Name Orion, Gene laser Andrew E.

Industry Focus # MQRUV, Monday, 7 AM -1 PM

Student Number 2015-12624 Date of Submission March 28, 2021
Section & Schedule Section, Day, Time

1. Resource Material Topic: Shovels [Manufacture of shovels from rail steel, https://www.youtube.com/watch?v=Swf45MlkgB4]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

The rail steel are welded off into three different parts 1. Welding Machine - 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
wherein in here, the top, middle, and bottom parts of the rail Current 𝐼𝑛𝑝𝑢𝑡
steel are separated from each other. These are again cut into 2. Furnace - Temperature Input: Rail Steel (mass, quantity), Lumber (mass, quantity)
smaller pieces before they are place into a furnace. Then, 3. Roller - RPM Output: Shovels (mass, quantity), waste (mass, quantity)
the steel are placed to a rolling machine that will reduce the 4. Forge hammer – Newton
thickness of the steel. It is then placed under a forge hammer (Force)
𝑂𝑢𝑡𝑝𝑢𝑡
to pound the hot steel. The rolling and the forging of the 5. Puncher – Newton (Force) 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
steel are done multiple times until they become flat. Then, 6.. Semi-automated wood 𝐼𝑛𝑝𝑢𝑡
they go to a machine that punches out a flat, shovel-head lathe – rotational cutting Input: Time to assemble a set of shovels (hrs)
shaped steel, from the flattened steel. These punched out speed Output: Number of shovels assembled in one
steel are placed by a worker one by one to a punching manufacturing cycle (mass, quantity)
machine, to put a hole on one side. They are placed again
into a furnace for them to be malleable again. The hot steel
is placed to a die forger, that transforms the initially flat
steel into the blade of the shovel. The blade goes to a water
bath to harden the steel again. Labels are manually placed
on them. After that, these blades undergo quality control
and testing.

On another line, they use lumber to create shaft of the

shovel. It goes into a aemi-automated wood lathe that cuts
the edges of the wood as it is inserted to the machine. This
is done to obtain a circle cross-section. The tip of stick is
made sure to fit inside collar or socket of the blade.
 2. Resource Material Topic: Hammers [How It’s made Hammers, https://www.youtube.com/watch?v=V5iOju-ns54]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

For hammers to be made, it starts with a fixed steel bar to 1. Induction Furnace - 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
be loaded by an automated system to an induction furnace Temperature 𝐼𝑛𝑝𝑢𝑡
making it the steel malleable. The forge hammer pounds the 2. Forge hammer – Force Input: Fixed steel bar (mass, quantity), Vinyl (mass,
steel to a number of hammer shaped impressions. The (Newton) volume), Leather rings (mass, quantity), waste (mass,
punch cutter then trims the uneven edges of the forged steel. 3. Punch Cutter - Force quantity)
The forged steel goes to a press that fine tunes the shape. (Newton) Output: Hammers (mass, quantity)
Then, it is cooled down into a revolving rack. The hammers 4. Revolving rack - RPM
are then loaded to a rotating tumbler along with some tiny 5. Rotating Tumbler - RPM
𝑂𝑢𝑡𝑝𝑢𝑡
steels to rub off debris on the hammer. Then, the hammers 6. Abrasive/Sanding Belts - 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
are clamped into a device that spins it against abrasive belts RPM 𝐼𝑛𝑝𝑢𝑡
to contour the striking head, and to bevel the hammer’s 7. Cutting wheel - RPM Input: Time to manufacture a set of hammers (hrs)
head. Next, the jagged cutting wheel carves the hammer’s 8. Hydraulic tool - pressure Output: Number of shammers assembled in one
head with ridges and grids. Next, they undergo a tempering manufacturing cycle (mass, quantity)
process. Now, it is polished to make the steel gleam.

They assemble leather rings to each tray and slid it to a

compartment and insert the hammer in the rings. In here, a
hydraulic tool rams it through them encasing the handle in
a neat wrap that is comfortable to grasp. Then, it is dipped
to a leather lacquer for a tough sleek finish .

For a different kind of handle , they will pour a liquid vinyl

to a hammer shaft that’s encased in a mold. They grind off
the remaining vinyl spillover and contour the handle.

