Olndex

Note: for topics with more than one reference any pages of greater significance are highlighted in bold.

A abrasive jet machining 142 absenteeism 293 absolute encoder 328 absorption costing 269 acceleration measurement 328 accidents 294, 295ff accounting 257ff acetone 188 acetylene 156 acrylic 59, 61; fibres 169 action limits 284,286 activity sampling 248, 252 acoustic mufflers 311 actuator 325,326, 330 adhesive bonding 164, 166, 196 adhesives 150 aesthetic appeal 70 AGVs 350 airlock 190 air pressure differential 190 air speed 312 air temperature 312 aisles 207 allowances (Time Study) 252 alloy(s) 55, 16 alloy steels 56, 156 alphanumeric characters 192, 352 alumina 94 aluminium alloys 56, 159 aluminium contacts 183 aluminium production 94 American National Standards

Institute 74, 278 amorphous structure 51 analogue devices 327 analogue display 304 analytical estimating 248 anemometer 312 angular displacement

measurement 327 annealing 53, 54, 57, 113 anodising 147

ANSI 74,278 anthropometry, 301 antimony, 153 application specific package

(CAD) 339 applied research 74 apportionment of costs 269 arc welding 151, 156ff, 347 archaeological evidence 14 Archimedian feeder screw 171 argon 159 Articles of Association 41 artificial vision systems 197, 280 artisans 17 asbestos 295 assembly 150 assembly charts 218 assembly of PCBs 193 atomic arrangement 51 atomic bonding 51 atomisation 149 Australopithecus 14 automated guided vehicles 350 automated identification (ID)

systems 354 automated storage and retrieval of

parts 335 automatic assembly 194ff automatic control 319 automatic factory 28, 319 automatic inspection 279 automatic lathe 24, 26 automatic swarf removal 208 automation 10, 20, 46, 236, 319ff autonomous guided vehicles 351 A-weighting 307 axes(machine) 341 axes (robot) 346 axial component 193

B Babbage, Charles 24 Balance of Payments 11

362 Index

bandoliers 194 handsaw 121 barcode 192,354 basic oxygen process 91 basic time 251 252 batch production 43, 207, 339 bauxite 94 Bedaux, Charles 239 belt conveyors 323 bending 138, 139 benzene 169 Bessemer 91 bill of materials 223 billet 96, 114, 118 binary image 353 blanking 138, 134 blast furnace 89, 90 blister copper 94 blister tapes 194 blow holes 108 blow moulding 172 blown film process 173, 174 blows 108 'blue sky' research 74 board of directors 41 body centred cubic lattice 51, 52 bogore 17 bolted joints 150 BOM 223, 224, 225 Boothroyd, G 83 boredom 293 boring 125 boring machine 20 bornite 93 bottlenecks 232 'boule' 185 bowl feeder 329, 330 brainstorming 76 'brain wheels' 24 Bramah, Joseph 21 brass 57 brazing 153 break even charts 263 briquetting 144 bronze 57 Bronze Age 16 British Standard Performance 251 British Standards Institute 74 Brunei, Mark Isambard 22 brushless motor 325,327,346 BS 5750 276 BSI 74 bulk deformation 113 bureaucratic structure 39 burning 134

butt joint 154, 155 butt welded pipe 145

c CAD 185, 192,321,335, 336ft' CAD generated plot of integrated

circuit 186 cadmium sulphide 184 caging 297 CAl (computer aided inspection) 357 calendering 172, 173 CAM 335, 339fT cams 24, 46, 177,322 canal network 20 capacity (manufacturing) 229 capacity requirements planning 226,

229 capillary action 153 capital allowance 267 capital productivity 259 capitalist 19 CAPP 218,335,356 cap screw 152 carbon 55 carbon dioxide 159 carbon dioxide lasers 135 carburising 57 'card' (in Kanban), 234 Cartwright, Edmund 20 cash flow 232, 266 castability 208 castellated nut 152 casting 98, 17 casting (when to use) 111 casting processes (summary) 109 cast iron 20, 55, 91, 127, 159 catalyst 169, 120 catalytic converter 62 causes of accidents 296 caustic soda 94 cavity layout (plastic moulds) 177 ac (classification and coding) 203,

