MEE 315:

MANUFACTURING TECHNOLOGY
(SUBTRACTIVE OPERATION)

Dr V.D. Obasa
Course Outline
1.Joining of metals; brazing, principle of bonding. Welding
methods; principles of metallurgical welds.
2.Casting methods; sand casting, billet-casting methods.
3.Durvile and continuous casting and other forms of
casting.
4.Fundamentals of solidification and structural
developments in casting.
5.Introduction to manufacturing processes.
 Manufacturing Technology

Manufacturing Technology
Process of converting raw Application of scientific knowledge
materials into products. to improve processes

Production process
Manufacturing Process
Manufacturing is derived from the Latin word “manufactus”, meaning
“made by hand”.
It involves making products from raw materials by using various
mediums such as hand tools, machinery and computers.
Manufacturing Technology
It is the application of scientific knowledge to improve manufacturing
processes required to make components, utilities or machines from
start to finish.

The living condition of the people in terms of shelter, clothing and

food is determined by how much they produce and the level of
production is dependent on technological know how deployed to
the manufacturing processes.
 Manufacturing process:
➢ It is that part of the production stages which is directly concerned with the
change in form or dimensions of the part being produced.

➢ It does not include the transportation, handling or storage of parts, as they are
not directly concerned with the changes into the form or dimensions of the part
produced.

Classifications of Manufacturing Processes

Manufacturing processes can be broadly classified into the following basic
categories based on how materials are transformed or processed:
Casting and Foundry Processes
• Purpose: Shaping molten materials into solid forms by pouring them into
moulds.
• Examples: Sand casting, die casting, investment casting.
• Applications: Casting is notable for its ability to produce intricate shapes
like Engine blocks, machine, decorative items
2. Forming or Shaping Processes
• Purpose: Deforming materials into desired shapes without adding or
removing material.
• Types:
o Hot Forming: Processes performed at high temperatures, e.g., forging,
rolling, extrusion.
o Cold Forming: Performed at room temperature, e.g., sheet metal
stamping, cold rolling.
• Applications: Structural components, pipes, sheets.
3. Machining Processes
• Purpose: Removing material to achieve specific shapes, sizes, or finishes.
• Examples: Turning, milling, drilling, grinding.
• Applications: Gears, screws, precision parts.
4. Joining Processes
• Purpose: Combining two or more parts into a single assembly.
• Examples:
o Welding (arc welding, MIG, TIG)
o Brazing and soldering
o Adhesive bonding.
• Applications: Automotive bodies, pipelines, electronic circuits.
5. Additive Manufacturing
• Purpose: Building objects layer by layer using materials like plastics, metals,
or composites.
• Examples: 3D printing, direct metal laser sintering (DMLS).
• Applications: Prototypes, customized parts, aerospace components.
6. Surface Treatment or Finishing
• Purpose: Improving surface properties (appearance, corrosion
resistance, wear resistance).
• Examples: Polishing, painting, electroplating, anodizing.
• Applications: Jewelry, car bodies, consumer electronics.
7. Material Removal (Non-Conventional)
• Purpose: Removing material using advanced technologies without direct
contact.
• Examples: Laser cutting, water jet cutting, EDM (Electrical Discharge
Machining).
• Applications: Intricate parts, aerospace components.
8. Advanced/ Modern Manufacturing Processes
• Purpose: Combining multiple processes with advanced
technologies for precision.
• Examples: CNC machining, robotics, smart manufacturing.
• Applications: Medical devices, electronics, automotive.

• Assignment List and discuss 20 Modern

Manufacturing Processes
Flow of Manufacturing
1.Primary Manufacturing: Producing raw materials or basic forms
(e.g., casting, forming).
2.Secondary Manufacturing: Refining materials into functional
components (e.g., machining, finishing).
3.Assembly and Testing: Joining components and ensuring quality.
4.Inspection and Certification: Inspection of assembled parts is done
to ensure that the products certify the quality requirements. Quality
products are then certified OK for packaging.
5. Packaging, Warehousing and Forwarding Processes: Packaging
involves putting the products into cartons for onward transfer to the
warehouse (warehousing) and delivery to the consumers/customers.

