’) 157
Finishing 33, 35
Finishing methods 203
anodising 206
applied finishes (organic) 204
applied finishes (inorganic) 205
ceramic coatings 205
colouration 208
conversion coatings 205
electroplating 206
glazing 207
hot-dip galvanizing 205
laminating 207
metallic coatings 205
plastic coatings 206
porcelain enamels 205
vitreous enamels 205
Fire alarms 229
First aid 218
Fish 18
Fitness for purpose 53
Fixing and assembly tools:
hammers and mallets 164
needles 167
riveting tools and guns 167
screw drivers 162
spanners 162
soldering irons 164
Flavours 80
Flexible manufacturing (FMS) cells 39
Flow rate 79
Food and drinks, technology applied to 273
Food industries 16
Food products, miscellaneous 18
Footwear 26
Footwear manufacturing industry 23
Forging (metal) 181
Forming tools 162
Frequency of analysis 210
Fruit 17
Fruit drinks 19
Fuses 227
Galvanizing, hot-dip 205
General arrangement drawings 115
General expenses 130
Gin, see Spirit distilling
Glass fibre reinforced plastics (GRP) 64
Glazing 207
Globalization 2
Graphical communication:
bar charts 109
charts 112
data sheets 114
flow charts 112
Gantt charts 110
graphs 108
pictographs (ideograms) 111
pie charts 109
system flow chart (algorithm) 113
Gravity die-casting 181
Gross domestic product (GDP) 27
Gross national product 27
Guards 225
Guillotine shears 157
Hacksaw 157
Hammers 164
Handling of materials 184
Hard magnetic materials 78
Hardening (metals) 174
cold-working 174
precipitation hardening 174
quench hardening 175
tempering 175
Hardness 77
Hazardous environments, see Environments
Health, safety and hygiene 95
Health and safety at work act 228
Health and safety 215
emergency equipment (fire) 216
emergency equipment (first aid) 218
personal safety clothing and equipment 218
requirements 84
risk assessment 216
Human resources 29, 140
Human resource costs 128
Incentives 29
Independent demand 287
Indirect costs 128
Index 299Indirect costs, allocations of 130
Industrial globalization 2
Industrial revolution 1
Industry, the engineering 7
Information and communication technology (ICT),
the use of 232
Injection moulding 176
Inorganic chemicals 4
Internet 233
Inspection, points of for 87
assembly 89
bought in parts 89
finished products 89
material preparation 89
processing 89
raw materials 89
Inspection and testing:
methods of 93
health, safety and hygiene 95
levels of output during production 93
level of performance 93
product finish, packaging and presentation 95
quality of materials 93
tolerances 94
instrument engineering 10
Insulators (electrical) 78
Intranet 233
Investigating products 292
Islands of automation 257
Jacquard weave 70
Just-in-time (JIT) philosophy 135, 286
Jobbing production 40
Jute manufacture 25
Key stages of production 137
example 31
general 33
Knives 157
Labour, availability of 83
Laminated plastic (Tufnol) 64
Laminating 207
Limits of size (bilateral) 94
Limits of size (unilateral) 94
Linen 24
Location of industry 29
Machine tool manufacturing 16
Machinery:
accessory manufacture 13
automated 157
manual (non-automated) 150
working environment, in the 150
Magnetic properties 78
Malleability 76
Mallets 164
Manual equipment and machinery, control and
adjustment of 168
Manufactured products, improved characteristics
of 279
Manufacturing:
a definition of 1
importance to UK economy 26
materials used in 53
resource planning (MRP 2) 290
sectors, the 8
schedule for 134
the purpose of 2
Manufacturing a product, stages in 284
Management costs 130
Marketing 280
Markets 30
Master production schedule 288
Material requirement planning (MRP 1) 287
Material substitution 212
Materials:
availability of 54, 83
bill of 288
discolouration 187
contamination of 186
forms of supply 62
handling and storage of 184
hygiene 187
key characteristics of 73
oxidation of 185
preparation of 33, 149
radioactivity in 184
resources 140
sharpness 187
shelf life 183
smart 267
toxicity 184
Materials (non-metals), availability and forms of
supply of 58
Materials, properties of 73
brittleness 74
ductility 76
elasticity 75
flammability 186
hardness 77
malleability 76
perishability 186
plasticity 75
rigidity and stiffness 74
strength 73
toughness 74
Materials, quality of 93
Materials used in manufacturing 54
Meat 18
Mechanical engineering industry 10
Mechanical handling equipment manufacturing 13
