Tutorial 1

–Answer all questions in a special dedicated



tutorial book to be submitted periodically for

assessment.


• What role does manufacturing play relative to

the standard of living of a country?
• How does a system differ from a process?
• Elaborate or give an example of concurrent
engineering practice and traditional
sequential process?
• In the process of buying a calf, raising it to a
cow, and disassembling it into “cuts” of meat
for sale, where is the “value added”?
• List and describe the major considerations
involved in selecting materials for products.
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Chapter 2 Manufacturing
Aspects
Lecturer: Dian Daruis
Email: dian@upnm.edu.my

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 Introduction
● One of the most important aspects in manufacturing is
product quality and to make sure it is marketable at
reasonable price.
● It is important to ‘build quality into product rather than
inspecting the quality of the product after it is made’.
● Aspects to be considered are assembly process,
specification, standardization, quality control, testing
and checking, limits and fits as well as its tolerances.
● Other aspects include human safety, hazards, risks and the
legal aspects of product liability.
● However this chapter will only focus on products quality,
metrology and instrumentation .

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 Product assembly
● There are 3 types of assembly type:
1.Make to suit
» Parts and components are to be made as
accurate as possible to the desired size as
per designed.
» Measurement tools and equipment are used
to measure and match them together
» Not suitable for high quantity production.
» Require highly skillful labor.

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 Product assembly – cont’d
2. Selected Assembly
» A method where each and every component is measured and
being graded into different grading according to the range
of limits and fits.
» Applied under two conditions;
● Component can’t be produced economically up to the
precision required but can be measured and
graded
● Assembly can be replaced in a complete unit/set.

● This method is generally used in the assembly of ball

bearing, roller, cylinder or piston for automobile
application.
● Say there is 5 grades for shaft and 5 grades for hole, if
shaft of grade 5 is assembled with hole grade 5,
then the assembly will be functioning very well.


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Product assembly – cont’d
3. Interchangeable manufacture
» It is an ideal manufacturing type and most economical.
» Use automated and partial automated machine and
required semi-skillful labor.
» Components can be interchangeable, for example if
there are 1000 shafts and holes, then each and
every of them can fix into each other and still
functioning (common components).
» Low manufacturing cost and high quality product.
» It can only be done under certain conditions;
● Types of fits of the mating parts have;
clearance fits, interference fit and
transition fit.
● Tolerance at each dimension (variation of
dimension, the smaller the tolerances,
the more expensive the manufacturing
cost is).
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 Specification
● Manufacturing specification explains those measurement values
which correspond to the product.
● (when the measurement falls within the manufacturing
specifications, we can say that the product is within the
customer specifications.
● It defines and determines the processes and methods necessary to
produce a given product; including converting raw materials,
components, or parts into WIPs (work-in-process) or finished
goods.
● A part or component can be shown accurately through its
engineering drawing with the detail specifications such as
materials, finishing requirements, dimensions, tolerances and
etc. are included in the drawing.

● 7
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 Standard
● Can be defined as a criteria related to size, shape, quality,
procedure and process for a certain product.
● It can be a standard parts or components like screw, gears,
shaft.
● It is inspected using standard equipment, tools and
methods.
● Bodies that organize and control the specification and
standard such as International Organization for
Standardization (ISO) , British Standard Institution
(BSI), American National Standard Institute (ANSI)
and SIRIM.
●

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 Dimensional Tolerance
● It is defined as the permissible variation in the dimensions (h, w, d, r,
angles) of a part. It can be bilateral, unilateral and in terms of
dimension limits.
● Tolerances is only important when a part is to be assembled or mated
with another part. (refer Figure 35.23 in text book)

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 Limits and fits
● Limits is defined as the maximum and the
minimum dimensions of parts (using ± symbol
on the engineering drawing)
● Fits are divided into certain general
classifications; clearance fits, transition fits
and interference fits (refer text book). It is
defined as the range of looseness or tightness of
hole and shaft or the mating parts.

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 Quality
● It is an important aspect in manufacturing industry to
satisfy customers’ requirement.
● To meet the requirement, an organization will lay out
their activities into two approaches:
– Quality warranty
– Quality is build into the product since the beginning of the
process
● Quality control – product inspections, certification, use
of gauges and intruments
– Sampling
– Control chart

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 Calculation of Limits and Fits
Example:


Consider one component of size 50mm diameter

is mated together. It was given that the grading of

hole is H7 (ISO standard hole chart) and shaft is
n6. You have to find, hole tolerance, shaft
tolerance, hole size range, shaft size range,
minimum looseness, maximum looseness and the
type of fits.

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Answer

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 Tutorial 2
● Describe types of tolerances complete with
appropriate illustration.
● Find and explain the differences between the three
fits types complete with appropriate illustration.
● What are the differences between inspection and
quality tests?
● Find definitions for basic size, tolerances, limits,
clearance.
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