206,207 cellular layout 203, 205,206, 207, 233,

234 cements 50 central database 336 central processing unit 355 centrally planned economy 4 centre drill 133, 134 centre lathe (basic elements) 126 centrifugal casting 102, 145 centrifugal governor 20 ceramics 49, 50, 62 ceramic tools 123

CF 232 chalconite 93 changeover times 234 chaostheory 231 charcoal filters 189 Charpy test 68 Chartered Institute of Building Services

(CIBS) 306, 309 'chatter' 127, 130 chemical machining 141 chemical vapour deposition 188 Chinese (early) 16 'chip' (integrated circuit) 182 chip removal (in cutting) 122 chlorine 59 chromium 56 chronocyclegraphs 245 chuck 127,128 CIM 321, 335fT, 358 Cincinnati Milacron 28 cladding 163 classification of materials 49 classification of parts 203, 207, 206 clay 101 cleaning of castings 108 cleanliness 295 clean rooms 189ff clearance fits 287, 288 closed impression die forging 117, 118 closed loop control 332, 333, 341 closed loop MRP 229, 230 closed loop system (human) 300, 301 CNC 192,343 CNC drilling machine 192 coaxial cable 357 cobalt 122 codes of practice 300 coding of parts 203, 206, 207 cogging mill 114 coiler 116 coke 90 cold chamber process (in die

casting) 107 cold shuts 108 cold working 53, 113 collet 127, 128 colour shading 338 Colt, Samuel 22 Combination Acts 22 combination tool 139 combining actions 247 'Comet' 23 comfort 311 commission system 19 communication(s) 36, 202

Index 363

company secretary 41,43 comparative estimating 248 comparators 289 competitive advantage 335 component configurations

(electronic) 193 component delivery packages 194 composites 49, 63 composition of manufacturing

costs 257 compressed air 324 compression 64 compressive strength 66 computer accessible 222 computer aided design 185, 192, 321,

335, 336fT computer aided manufacture 335,

339ft computer aided process planning 218,

335,356 computer integrated

manufacturing 321, 335fT, 358 computerised equipment 46 computer numerical control 192, 343 concept design 34, 72, 76 concrete 127 concurrent engineering 201 conductivity 51 conformance 74 constraining resources 231 constraints 231, 232 constructional representation (in

CAD) 339 consumer 70 consumer durables 9 consumer goods 9 continuous casting 99, 100, 114, 206 continuous path control 343 continuous working 340 contouring control 343 contribution 264, 265 control charts (in SQC) 286 control elements (in ergonomics) 303,

305,306 control of automated machines 332 Control of Substances Hazardous to

Health Regulations 294 conventions (control and display) 305,

306 converter 94 conveyors 323 'cope' 101 copper 16,57, 156,191 copper chloride 192 copper production 93

364 Index

copper pyrites 93 'core' (in casting) 101, 176, 177 corporate goal 33 corporation tax 267 COSHH 294 cost analysis and control 269ft cost apportionment 269 cost centres 269 cost distribution in manufacturing 258 cost elements 269 cost of accidents 295 cost of computerised equipment 340 cost of labour 209 cost of quality 280ff cost per unit 332 costs for decision making 260 cost variances 270 cotton gin 21 counterbore 133, 134 countersink 133, 134 covalent bond 51 Cowley 20 CPA 212, 215tT CPU 355 'cracking' (in plastics

manufacture) 169 CRP 226,229 creation of wealth 10, 33, 359 critical path analysis 212, 215ff cropping 138, 139 cryolite 95 crystal growing (in electronics) 184 crystal structure 51 cubic boron nitride 123 cupola 91 customer 33 cutting 121 cutting torches 134 cyanoacrylates 165 cyclegraphs 243 cycloidal speed reducer 342 cylindrical components 129 Czochralski process 185

D Daily Personal Noise Exposure 310 Darby, Abraham 20 data base 222, 336, 339, 356, 357 Days at the Factories (by George

Dodd) 23 dB(A) 307 DCF 266ft deburring 192 deceleration measurement 328 decibels 307

decision matrix 202 dedicated auto assembly machines 195 dedicated equipment, 44, 45,321, 332 defects in castings 107 deformation processes 113 degrees of freedom 347 departmental performance 254 depreciation 267 depth of cut 125 design 34, 36, 70ft' design for assembly 83 design for manufacture 70, 73, 78, 81,