These classifications collectively enable the production of a wide

range of products, from basic tools to complex machinery.
Further classification based on stages
➢ Primary shaping processes involve manufacturing a product from an
amorphous material. Some of the outputs of this process are in their final
state while others need to be processed further.

• Some important primary shaping processes are Casting, Powder metallurgy,

Plastic technology, Gas cutting, Bending and Forging.

➢ Secondary or machining processes: This has to do mostly with improving the

physical appearance of the product from the primary production process

▪ Some of the common secondary or machining processes are- Turning,

Threading, Knurling, Milling, Drilling, Boring, Planning, Shaping, Slotting,
Sawing, Broaching, Hobbing, Grinding, Gear cutting, Thread cutting etc
Aspect Primary Manufacturing Processes Secondary Manufacturing Processes

Convert raw materials into basic shapes or Refine or enhance the basic forms into final
Purpose
usable forms. products with precision.
Machining, drilling, grinding, welding,
Examples Casting, forging, extrusion, rolling, molding.
polishing.
Semi-finished products (e.g., castings, forged
Materials Used Raw materials like ores, metals, or plastic resins.
parts).
Rough, semi-finished products (e.g., metal Finished products or parts with tight
Output
billets, plastic sheets). tolerances and surface finishes.

Tools/Equipme Lathes, milling machines, CNC machines,

Furnaces, extrusion dies, rolling mills.
nt grinding wheels.

Key Characteristics Focus on shaping the material into a basic usable form. Focus on precision, detail, and functional characteristics.

Complexity Less precise but necessary as the first step in manufacturing. More precise and detailed for product specifications.
Production process?
It is the route followed in plants for converting semi-finished
products or raw materials into finished products.

In general, there are three basic types of production systems

which are:
1. Job production
2. Batch production
3. Mass production
Job (or Project) Production System
• Description: A single product or a small quantity is custom-made to specific
customer requirements. Each product is unique, and production often
involves skilled labor.
• Features:
o High flexibility and customization.
o Production times and costs are higher.
o Generally labor-intensive.
• Examples:
o Building a custom home.
o Producing a prototype or specialized machinery.
Each system is selected based on factors like product type, production volume,
and customer requirements.
2. Mass (or Flow) Production System
• Description: Products are produced continuously on an assembly line in large
volumes. The system is designed for efficiency and high output.
• Features:
o Highly standardized with minimal variation.
o Requires significant initial investment in machinery.
o Low unit costs due to economies of scale.
• Examples:
o Automobile manufacturing.
o Bottling beverages.
Batch Production System
• Description: Products are manufactured in specific groups or quantities called
batches. Each batch goes through one production step before moving to the
next.
• Features:
o Suitable for moderate production volumes.
o Flexible and can handle variations in design or product type.
o Requires retooling or setup changes between batches.
• Examples:
o Baking bread in batches.
o Manufacturing clothing with different sizes or colors.
 PLANT LAYOUT
“Plant layout is a systematic and efficient functional arrangement of
various departments, machines, tools, equipment and other support
services of an industrial organization that will facilitate the smooth
processing of the proposed or undertaken product in the most effective,
most efficient and most economical manner in the minimum possible
time.
➢ In a manufacturing organization, a job to be manufactured spends most of the time moving
and waiting. To reduce this moving and waiting time of jobs/parts, it is necessary to have a
proper layout and proper scheduling procedure.

➢ Plant layout specifies the position of the overall arrangement of the various facilities such as
equipment, materials, manpower, materials handling, service facilities, and passage required
to facilitate the efficient operation of the production system of the plant within the area of
the site selected previously. Shop layout in manufacturing plants also forms an integral part
of the factory planning or plant layout.
➢ The plant layout of an industrial organization comprises all the aspects
connected with the industrial enterprise, viz., grounds, buildings, machinery,
equipment, departments, methods of manufacturing, factory services, material
handling, flow of production, working conditions, hygiene, labour and shipment
of goods, etc.