Mechanical restraint devices 226
Metallic coatings 205
Metals 54
300 IndexMicroprocessor systems 275
Mineral waters 19
Miscellaneous materials 72
Mission statement 291
Mixtures 77
Modern materials 267
Modern technology:
advantages and disadvantages, the 280
improved characteristics of manufactured
products, influence on the 279
marketing, influence on 280
range, type and availability of products,
influence on the 278
safety and efficiency in manufacturing, influence
on the 279
the impact of 278
workforce, changes in type and size of 280
working environment, changes in the 281
Moulding and forming (plastics)
blow moulding 178
compression moulding 176
extrusion moulding 177
injection moulding 176
vacuum forming 179
Needle felts 71
Neoprene 60
Nitrile rubber 60
Nitro-cellulose 60
Non-woven fabrics 70
Normalizing 174
Office machinery and equipment
manufacturing 14
Open-loop system 249
Organic chemicals 4
Orthographic drawings 115
Over-run devices 226
Packaging 33, 36
Paper and board manufacture 21
Pasteurization 175
Patterns 120
Performance 50
Permanent fastenings (thermal) 193
Perry 19
Personal safety clothing and equipment 218
eye protection 221
gloves 221
hats and caps 222
respirators 221
safety footwear 220
safety helmets (hard hats) 221
Phenolic resins 61
Physical properties:
colour 80
degradation, resistance to 81
density 79
electrical conductivity 78
flavour 80
flow rate 79
texture 80
Pictorial drawings 115
Pigments 208
Pile fabrics 70
Plain weave 68
Plant manufacturing 14
Plastic coating 206
Plastic coatings and adhesives 268
Plasticity 75
Plastics:
thermosetting 61
thermoplastic 62
elastomers 58, 60
Pliofilm 60
Plywood 63
Points of inspection, see Inspection, points of,
Polishing 207
Poultry 18
Polyurethane rubber 60
Polychloroprene rubber 60
Polyester (cross-linked) resins 61
Polyethylene teraphthalate (terylene) 62
Polymethyl methacrylate 62
Polypropylene 62
Polystyrene 62
Polysulphide rubber 60
Polytetrafluoro-ethylene (PTFE) (Teflon) 62
Polythene 62
Polyvinyl chloride (PVC) 62
Porcelain enamels 205
Preferred designs, selecting 101
Preparation of tools and equipment,
the 155
Presentations, support material for 105
overhead projector transparencies 107
slides (35 mm transparencies) 107
reports 105
video recordings 107
visual aids 106
Presentation techniques 102
computerized presentation 103
flipcharts 103
overhead projector (OHP) 102
slides 103
technical vocabulary 104
verbal 102
video recording 103
Preserves 18
Pressure die-casting 181
Printing and publishing 22
Process capability study 101
Process condition change, the effect of 211
Processed food 17, 18
Processing 33, 34
Processing materials 172
Processing methods 168
Index 301Processing methods (heat treatments) 174
annealing 174
canning 176
hardening 174
normalizing 174
pasteurisation 175
solution treatment 174
steam pressing 175
ultra-heat treatment 175
Processing methods (shaping) 176
casting 179
forging 181
moulding and forming 176
sheet metal pressing 181
Procurement 32
Product concept 46
Product design specification 44
key features in a 49
Product finish – packaging and presentation 95
Production:
batch 37
continuous flow and line 37
small batch, prototyping and jobbing 40
Production details and constraints 83
available labour 83
available materials 83
available technology 84
health and safety requirements 84
Production, key stages of:
example 31
general 33
Production parameters 51
Production plan, producing a 146
Production planning 134
critical control points 136
key production stages 137
processing times 141
product specification 135
quality indicators 137
resource requirements 138
Production, prototype 40
Production, scales of 36
Production schedules 143
Production systems 42
Products investigating 292
Programmable logic controllers (PLC) 257
Programming 250
dimensional words 250
management words 250
canned cycles 252
Prototype production 40
Quality and production control 209
Quality assurance 86
Quality control 86
as applied to a typical production system 43
effect of composition and proportion changes
212
control of ‘bought-in’ parts 37
control of design 87
control of manufacture 87
dealing with defective products and components
213
defects and their causes 210
defects, critical 92
defects, incidental 93