201 design of plastic components 178 design process 72 deskilling 44 detail design 72, 76 Dewhurst, P 83 DFA 83 DFM 70, 73, 78, 81, 201 die casting 106 die: forging 117; press tool 138, 140 dielectric fluid 140 differential costing 264 diffusion welding 162 digital devices 327 digital display 304 digital encoder 327 digitiser 338 dimensional control 113 dimensional tolerancing 288 diode configuration 183 DIP 189,193 dip painting 147 direct cost 241, 262, 269 direct extrusion 119 direct numerical control 344 discounted cash flow 266ff disposable tool inserts 123 distributed numerical control 344 division of labour 19, 24, 39 DNC 344 Dodd, George 23 dopant diffusion 188 dopants 183 DOS 338 down milling 130, 131 'draft' 101, 179 'drag' 101 drawing (in presswork) 138, 139 drill 122 drilling (of PCBs) 192 drilling machine 131 drill jig 131 drop forging 118

drop hammer 116 drumcams 24 dry oxidation 187 dry resultant temperature 312 dry sand 100 dual in line package 189, 193 ductility 53, 67, 113

E ear protection zones 311 ear protectors 311 EBQs 43 ECM 141 economic batch quantities 43 economic wealth 4 edge preparation 155 edgetape 194 EDM 140 Egy~tians (early) 16 electric arc furnace 92, 185 electric motors 24, 325tT, 333 electrochemical machining' 141 electrocoating 148 electrodischarge machining 140, 141 electrolysis 141 electrolyte 141 electrolytic reduction cell 95 electrolytic refining 94 electromagnets 325, 329 electron beams 185 electronic control 27 electronics manufacture 182ff electroplating 146, 147, 191 emergency stop button, 349 end milling 129 endothermic cutting process 135 ENIAC 182 environment: in clean room 189; of

product 208; working 305 epoxy 61, 165, 189 Equivalent Continuous Sound

Level 307 ergonomics 75, 78, 300ft' Erlicher, H. 83 estimating 248 etchant solution 187 etching 141, 192 ethylene 59, 169 examine (in method study) 245 exothermic cutting process 135 explosive forming 142, 143 explosive welding 163 exports 10 extrusion, 118, 145, 171 eye strain 306

Index 365

F fabrication 150 face centred cubic lattice 51, 52 face milling 129 facing 125 factories 18, 25 Factories Act 1961 294 factory automation 319 factory manager 41 factory system 19, 21, 23 families (of parts) 206 FAS 356 fatigue resistance 68 feedback 333, 342 feedback control 322, 325 feedback devices 327ff feed rate 125 fencing 297 Ferranti 28 ferric chloride 192 ferrous metals production 89 fibreglass 295 fibre optic cable 357 filing 121 filler rod 156 filters 189, 190 final specification, 35 finance 42 financial incentives 202 finishing processes 146 'fins' (casting defect) 107 fire precautions 299 fixed costs 261 fixed position plant layout 205, 206 fixture 131 'flash' (in forging) 118 flexibility 207 flexible assembly systems 356 flexible manufacturing cells 335 flexible manufacturing systems 335,

350,356,357 flint tools 16 'float' (in planning) 214 floppy disks 337 flotation process 93 flow diagrams 242 flow of work 321 flow process chart 218 flow solder process 196 fluorospar 91 flux 152,158,195 flux cored arc welding 156 flyingsaw 145,171 flying shuttle 20 FMCs 335

366 Index

FMSs 335,350,356,357 foam plastics 169 focused factory 233, 261 foil 116, 191 Ford, Henry 27 foreign investment 202 forging 116 formability 208 form cutters 130 forming a surface 123, 124 forms of material supply 95 forward planning 253 fractional distillation 169 fractionating column 169 frame store 353 friction welding 163ff fuelgas 134 full mould process 104 functional plant layout 204 fusion welding 154

