Industrial Safety and Manufacturing Processes Flashcards

Vocabulary flashcards covering industrial safety, manufacturing processes, joining techniques, accident classifications, and plant layout types.

Manufacturing Process

The process of producing a desired object from raw materials, which are often provided in the form of rough castings called ingots.

Ingots

Rough castings of metal available in the industry that are subjected to various manufacturing processes to be converted into usable products.

Primary Shaping Processes

Processes used to convert ingots or molten metal into usable forms, including casting, forging, smithy, drawing, rolling, and bending.

Machining Processes

Operations performed on machine tools (such as lathes, shapers, milling, drilling, and grinding machines) to produce complex shapes and profiles by material removal.

Surface Finishing Processes

Processes used to provide a fine surface finish where negligible metal is removed or a small amount of material is added, including polishing, buffing, electroplating, honing, lapping, and painting.

Permanent Joining Processes

Processes used to permanently connect two or more metal pieces, including welding, soldering, brazing, and riveting.

Temporary Joining Processes

Fastening methods used to join metal parts temporarily, including nut and bolt, screwing, and keys and cotter joints.

Processes Affecting Change in Properties

Heat treatment processes used to impart specific mechanical properties to metal parts, including annealing, tempering, normalizing, hardening, carburizing, cyaniding, nitriding, and induction hardening.

Powder Metallurgy

The art of making objects by heat treatment applied to compressed metallic powder.

Non-Conventional Manufacturing Methods

Advanced processing techniques using thermal, electrical, magnetic, or chemical energy (e.g., ECM, EDM, USM, Electron Beam) developed for high hardness and heat-resistant materials.

Industrial Safety

Principles and practices aimed at preventing industrial accidents, protecting worker health and income, avoiding property damage, and reducing work stoppage costs.

Accident

A mishap that causes injury to humans, machines, tools, or equipment, which may result in death, temporary disablement, or permanent disablement.

Mechanical Causes of Accidents

Accident hazards arising from unsafe or poorly maintained equipment, unguarded machinery, unsafe building construction, improper material handling systems, or lack of protective devices.

Working Environment Causes of Accidents

Accident factors related to improper temperature, humidity, defective illumination, presence of dust/fumes/smoke, improper noise levels, blocked exits, or poor housekeeping.

Human Causes of Accidents

Accident causes stemming from human behavior or condition, such as operating without authority, unsafe speeds, fatigue, improper tool use, or working with mental worries and carelessness.

Near Accident

An accident occurrence that results in no damage or injury.

Trivial Accident

An accident that results in very minimal damage and minor injury.

Minor Accident

An accident involving damage and injury greater than a trivial accident.

Serious Accident

An accident involving heavy property damage and significant injuries.

Fatal Accident

A severe accident resulting in heavy property damage along with the loss of life.

First-AID

The immediate assistance provided to an injured or ill patient.

Plant Layout

The systematic and functional arrangement of departments, machines, equipment, tools, and services in an industry to optimize resource utilization.

Fixed Position Layout

A plant layout where the major product component remains fixed in one position while tools, machinery, materials, and labor are brought to it, used in shipbuilding and aircraft assembly.

Process Layout (Functional Layout)

A layout where similar operations and machines are grouped together in dedicated departments (e.g., all lathe machines in one area, all drilling in another).

Product Layout (Line Layout)

A plant layout where machines and operations are arranged strictly according to the sequential order required to manufacture a product.

Combination Layout (Group Layout)

A layout combining process and product layouts based on group technology principles, arranging machines according to required operational sequences for product groups.

Group Technology

A manufacturing principle where products requiring similar operational sequences for production are categorized as one group regardless of their shape or size.