They stamp the model number on it. Then, paint guns spray
the hummer with lacquer for rust proofing. Then, it goes to
an oven to cure the lacquer. After the logo is stamped on to
it, the hammers are visually inspected for quality control
before it gets a seal of approval.
 3. Resource Material Topic: Pliers [How Its Made – 502 Pliers, https://www.youtube.com/watch?v=BBf0V7AC49w]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

Steel rods go to an electric furnace to heat the steal in just a 1. Electric Furnace – 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
few seconds. A massive die forger hammers the rod against Temperature and Current 𝐼𝑛𝑝𝑢𝑡
the die using tons of force. Then, it goes to a press that trims 2. Forging hammer – Force Input: Steel rod (mass, quantity), rivet (mass, quantity)
off any excess steel. Next, is to machine the teeth in to the (Newton) Output: Pliers (mass, quantity), waste (mass, quantity)
jaws. They go into a broaching machine, which has tiny 3. Press – Temperature,
cutters to shave away steel under a shower of lubricant. The Pressure
𝑂𝑢𝑡𝑝𝑢𝑡
steel then undergoes austempering. Then, they travel to a 4. Gas fired furnace - 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
gas fired furnace. Then, they quench the steel in salt water Temperature 𝐼𝑛𝑝𝑢𝑡
to cool it rapidly and evenly. The teeth will be given a laser 5. Grinding wheels - RPM Input: Time to assemble a set of pliers (hrs)
heat treatment to make them harder and more durable. Now, 6. Gas Oven - Temperature Output: Number of pliers assembled in one manufacturing
they are ready for assembly. 7. Robotic arms - Automated cycle (mass, quantity)
8. Grinding belt - RPM
For gripping pliers, a worker inserts a single piece rivet to 9. Laser Engraving
join the two halves. He then sets the joint on to a machine Machine- Temperature
that spins at high speed, generating force and friction to set
the rivet.

For cutting pliers, a rivet is still inserted however, in here,

they are held onto a press the applies heat and pressure to
secure the rivet firmly. Next, they insert the cutting pliers
between two stone grinding wheels wherein again a
lubricant prevents the steel from overheating. Next, they go
into a gas oven to undergo a process of martempering.
When they come out, they are cooled using an oil solution.
Then, they go into a bath to inhibit rusting and lubricates
the rivetted joints. A robotic arm, runs one pair of pliers at
a time onto a grinding belt for a polished finish. A laser then
engraves the company logo and product number.

Automated bars lower down hundreds of pliers to a vinyl

dip. The factory heats the pliers for this coating to stick to
the steel. Then, it goes to an oven to harden the coating.
 4. Resource Material Topic: Wrenches [How the RIDGID Wrench is made factory Made, https://www.youtube.com/watch?v=QudZhdAJG_Q]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

Raw iron and scrap steel are mixed to produce a strong and 1. Electric Furnace - 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
flexible ductile cast iron. The cast iron is then placed into Temperature 𝐼𝑛𝑝𝑢𝑡
an electric furnace. The handles are cast using a 2. Pressing Machine - Input: Raw iron (mass, quantity), scrap steel(mass,
polyurethane template which is pressed using a machine Temperature, Pressure and quantity), paint (volume)
into a bed of sand to make a mold. When the molds are Force Output: wrenches (mass, quantity), waste (mass, quantity)
ready, a huge ladle transfers molting iron from the holding 3. Cooling tunnel -
surface into a pouring tank that pours it into the molds. Temperature
𝑂𝑢𝑡𝑝𝑢𝑡
After they are filled, the sand molds go to a cooling tunnel Pressure, Automated 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
before they are broken apart by workers and dumped into a 4. Milling Machine - RPM 𝐼𝑛𝑝𝑢𝑡
vibrator to shake the sands away. The molds left on the 5. Automatic screw machine, Input: Time to manufacture and assemble a set of
handles are grounded away. The handles are then finished Nut tapper – Automated, wrenches (hrs)
with a coat of electrically charged auto body paint. This coat RPM Output: Number of pliers assembled in one manufacturing
creates a watertight seal that protects the iron from leaky 6. Vibrator - Frequency cycle (mass, quantity)
pipes.
Example: In the video, it was stated that they can produce
On another line, the steel jaws of the pipe wrench are 2300 wrench handles in one cycle. Assuming this is done
machined to add the teeth that will bite into the pipes. The in one day, the plant productivity is equal to 95 wrenches
jaw come with two parts, the heel jaw which sits on top of per hour.
the handle, and a hook jaw that moves up and down from
the heel jaw when you adjust the jaws to tighten it around 2300 𝑤𝑟𝑒𝑛𝑐ℎ𝑒𝑠
any sized pipe. After the teeth are cut, another machine is 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = = 95.83
24 ℎ𝑜𝑢𝑟𝑠 ℎ𝑜𝑢𝑟
used to mill threads into the long shank on the hook jaw to
the nut that moves up and down. When both pieces of the
jaws are fully milled they are heat treated in a furnace to
strengthen the teeth of the jaws.