➢ it does not necessarily mean planning a new enterprise only.

➢ However, it also involves minor improvements in the existing layout,

expansion of the existing plant, re-layout of the existing plant and layout of a
new proposed plant.
NECESSITY OF PLANT LAYOUT
1. Setting up a new plant
2. Change in the design of a product. This may result in a change in the
manufacturing operations or sequence of operations.
3. Expansion of existing department(s).
4. Relocation of existing department(s).
5. Addition of new department(s).
6. Addition of new products to the existing facilities.
7. Replacement of existing machines/equipment by modern and more efficient
machines/equipment.
8. Improving the existing plant layout.
IMPORTANCE OF PLANT LAYOUT
1. It avoids congestion and underutilization of plant site.
2. It minimizes material/part handling and movement.
3. Minimizes work in progress inventory
4. Minimizes workers movements and hence worker fatigue.
5. Ensure convenience and safety of workers.
6. Improves quality of production.
7. Minimizes cost of production.
8. Ensure optimum utilization of plant facilities.
9. Ensures efficient control over the various production processes.
10. Smooth and continuous flow of production or manufacturing work with least possible
bottlenecks and congestion points
OBJECTIVES OF PLANT LAYOUT
1. It should provide overall satisfaction to all concerned.
2. It should reduce the part and material handling costs.
3. It should provide for workers convenience, and better working conditions.
4. It should promote job satisfaction.
5. It should promote safety.
6. It should provide high work-in-progress turnover.
7. It should reduce inventory.
8. It should assist supervision and reduce manufacturing time.
9. It should help in the effective utilization of employees, machines and services.
10. It should utilize the plant site effectively, that is, no congestion and underutilization.
11. It should simplify control of production.
MERITS OF A GOOD PLANT LAYOUT
➢ The main advantages of a good plant layout involve effective and economical utilization of
entire floor space of the plant,
➢ increased rate of production,
➢ reduced men and machine hours per unit of production,
➢ reduced material handling, minimal production delays,
➢ effective utilization of men, machinery, material and other factory support services,
➢ reduced overall production time,
➢ elimination of large amount of paperwork,
➢ significant reduction in the indirect expenses,
➢ considerable reduction in inventory work for material,
➢ promote effective supervision, facilitate easy flow of men, tools and material,
➢ promote flexibility in arrangement to suit the future changes,
➢ promotes better planning and effective control,
➢ facilitates better and easier maintenance of plant and machinery,
➢ provides safer and healthier working conditions thereby improving the morale of the staff,
➢ provides the material as well as psychological satisfaction to the workers and enhance overall
efficiency of the plant.
TYPES OF PLANT LAYOUT
layouts are classified into four major categories namely;
➢fixed or position layout,
➢line or product layout,
➢process or functional layout
➢ combination or group layout.
Each kind of layout is explained with respective advantages, disadvantages and
application.

1. Fixed or Position Layout

➢ Fixed or position layout is also known as project layout.
➢ In this type of layout, the major part of an assembly or material remains in a fixed
position. All its accessories, auxiliary material, machinery, equipment needed, tools
required and labour are brought to the fixed site to work. Thus, the product by virtue
of its bulk or weight remains at one location.
➢ Therefore the location of the major assembly, semi-assembly component and
material is not disturbed till the product is ready for dispatch.
• This layout is suitable when one or a few pieces of an item are to be manufactured and
material forming or treating operation requires only tools or simple machines. This layout is
highly preferable when the cost of moving the major piece of material is high and the
responsibility of product quality by one skilled workman or group of skilled workers is
expected.

• This type of layout is mainly adopted for extremely large items manufactured in very small
quantities such as ships, aeroplanes, boilers, reactors etc.

• The main advantage of this layout is

➢ the minimum movement of men, materials, and tooling during the manufacturing process.

