A+ Answers

1. Drilling a long, 0.001-inch-diameter radial hole in the curved surface of a round rod would require
A. the use of special drilling tools such as an electron beam or laser drill.
B. a special drill with a locating tip.
C. a rigid drill press, and starting the hole with a thin drill.
D. careful perpendicular drilling.
2. Two technicians are discussing the advantages of rolled threads on fasteners over machined threads. Technician A says machined threads can’t be put on long parts. Technician B says that rolling is better because it can produce threads in harder materials. Which of the following statements is correct?
A. Only Technician A is correct.
B. Only Technician B is correct.
C. Both technicians are correct.
D. Neither technician is correct.
3. A roll of uncoated wire in the assembly room of a factory is to be used in a joining process. It has a diameter of 0.010” and is labeled with its melting-point temperature of 780ºC. This wire is most likely suitable for use
A. in forging threaded fasteners. C. as solder wire.
B. as raw material to make forging dies. D. as brazing wire.
4. A side effect of forging as a manufacturing process is that
A. it leaves the parts with a superior surface finish.
B. the parts are harder and stronger when finished.
C. no additional finishing is required.
D. it’s easy to machine compared to cast parts.
5. Among the main advantages of investment casting is the
A. ability to create intricately detailed parts.
B. ability to cast very large parts with precision dimensions.
C. ability to avoid part breakage when removing parts from the mold.
D. relative cost compared to sand casting the same part.
6. For high-volume production runs, machining parts from solid material might not be the
best choice of manufacturing operations because
A. manufacturing lead times are too long, and the material choices are limited.
B. tolerance capability is too low and piece price is very high.
C. tooling costs are high but surface finish capability is low.
D. tooling and piece-part costs are high.
7. A foreman ordering drill bits for a high-speed drilling machine would
A. first consider moving the drilling operation to the EDM department because this process is much faster.
B. order chromium plating for increased life.
C. use HS steel bits for the longest tool life possible.
D. specify TiN coated steel drills. 
8. Due to their low peak-power needs, pointing lasers are most likely _______ type.
C. helium neon
B. ruby D. argon
9. Two technicians are discussing extrusion processes used in manufacturing. Technician A
says extrusion is used for prototyping new parts because of the ease of producing extrusion
dies. Technician B says that it’s primarily used for manufacturing wire. Which of the following statements is correct?
A. Only Technician A is correct. C. Both technicians are correct.
B. Only Technician B is correct. D. Neither technician is correct.
10. A screw acts on molten plastic, pressurizing it and forcing it into a mold during
A. compression molding. C. injection molding. 
B. blow molding. D. thermoset molding.
11. A vacuum tight seal is to be made on a flat plate welded to a cylinder. The edges to be
welded are 0.014_ thick and are to be joined without a filler metal. The best process
for this weld joint would be
12. The purpose of the flux coating on a welding electrode for manual metal arc welding
(MMA) is to
A. protect the electrode from damage until it’s melted.
B. alloy with the melted material to increase strength of the weld.
C. generate inert gases to prevent oxidation of the weld.
D. form a protective slag coating of the weld area.
13. Spinning would be a preferred process to produce parts such as
A. metal funnels. C. automotive pistons.
B. cap screws. D. spark plug heads.
14. An impeller for a pump on a submarine must be made from a single piece of tungsten.
The impeller resembles a large screw about 3” in diameter and is 12″ long. What manufacturing process would best produce this part?
A. chemical machining C. sand casting
B. electrochemical machining   D. closed die forging
15. Two technicians are discussing ways of creating different parts. Technician A says that
forming is the process of creating a part by pouring or placing liquid metal or plastic into a mold. Technician B says that the described process is also called shaping. Which of the following statements is correct?
A. Only Technician A is correct. C. Both technicians are correct.
B. Only Technician B is correct. D. Neither technician is correct.
16. Using mechanically mounted inserts as cutting tools
A. allows rapid changeover to new cutting edges.
B. makes the part dimensions more precise.
C. avoids the necessity of using cutting fluids.
D. allows more complex cuts with turned parts.
17. The brown trim color found on aluminum window frames is made by
A. anodizing.  C. ECM.
B. EDM. D. chromating.
18. A primary manufacturing process usually
A. uses subassemblies to build a final product.
B. uses naturally occurring raw materials.
C. doesn’t use much manual labor.
D. doesn’t require as much capital equipment as secondary manufacturing processes.
19. A carpenter constructed a tool shed that showed streaks of rust from the exposed nail
heads after three weeks of rainy weather. This could have been avoided by
A. using chrome-plated nails.
B. painting the nails before use.
C. using galvanized nails.
D. painting the heads after installation.
20. The best way to produce small threaded plastic bottles is probably
A. shell casting. C. vacuum forming.
B. sand casting. D. blow molding.
1. Work transfer stations
A. often use simple robots for handling small parts.
B. can’t be used when people remove the parts for some portion of the assembly operation.
C. utilize only the most sophisticated six-axes-of-motion robots.
D. are found only in build-in-place type manufacturing facilities.
2. Just-in-time manufacturing was developed in Japan
A. for the transistor radio manufacturing facilities.
B. to compete with job-shop manufacturing methods.
C. to avoid shipping problems with raw material suppliers.
D. to minimize WIP inventory costs and improve automobile quality.
Questions 1–20: Select the one best answer to each question.