G gallium arsenide 184 gang drilling 132 CJanttchart 212,213,214 gap press 138 gas metal arc welding 159 gas tungsten arc welding 159ff gas welding 156 gating system (plastics) 177ff gauges 289 CJDP 4, 5, 6, 33 gearreducer 342 CJeneral Electric Company 28 general purpose equipment 46 generating a surface 123, 124 CJeneva mechanism 322, 323 CJiddings and Lewis Machine Tool

Co. 28 giga scale integration 182 CJilbreth, Frank and Lillian 26, 239 glare 306 'global village' 202 globe thermometer 312 CJNP 4, 5, 11, 33 gold plated 193 CJoldratt, E. 231 grain boundary 52 grain flow 117 grain formation 51, 117 grain growth 53 grain structure 54, 114, 117 granite-epoxy composite 127 grants 202 graphics cards 337

graphics screen 337 graphics software 338 CJreeks (early) 18 'green' issues 71 green sand 100 grey levels 353 grippers 330 gross domestic product 4, 5, 6, 33 gross national product 4, 5, 11,33 group technology 203, 206ff CJSI 182 CJT 203, 206fT guards 299 guidance 352

H hacksaw 121 haematite 89 hammer forging 118 hammering 17 handling robot 176 hard automation 46, 321 hard disks 337 hardenability 54 hardening 57 hardness 17,67,113 hardware for CAD 337 Hargreaves,Ja01es 20 harmonic reducer 342 health and safety 294ff Health and Safety at Work (etc.) Act

1974 294 Health and Safety Executive 294 hearing 307 hearing defenders 311 hearing loss 307 heating and ventilation 311 heat treat01ent 57 heliun1 159 HERF 142 hexagonal close packed lattice 51,52 hierarchy of objectives 38 high carbon steel 55 high energy rate forming 142 high speed photography 242 high speed steel 56 historical costs 270 Hittites 17 homo erectus 14 homo sapiens 14 Hookslaw 64 horizontal Dlilling 129 hot cha01ber process 106 hot tears 108 'hottop' 99

hot working, 53, 99, 113, 114 human development index 4 human engineering 300 human error 294 human factors 292ff human factors engineering 300 hydraulic devices 324 hydraulic fluid 324 hydraulic press (early) 21 hydrocarbon 169 hydrochloric acid 192 hydrodynamic jet machining 142 hydro-electricity 94

I 'I' beams 116 identification 352 image definition 352 impact resistance 68 imports 10 incentives 202 inclusions (casting) 108 incremental design 71 incremental encoder 328 indexible inserts 123 indexible toolholder 127 indexing worktable 323 indirect cost 241, 262, 269 indirect extrusion 120 indirect workers 254 indirect work study 253 Indus valley 16 industrial designer 77 industrial engineering manager 42 industrial relations 313 Industrial Revolution 19ff industrial robot 15, 28, 45, 159, 162,

195,297,331,343,345ff ineffective time 249 inert atmosphere 153 infrared reftow solder 196 ingots 93, 98, 114 injection moulding 174ff inorganic materials 50 input devices (for CAD) 337 inspection 35, 279, 352; in

process 284,320 inspection probes 330 instruction file 349 instrument displays 303, 304,305,306 integrated circuits (ICs) 28, 141, 182,

183, 187; manufacturing sequence 184ff; packaging 188ff; production 185ff

integrated steel plant 92

integrating the effort 36 Intel 28 interchangeability 22, 287 interfacing 344, 353 interference fit 287

Index 367

interior lighting 306, 308, 309 interlocked guards 297, 298 internal combustion engine 24 international metre 288 International Standards Office 74 international units of

measurement 288 inventory 224,227,232,257 inventory levels 229 inventory pulling 234 inventory pushing 234 inventory turnover ratio 224 investment appraisal 265,268 investment casting 104 investment goods 9 iron 55 Iron Age 16, 17ff iron moulds 98 iron oxide 101 islands of automation 335 lSO 74 ISO 9000 276 278 isoprene 168 Izod impact test 68

J Jacquard, Joseph Marie 21,319 jobbing production 43, 45, 212 job satisfaction 292ff joining processes 150ff joints (adhesive) 165 joints and welds (welding) 154 joysticks 338, 349 Just in Time manufacture (JIT) 80,

