QUANTITY PRODUCTION METHOD

Q. Mention briefly the process of Mechanical Assembly and conventional

ways of Inspection.

A. Mechanical Assembly:

It comes under the second phase of basic manufacturing operation after the
preliminary process of operations in which two or more separate parts are joined to form
a new entity. Components of the new entity are connected either permanently or semi
permanently. Permanent joining processes include welding, brazing, soldering and
adhesive bonding. They form a joint between two components that cannot be easily
disconnected. Mechanical Assembly uses various methods to attach mechanically two
or more parts together. In most cases, the method involves the use of discrete hardware
components, called fasteners that are added to the parts during the assembly
operation. In other cases, the method involves the shaping or re-shaping of one of the
components being assembled, and no separate fasteners are required.

Many products are produced using Mechanical Assembly in the Industries like:
automobiles, large and small appliances, telephones, furniture, utensils – even wearing
apparel are “assembled” by mechanical means. In addition, industrial products such as
airplanes, machine tools, and construction equipment almost always involve mechanical
assembly.

Mechanical fastening methods can be divided into two major classes:

1. Those that allow for disassembly, and
2. Those that create a permanent joint.

Threaded fasteners (e.g. screws, bolts and nuts) are examples of the first category
and, rivets illustrate the second type.

There are good reasons why mechanical assembly is often preferred over other joining
processes. The main reasons are:

1. Ease of assembly and

2. Ease of disassembly (for the fastening method that permit disassembly)

Mechanical Assembly is usually accomplished by unskilled workers with a minimum use

of special tooling and in a relatively short time. The technology is simple, and the results
are easily achievable with an objective of easy inspection. These factors are
advantageous not only in the factory, but also during field installation. Large products
that are too big or voluminous and heavy to be transported completely assembled can
be shipped in smaller sub-assemblies and then put together at customer’s site.
Ease of disassembly applies, of course, only to the mechanical fastening methods that
permit disassembly. Periodic disassembly is required for many products so that
maintenance and repair can be performed: for example, to replace worn out
components, to make adjustments, and so forth.

Permanent joining techniques such as welding do not allow for disassembly.

Mechanical Assembly methods are divided into the following categories : (I) Threaded
fasteners (II) Rivets (III) Interference fits (IV) Other mechanical fasteners ( studs,
threaded inserts, washers, stitching, stapling, sewing etc.) (V) Molded-in-inserts and
integral fasteners.

Besides the same, the following assembly operations are also to be considered:
1. Manual assembly line
2. Automated production line

A manual assembly line consists of multiple workers arranged sequentially at which

assembly operations are performed by each worker. The usual procedure on a manual
line begins with a base onto the front end of the line. The base part travels through each
of the stations where workers perform tasks that progressively build the product.
Components are added to the base part at each station so that all tasks have been
completed when the product exists the final station.

An automated line consists of automated workstations connected by a parts transfer

system that is coordinated with the stations. In the ideal situation, no human workers
are on the line, except to perform auxiliary functions such as tool changing, loading &
unloading parts at the beginning and end of the line, and repair and maintenance
activities. Modern automated lines are highly integrated systems, operating under
computer controlled.

Inspection:

It involves the use of measurement and gauging techniques to determine whether a

product, its components, sub assemblies or starting materials (raw materials ) conform
to design specifications. The design specifications for mechanical products refer to
dimensions, tolerances, surface finish, and other similar features.

Inspection is performed before, during, and after manufacturing. The incoming materials
and starting parts are inspected upon receipt from suppliers; work units are inspected at
various stages during their production ; and the final product should be inspected prior
to shipment to the end user or the customer.

There is a difference between testing , which is a closely related topic. Inspection

determines the quality of the product relative to design specifications, whereas testing
generally refers to the functional aspects of the product.
In quality control, testing is a procedure in which the product, sub assembly , part or
material is observed under conditions that might be encountered during service. For
example, a product might be tested by operating it for a certain period of time to
determine whether it functions properly. If it passes the test, it is approved for shipment
to the customer.

Testing of a component or material is sometimes damaging or destructive. In these

cases the products must be tested on a sampling basis. The expense of destructive
testing is significant and great efforts are made to develop the methods that do not
destroy the product. These methods are referred to non-destructive testing (NDT).

Manual and automated inspection also comes into play under the context of Inspection.
Manual inspection follows statistical sampling procedures. The possibility of the errors is
obvious as certain number of a poor quality parts may be accepted or a certain number
of good quality parts may be rejected. Therefore, 100 % inspection using manual
methods is no guarantee of 100% good quality product.

Automated 100% inspection is a possible way to overcome the products associated with
100 % manual production. The steps are (i) automated presentation of parts by
automated handling system (ii) manual or automated loading of parts into an automated
machine (iii) fully automated inspection cell where parts are presented & inspected
automatically (iv) computerized data collection method prevails from electronic
measuring instruments.