3. As the operator in charge of the CNC milling machine in a manufacturing cell, you decide to make 100–200 parts more than are called for by your production manager to avoid future delays. Your decision results in
A. a typical benefit of job-shop style manufacturing.
B. an increase in WIP inventory.
C. decreased product quality.
D. decreased manufacturing times and no delays.
4. Cellular layouts are effective in certain high-volume applications because
A. product quality isn’t dependent on worker skill.
B. equipment use through all adjacent cells is easily optimized.
C. material handling is simpler because of the proximity of related machines.
D. cells usually don’t require close supervision.
5. You’re working in a finish-painting operation that’s undergoing a shift to lean anufacturing
methods. Your supervisor asks you to stop photographing the parts that are sent from your
operation to assembly. He probably does this because
A. six-sigma inspectors can’t evaluate defects using photos.
B. photos aren’t considered acceptable forms of documentation in ISO 9000 certified operations.
C. your photos will interfere with the department’s JIT Quality system.
D. photographing the parts doesn’t add value to the finished product.
6. As the supervisor of the assembly area in an electric motor manufacturing business, you notice that a group of motor housings has been rejected because of an oversized hole in the side of the housing. Since the assembly bolts will go through without any problems, you remove the housings from the nonconforming material area and send them to the assembly department for use in the final product. Your decision to use these parts will
A. save the company money.
B. reduce the amount of reworked material and thus manufacturing costs.
C. probably violate your company quality assurance procedures.
D. save overall time and money as the end result.
7. A rural area in Pennsylvania has a regional population of 82,000 and an unemployment
rate of 8.9%. In evaluating the possible location of a large job shop in this area, one of the most important things you would need to consider would be the
A. availability of highly skilled workers in the available labor pool.
B. availability of batch-style manufacturers in the area.
C. number of assembly-line workers in other area manufacturing businesses.
D. number of mass-production facilities in the area.
8. A technician in a manufacturing cell reports a faulty velocity sensor on an actuator. Of
the following, he or she is most likely referring to a problem with a component on a(n)
A. aircraft-servicing scaffold. C. ship-building work platform.
B. programmable robotic welder. D. mass-production conveyor line.
9. A quality assurance technician has collected performance data about the defects produced
by a certain milling machine in a factory producing high-cost aviation parts.
The data indicates that the machine produces parts with truly random variations
in the critical dimensions, and no operator-caused variations. The next step the technician
would take after collecting this data would be to
A. try to improve the machining process by adjusting feeds and speeds or other
manufacturing parameters.
B. contact a manufacturing engineer about advanced machining process capabilities to
decrease variations.
C. analyze the process for potential trouble spots.
D. determine if the variations meet customer specifications at an acceptable level.
10. A supplier of specialty prototype parts made from beryllium is likely to have
_________ as a manufacturing format.
A. cellular layout C. assembly line
B. job shop D. functional shop
11. While arranging for the installation of three new milling machines, you have a question
about the best placement positions for the machines and their loading robots. For the
best answer you would go see the _______ of the factory.
A. industrial engineers C. CFO
B. product designers D. QA managers
12. Production managers must monitor and supervise critical factors such as
A. QA audits, shipping schedules, and order entry.
B. line maintenance, customer relations, and returned goods.
C. worker training, equipment layout, and WIP inventories.
D. capital costs, machine inventory, and value-added calculations.
13. The main factor that determines how manufacturing businesses are classified is the
A. cost of the equipment.
B. number of employees needed to run the machines.
C. number of machines and equipment necessary for production.
D. production volumes anticipated.
14. Fixed-automation devices
A. aren’t used in modern factories.
B. use mechanical means such as cams and gears to accomplish tasks.
C. can be easily changed to programmable automation if necessary.
D. can’t be used in automation on flow lines.
15. Mass production advantages include
A. low capital costs and low WIP.
B. low-cost machine tools and high cycle times.
C. consistent product quality and low-skilled labor requirements.
D. rapid product customization and high production volumes.
16. A method used to control work-in-progress by signals sent back to producing areas for
replacement stock is  
B. kanban. D. DFM.
17. A robot needed to do a complicated three-dimenstional welding operation
A. would likely be a one-axis pick-and-place model.
B. would have either one linear or one rotational axis of motion.
C. would likely be a continuous-path type robot.
D. isn’t yet commercially available.
18. In automated manufacturing systems, smart actuators
A. are those that operate without the need of controllers.
B. can easily replace fixed automation devices to increase production rates.
C. can increase cycle times and decrease WIP.
D. have built-in sensors for position and velocity control.
19. One reason for extensively automating a manufacturing process is that
A. low-skilled labor is inexpensive and easily available.
B. production volumes are low.
C. operations must be done in a hazardous environment.
D. all prototype-building operations are highly automated.
20. A robot that can move a hand left and right and rotate the hand 360º is said to have
_______ axis (axes) of motion.
A. one C. three
B. two D. four