defects, major 93
defects, minor 93
frequency of analysis 210
material substitution, the effects of 212
points of inspection 87
process condition changes, the effects of 211
operator errors 210
output, the effect of level of 87
traceability 86
Quality indicators 90, 137, 209
attributes 90
variables 90
Quality manager 86
Quality standards 85
fitness for purpose 85
Rapid prototyping 244
Raw materials 29
Research and development costs 129
Resource requirements:
capital resources 138
human resources 140
material resources, typical 140
service resources 141
tooling resources 189
Reverse engineering 246
Rigidity (stiffness) 74
Risk assessment 126
Riveting tools and guns 167
Robot arm geometry 261
Cartesian co-ordinate robots 261
cylindrical co-ordinate robots 262
revolute co-ordinate robots 262
spherical co-ordinate robots 262
wrist, the 262
end effector, the 263
Robots, industrial 259
Robot programming methods 260
drive through 260
lead through 260
off-line programming 260
Rubber, natural 58
Rubbers, synthetic 57
Safety, see Health and safety
Safety and efficiency in manufacturing 279
Safety equipment and systems 224
circuit breakers 227
circuit breakers with residual current detection
(RCD) 227
302 Indexemergency stop buttons 227
fuses 227
guards 225
mechanical restraint devices 226
over-run devices 226
safety valves 226
simultaneous control devices 226
trip devices 226
visual and audible warning devices 226
Safe working practices 228
assembly tools 229
cutting tools 229
fire alarms 229
maintenance procedures 228
protective clothing 229
safety equipment 224
supervision 229
training 229
Samples 120
Sand casting 129
Satin weave 70
Scales of production 36
Schedule for manufacture 134
Scissors 156
Scrapers 159
Service industries 4
Service resource costs 128
Servomotors 250
Shape memory materials 268
Shaping (forming) tools 162
Shears 157
Sheet metal pressing 181
Shell moulding 179
Silicone rubbers 60
Simultaneous control devices 226
Small batch production 40
Smart materials, modern materials and
components 267
adhesives 270
biodegradable plastics 272
coated and smart fabrics 269
plastic coatings and adhesives 268
shape memory materials 268
Soft drinks 18
Soft magnetic materials 78
Soldering irons 164
Solution treatment 174
Sourcing 32
Sourcing and handling information and data 233
Spinning:
complex and plied yarns 67
woollen and worsted 67
yarns 66
Spirit distilling 20
Spread sheets 238
Squashes 19
Statistical sampling techniques 90
Steam pressing 175
Stepper motor 249
Stiffness (rigidity) 74
Storage of materials 180
Strength 73
Styrene-butadiene rubber (SBR) 60
Swatches 120
Synthetic 24
Teamwork 149
Technical drawing 114
circuit diagrams 117
computer aided design (CAD), see also Computer
aided engineering 117
detail drawing 116
exploded drawing 116
general arrangement drawing 115
orthographic drawing 115
pictorial drawing 115
Technology:
application to food and drinks 273
availability of 84
Teflon 62
Terry-towelling 74
Terylene 62
Textile industry 23
Textile yarns (miscellaneous) 25
Texture 80
Thermal properties 79
conductivity 79
insulation 79
refractoriness 79
stability 79
Thermoplastics 61
Thermosetting plastics 61
Thiokol 60
Timber (wood) products 63
Tobacco industry, the 21
Tolerances 94
Tools and equipment, the preparation of 155
Tools and equipment in the working environment
150
Tooling resources 139
Total quality management (TQM) 85
Toughness 74
Training 229
Transport 30
Transport equipment manufacturing 11
Trip devices 226
Tufnol 64
Twill weave 69
Ultra-heat treatment (UHT) 175
Vacuum forming 179
Variables, see Quality indicators
Vegetables 17
Vinyl plastics 62
Index 303Visual and audible warning 226
Vitreous enamels 225
Warp knitted fabrics 71
Weathering 81
Weave:
Jacquard 70
plain 68
satin 70
twill 69
Webs, bonded 71
Weft knitted fabrics 70
Welding:
electric arc 194
friction 197
oxy-acetylene (gas) 195
resistance (spot and seam) 197
solvent (chemical) 200
ultrasonic 198
Whisky, see Spirit distilling
‘White goods’ 9
Wine 21
Wool 24
Wool felts 71
Woollen spinning systems 67
Workforce, changes in the type and size of the 280
Working environment, changes in the 281
World Wide Web 233
Worsted spinning systems 67
Woven fabrics 67
Yarns 66
304 Index
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