The nut on the other hand are milled out of long steel rods
by an automatic screw machine. The nut tapper cuts threads
on the inside of each nut to screw into the matching threads
on the shank of the hook jaw. Workers then assemble the
wrenches.
 5. Resource Material Topic: Saws [How Its Made – 347 Hand Saws, https://www.youtube.com/watch?v=r8qUVXgBaSs]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

A machine uncoils a steel and draws it into a mechanized 1. Uncoiling Machine - RPM 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
punch. This punch is used to cut the teeth on the edges of 2. Mechanized Punch – 𝐼𝑛𝑝𝑢𝑡
the steel (140 notches/minute). It makes two cuts for each Force (Newton) Input: Steel plate (mass, quantity), Rivet (mass quantity)
saw tooth. A rail takes up the newly serrated steel and then 3. Die punch Output: Saws (mass, quantity), Labels (quantity), waste
will feed it back, to cut teeth on the other side of the steel. 4. Shear machine (mass, quantity)
Next, a finger-like device unrolls the steel and pushes it to 5. Conveyor belt - Speed
automated jaws, that will bend the teeth alternating the 6. Infrared oven -
𝑂𝑢𝑡𝑝𝑢𝑡
direction of each one (setting the teeth). Then, a die punch Temperature 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
cuts the steel coil into pieces called double blanks (2 saw 𝐼𝑛𝑝𝑢𝑡
blades are made from them). The die also makes holes at Input: Time to manufacture and assemble a set of saws
one end of the double blank for the handles to be attached. (hrs)
Then, it goes to a shear machine wherein a long blade Output: Number of saws assembled in one manufacturing
descends and cuts it in half on the diagonal making two saw cycle (mass, quantity)
blades. Next, they press the saw blades up against a saw belt
to smooth out the edges (deburring).

The blades drop into a conveyor, then to a bin. Conveyor

wheel dumps them into a pool of clear protectant which will
keep them looking shiny. When they are dry, they are
placed on table that rises for the squeegee to silkscreen the
company name onto it. They go to an infrared oven, to bake
on the brand name. They slide cardboard sleeves onto the
blades. Then, a worker fits two plastic handle parts together
which will then be placed on a carousel. The ultrasonic
sealer moves in to emit a high frequency sound that will
cause vibrations. This is done in order to melt the two
plastics together forming a handle. A worker fits the handle
on to a blade. Then, a machine rivets it in place.
 6. Resource Material Topic: Rubber Gloves [How It’s Made Rubber Gloves, https://www.youtube.com/watch?v=IJ96aI2xUJI]
Process Summary List of Essential
● 200(min) – 300(max) words Equipment and
● Single space
● Justified corresponding Process Flow Diagram Productivity and Efficiency General
● Font Type: Time New Roman Font performance (Based on your own understanding.) Formula
Font Size: 8
●
● Font Color: Black
parameters.
● Medium: English

In the production of rubber gloves, it all starts with latex 1. Spinning Machine - RPM 𝑂𝑢𝑡𝑝𝑢𝑡
𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
rubber. First, they add an orange dye to change the original 2. Furnace - Temperature 𝐼𝑛𝑝𝑢𝑡
color of latex rubber. To mold the shape of the hand, they 3. Tumble dryer – RPM, Input: Latex rubber (mass, quantity), orange dye(volume)
use ceramic hands to model the gloves. These ceramic Temperature Output: Gloves (mass, quantity), waste (mass, quantity)
hands are dipped to a salt water bath for the latex rubber to 4. Conveyor - Speed
stick on to its surface. After a quick dip, a spin get rids of
𝑂𝑢𝑡𝑝𝑢𝑡
any drips. Next, they are dipped to a cotton lining. Since, 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 =
the gloves are made inside out, so when they are dipped into 𝐼𝑛𝑝𝑢𝑡
this glue, it‘s actually the inside that’s getting coated. Now, Input: Time to manufacture a set of gloves counted in pairs
the gloves are sprayed with a fine cotton mist to make them (hrs)
easier to put on. To strengthen the latex rubber, it needs to Output: Number of gloves (counted in pairs) produced in
be baked in a furnace (vulcanization), so that when it’s one manufacturing cycle (mass, quantity)
stretched it will just return to its original shape. Then, they
are given a cooling dip after being baked up to 100 degrees. Example: In the video, it was stated that they can produce
The workers will then pull them off the molds. To finish it 50000 pairs of rubber gloves in one day. Thus, we can say
up they go to a tumble dryer which will then go to a that they can produce 2083 pairs of gloves per hour.
collecting bin.
50000 𝑝𝑎𝑖𝑟𝑠 𝑜𝑓 𝑔𝑙𝑜𝑣𝑒𝑠
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 = = 2083.33
24 ℎ𝑜𝑢𝑟𝑠 ℎ𝑜𝑢𝑟