201,233ff,274,279

K Kanban system 234ff Kay, James 20 kerf 134 Kevlar 63 keyboard 337,348 keyboard manufacture 331 krypton 86,288

L labour control 253 labour productivity 259, 320 labour rates 202 labour reporting data 226

368 Index

labour turnover 320 ladder logic diagram 355 LAN 357 'lands' (on PCB) 192 large scale integrated circuits 28 laser cutting 135 laser printer 338 lateral compliance 348 later factory period 24 latex 59, 168 lathe 122, 125 leaded components 193 lead sulphide 184 lead time 227, 336, 340 LEDs 298,328 legal costs 296 legislation (health and safety) 294 Leonardo da Vinci 18 'Leq', 310 life cycle, 71ff, 321 life expectancy (of product) 75 light curtains 298 light emitting diodes 298, 328 lighting 295, 296,306, 308, 309 light meters 306 light pens 338 lime 91 limits and fits 287, 288 limit switch 174, 323fT limonite 89 linear control 343 linear indexing 323 linear transfer systems 330, 331 line layout 233ff line personnel 39 line production 27 lithium 57 local area network 357 locking compounds 165 loom 20,21 lost wax process 104ff loudness 307 low carbon steel 55, 156 Luddites 22

M machinability 208 machine tools 124ff machine utilisation 226 machining 121, 122ft" machining centre 345ff magnetic strip 354 magnetite 89 maintenance 75 'make or buy' decision 260

man and machine charts 242, 243 Management by Objectives 36ff, 232,

274 management information system 222,

230,321 managing director 41 manual data input (MDI)

programming 344 manual metal arc welding 156 manufacturability 208 manufacturing 3ff; as a % of

employed population 8; as a% of GDP 6; as an economic stimulant 7; as a% of visible exports 12; relationship to GNP per head of population 11

manufacturing costs 258 Manufacturing Resource

Planning 201, 226, 229fT manufacturing system 33ff marginal costing 264, 267 marginal investment rate 266 market economies 3 marketing 42 market need 34 market share 37 masks (electronics) 185, 187, 192 Maslow, Abraham 292 Maslow's scale 293 mass production 43, 44 mass storage mediums 337 master production schedule 223 material control manager 42 material flow 208 material handling 207 material productivity 259 material scheduling 228 material selection 208ff Materials Requirements Planning 226 maths co-processor card 337 Maudsley, Henry 21, 22 MBO 36, 232, 274 mean radiant temperature 312 measurement 288 mechanical fastening 150 mechanical properties 208 mechanisation 19, 319 mechatronic devices 333 medium carbon steel 55 memo-motion photography 243 Memorandum of Association 41 metal inert gas welding 159 metal inserts 179, 180 metals 49, 51 metal spraying 359

metal vapour deposition 188 metallic bond 51 meteorites 17 Methods Time Measurement 253 Method Study 239, 241ff metrology 288ff micromotion study 245 microprocessor 10, 28, 182, 321 microprocessor based systems 341 micro-switch 323 Middle Ages 17 MIG 159 mild steel 56 Miles, L.D. 83 milling 129, 344 milling machine 129 miniaturisation 190 minimum profitability criterion 266 MIS 222,230,321,335 misruns 108 Model TFord 27,79 Modern Man 15 modularisation 44, 79fT," 233, 355 modularity (ofMRP II system) 231 molecular structure 51 molybdenum 56 monomer 59 Motion and Time Study 239 motion control 342 mould for injection moulding 176 MPS 223,225 MRP 226 MRP II 201, 226,229, 335 MTM 253 MTS 239 'Multi Class' system 207 multiple activity charts 242 multiple cavity mould 176 multiple dies · 137 multiple spindle drill 132 multiple spindle screw machine 128 multiple stage press tool 139 multiple tasking 338 multiplier effects (in the economy) 10

N naphthas 169 Neanderthal Man 14 needle file 122 negative resist 187 Neolithic period 15 net present value 266 net profit (NP) 232 network planning 214 networks 40

Newcomen 20 New Stone Age 15 noise 295, 307ff noise assessment 310

Index 369

Noise at Work Regulations 1989 310 non-ferrous metal production 93 non-standard components

(electronics) 193 non-traditional machining 139 non-transferred arc 160 normal distribution curve 285, 302 numerically controlled (NC) machine

tool 28,124,207,219,321,339, 343ff

nylon 59, 169

0 objectives 38 'off line' programming 349 Olds Motor Works 27 'on line' programming 349 On the Economy of Machinery and

Manufactures (by Charles Babbage) 26

open hearth furnace 91 open loop control 332 operating expenses 232 operating system 338 operation layouts 224 operation layout sheets 219, 344 operator performance 254 optical character recognition

(OCR) 354 optical disks 337 optical shaft encoder 328ff Optimised Production Technology

(OPT) 201, 231ff optimum quality level 282 organic materials 50 organic molecules 60 organisation chart 39 organisation for quality 275 orientation of components 330, 352 orthogonal cutting 122 output devices 338 outworkers 19 overall performance 254 overall productivity 259 overtime 225 oxidation 114, 134, 187 oxyacetylene welding 156, 157 oxyfuel cutting 134

p packaging of integrated circuits 188

370 Index

painting 147, 355 paint spraying 295 parallax error 305 Pareto analysis 290 Parsons, J.T. 28 parting off 125 patents 76 path control 332 pattern (in casting) 101 pawl linear transfer system 323, 324 payback period 265ft payment by results (PBR) 255 Pazgal, I. 231 PDS 74 Peking Man 14 permit to work 297 Perronet, Jean R. 24 personal computer (PC) 336, 355 personnel (function) 42 PERT 215 photolithography 185, 190, 192 photopolymerisation 359 photoresist 187, 192 photosensors 298,328,352 pick and place devices 196 pickling 146 piecework system 23 piercing and blanking tool 140 pig iron 24, 89 pipe and tube manufacture 118, 144ff piping (flaw) 98, 119 pistol grip 349 pixels 352ft planetary mill 115 planning (Work Study) 255 planning engineers 78 plant layout 203ff, 242 plant location 201 plasma arc 135 plasma arc welding 159ft plastic component design 178ft plasticiser 60 plastics: structure 58; production

of 168 Ploss!, George 226 p-n junction 183 pneumatic circuit 326 pneumatic devices 324, 326 pneumatic robot 346 point file 349 point to point control 342ff pollution 4 polycrystalline metal 53 polycrystalline silicon 185 polyethylene 58, 62, 169

polymerisation 169ft polymers 58 polystyrene pattern 104 population 19,28 population of PCBs 193ff, 339 porosity 108 positive resist 187 postprocessor 336 potentiometer 327, 328 powdered metal processes 142ft precedence relationships 215 precipitation hardening 58 Predetermined Motion Time Systems

(PMTS) 248, 253 preformed leads 195 press forging 118 press tool 137ff, 140 pressure sensitive safety mat 298, 299 pressworking 137ft prevention of accidents 296 price of conformance (POC) 281 price of non-conformance

(PONC) 281 primary bonds 51 primary deformation 113 primary industries 6, 7, 16 primary material handling 350 principles of motion economy 239,

247 printed circuit boards (PCBs) 153,

182, 190ff prioritising (in production

control) 225 prismatic components 129 process capability 264 process charts 242, 244 processlayout 206 process planning, 218ff, 344 process production 43 process selection 208ff processor speed 337 producer goods 9 product appearance 74 product design 70, 78 product design specification

(PDS) 74ft productlayout 206,204 product liability 273 product life cycle 71ff product performance 75 Production and Operations

Management (POM) 222 production control 222ff production control manager 42 production engineer 78

production engineering manager 41 production manager 41 production planning 201ff production schedule 232 productivity 42, 203, 258, 344 productivity improvement system 233 profit 265 programmable logic controller

(PLC) 332, 355, 356 programming 349 progress monitoring 226 progression tool 139 project planning 212ff projection welding 162 properties of materials 63 properties of plastics 60 prosperity 3 prototype 34,46, 77,142 psychological factors 292 PTFE 59 Pugh, Stuart 83 pulse width modulation 341, 325 punched cards 21 purchasing 78, 225 PVC 59, 61, 169

Q qualitative displays 304 quality 35, 273ft', 320, 336 quality approval 32 quality assurance 276ff quality awareness 276 quality circles 236, 289 quality control 278ff quality costs 280ff quality improvement team 276 quality manual 276 quality measurement 287ff quality of life 4, 33 quality records 226 quality standards 278 quantitive displays 304 quenching 54 quick change tooling 234

R radial components 193 radio frequency identification

(RFID) 354 rail system 20 random plant layout 204 rating 239, 250 reaming 133, 134 record playback control 28 recrystallisation 53

reduction 90 redundancy (in design) 79 reftow solder 196 relative humidity 312

Index 371

relative precision index (RPI) 286 Renaissance period 18 representational displays 305 reprogrammable equipment 46, 234,

332,339 research and development 71, 77 research function 43 residual value 268 resistance welding 154, 161 return on investment (ROI) 33, 37,

232 reverberatory furnace 94 risk 9,260,261 riveting 150 robot see industrial robot robot configurations 348 Rockwell hardness test 67 roller tinning 193 rolling 114 rolling mills 18, 93, 115 Romans (early) 18 Root, Elisha 22 rotary transfer systems 330ff rotational components 129 rough cut capacity planning 229 rubber 168 Ruskin, John 4

s sales department 225 sampling audit 231 sand casting 100 safeguarding 297ff safety 75,207, 295ft' safety equipment 299 safety manual 297 safety mat 298ff safety sensors 347 safety training 297 sawing 121 Savery, 111ornas 20 scabs (in casting) 107 scale 116 SCARA robot 331, 347ff schedule 217,223,227, 234 scientific management 24 scrap 91 screen printing 196 screwcutting 125 screwcutting lathe (early) 21 screw.-nut system 341, 342

372 Index

screw threads 22, 133 sealants 165 seamless pipe 145 secondary bonds 51 secondary deformation 113 secondary handling 350 secondary industry 6, 7 seed crystal 185 selective assembly 287 self tapping screw 152 semiconductor components 182ff sequence control 332 service illuminance (table) 309 services (plant) 208 servo control 333 servo motors 323, 327 servo valves 325 set up times 234 shaftencoder 327,328,333,342 shearloading 64 shear strength 66 sheet forming 113 sheet metal 137 shell moulding 103 shielded metal arc welding 156ff shock loads 131 shotting 143 shrinkage 107 siderite 89 silica 94, 101 silicon 56, 168, 184 silicon dioxide, 183ff 'Simfactory 11.5' 205 simulation (ergonomics) 302, 305 SIMO chart 245ff simplification of activities 247 simulation 76,339, 350 simultaneous engineering 36ff, 73, 201 simultaneous motion cycle chart 245ff single point tool 122ff sintering 142 skill level 202, 212 slabbing mill 115 slab milling 129 slabs 93, 99, 114 slag 90,94 slave arm 343 slip gauges 289 slitting saws 130 slot cutting 129 SMDs (surface mounted devices) 193 Smith, Adam 20 smith forging 118 smelting 17, 89 'soaking pits' 99

social relationships 313 soft automation 46, 321 software for CAD 338 solder paste 196 solder resist 193 soldering 152ft', 188, 192, 195 solenoids 325ff solid modelling (CAD) 338 solid state camera 352 solid state welding 154, 162 space lattice 51 spark erosion 140 special purpose equipment 44, 45, 321 specialisation oflabour 19, 39, 233,

293 specification 34, 72, 74, 287 speed control 332 speed of rotation measurement 327 Spencer, Christopher 24, 26, 319 spinning jenny 20 spot welding 161,347 spray painting 147,347 sprocket feedable tapes 194 sprues (in plastic moulding) 174ff,

177ff SQC see statistical quality control staff function 39 stainless steel 56, 159 staking 152 standard costs 270 standard minutes 250 standard of living 4 standard performance 249 standard time 249, 250fT standard unit of work 249 standardisation 22, 44, 79,203,233 standards 22, 74; in Work

Study 239, 248 static electricity 312 statistical quality control 274, 279,

284ff, 320 steam engines 19 steel 91 stepper motors 325 stick electrode welding, 27, 46, 156ft' stick tubes 194 StoneAge 15 stone axe 15 stopwatch 250 storage space 208, 227 strain 64 strain hardening 53, 113 strength 113 stress 64 stress concentrations 179

stress/strain diagram 65 string diagrams 242 stripper plate 138, 140 structure of metals 51 structure of plastics 59 style 78 submerged arc welding 160ff substances hazardous to health 297 substrate manufacture (PCBs) 191 substrate material 184 sulphur 59 Sumerians 16 supervisory computer 350 surface finish 113 surface hardening 58 surface modelling (CAD) 338 surface mounted components 193 surface treatment 146 sweatshops 23 synergy 76 synthesis (in Work Measurement) 248 synthetic polymers 50, 59, 168 synthetic rubbers 168

T tachogenerator 327ff 'tag' (electronic), 225 Taguchi 83 tap 133ff tax 267 Taylor, F.W. 26,239 teach by lead through 349 teach pendant 348 team effort 73 technical function 43 tee joint 154ff temperature (human aspects) 295,311 tempering 58 tensile strength 65 tension 64 tertiary industry 6, 7 test equipment 280 testing (electronics) 188, 197 testing of materials 63 textile industry 22 'Theory of Human Motivation' 292 therbligs 245, 247 thermal comfort 311 thermal cutting 121 thermal cycling 197 thermal indices 312 thermionic valve 182 thermometers 312 thermoplastics 58 thermosetting plastics 58

throughput 232 ticket system 23

Index 373

time factor (in work) 239 time lapse photography 242 Time Study 248, 250fT tin 106,153 Tinkertoy Project 28, 319 titanium 57, 159 tolerance band 284, 286 tolerancing 287ff toluene 169 tool design (injection moulding) 175 toolmaker 14 tool steel 56 total design 73, 84 total productivity 320; see also overall

productivity Total Quality Control (TQC) 201,

274ff Total Quality Management

(TQM) 201, 274ff touch sensitive screen 338 toughened variants 165 trade unions 23 trading 16 training 300 transfer systems 330ff transferred arc 160 transistor 182ff transmission systems 341 transponder 354 transport systems 19 travel charts 242 triode 182 Tull, Jethro 19 tumbling 146 tungsten carbide 56, 121, 122; cutting

tool 143 tungsten inert gas (TIG) welding 159 turning 123, 125 turret lathe 127 tuyers 90, 94 twist drill 132ff

u ultimate strength 65 ultrasonic bonding 189 ultrasonic machining 142 ultrasonie welding 163ff ultraviolet light 185, 192, 196 uncertainty 260 undercuts (re-entrants) 179 unemployment 320 Unimation 28 unit costs 45

374 Index

UNIX 338 unmanned factory 28 up milling 130, 131

v vacuum deposition 188 vacuum forming 172ff value 4, 245 value added 6, 10, 11 value analysis 83 value engineering 83 valves 325 vanadium 56 vapour deposition 188 vapour phase reflow soldering 196 variable costs 261 variances (cost) 270 veiling reflections 306 vendor appraisal 278 ventilation 295 vertical drill press 132 vertical milling 129 very large scale integration

(VLSI) 182 vibratory bowl feeder 329ff video 242, 250 virtual reality 359 vision systems 325ff vulcanisation 59, 168

w wafers (electronics) 185ff warm working 114 warning limits 284, 286 water jet cutting 135 water power 18 Watt, James 20, 319 wave soldering 195 wealth and prosperity 3, 4, 359 wealth creation 310

Wealth of Nations (by Adam Smith) 20

weldability 208 welded joints 150 welding 154ff weld terminology 155ff welfare 299ff wet oxidation 187 white goods 137 Whitney, Eli 22 Whitworth, Joseph 22 wide area network (WAN) 357 Wight, Oliver 226 Wilkinson, John 20 wire frame (in CAD) 338 wooden lathe 18 work content 250 work in progress (WIP) 224,340,354 Work Measurement 239, 248fT work sampling 243 Work Study 24, 42, 239fT working capital 267 working conditions 27, 320; see also

human factors working environment 75; see also

human factors workpiece classification and

coding 206 workspace design 301 works order 225 wrought iron 55

y Young's Modulus 65

z zero defects 279, 283, 320 zeroinventory 233 zinc 106