➢ This layout is highly flexible as the type of product and the related processes can be easily
changed without any change in the layout.
Advantages
Its main advantages are— Typical project layout
▪ Layout is highly flexible for varieties of products having intermittent demand as the type of product and the
related
processes can be easily altered without any change in the layout.
▪ There is a minimum movement of men, materials, and tooling during the manufacturing process.
▪ The material is drastically reduced.
▪ Highly skilled operators are required to complete the work at one point and responsibility for quality is fixed on
one person
or the assembly crew.
▪ Every personnel of the manufacturing team is responsible for quality work for manufacturing the product.
Disadvantages
The major disadvantages of this layout are:
▪ The cost of equipment handling is very high.
▪ Labors and equipment are difficult to utilize fully.
▪ It is limited to large items only.
Applications
This type of layout is mostly adopted for extremely large items
manufactured in very small quantity such as ships, aeroplanes,
aircraft, locomotives, ship assembly shops, shipyards, boilers, reactors
etc.
2. Process or Functional Layout
In this type of layout arrangement, similar machines, production facilities and
manufacturing operations are grouped according to their functions.

Machine tools of one kind are positioned together so that all similar operations are
performed always at the same place e.g. all the lathes may be grouped for all kinds of
turning and threading operations, all drilling machines in one area for carrying out drilling
work, all tapping machines in one area for carrying out tapping work, all milling machines in
one area for carrying out milling work all buffing and polishing machines at one place for
carrying out surface finishing work, and so on.

This type of layout is normally preferred for the industries involved in job order type of
production and manufacturing and/or maintenance activities of non-repetitive type. This
layout does not to have to be changed every time the product or component changes. Also,
the breakdown of any machine does not affect the production. This type of layout is highly
suitable for batch production.
Typical functional layout
Advantages
The major advantages of this layout are:
▪ There exists a wide flexibility regarding the allotment of work to equipment and
workers.
▪ There is a better utilization of the available equipment.
▪ Comparatively less numbers of machines are needed in this layout and hence thus
reducing capital investment.
▪ There is an improved product quality because the supervisors and workers attend to
one type of machine and operation.
▪ Varieties of jobs come as different job orders thus making the work more interesting for
the workers.
▪ Workers in one section are not affected by the nature of the operations carried out in
another section. For example, a lathe operator is not affected by the rays of the welding as
the two sections are quite separate.
Disadvantages
The major disadvantages of this layout are:
▪ This layout requires more space in comparison to line or product layout for the same amount
of production.
▪ Production control becomes relatively difficult in this layout.
▪ Raw material has to travel more which increases material handling and the associated costs.
▪ This layout requires more efficient co-ordination and inspections.
▪ Increased material handling cost due to more movement of process raw material to various
paths
▪ More material in process remains in queue for further operations.
▪ Requires large in-process inventory.
▪ Completion of same product takes more time.
Application
1. This layout is used for batch or moderate production.
2. It specify path for group technology.
3. Line or Product Layout: In this layout, the machines, equipment, and work centres are
arranged in a straight line or curved line in the order in which they have to be used, the
product layout, the product must be standardized and manufactured in large quantities.

Hence, it is a system best suited for mass production and ensures a smooth flow of materials
and reduced materials handling. Breakdown of any machine in the line in this layout may result
in even a stoppage of production.

For examples automobile assembly lines, bottling plants and so on. The raw material enters at
one end of the line and moves from one machine to another in the line without back-tracking
or cross-movements and finally the end product leaves from the other end of the line. It is
normally applied in assembly work.

Typical line layout

Advantages
Its main advantages are—
▪ It involves smooth and continuous work flow.
▪ It may require less skilled workers
▪ It helps in reducing inventory.
▪ Production time is reduced in this layout.
▪ Better coordination, simple production planning and control are achieved in this layout.
▪ For the same amount of production, less space requirements for this layout.
▪ Overall processing time of product is very less.
▪ This layout involves automatic material handling, lesser material movements and hence
leads to minimum possible cost of manufacturing.

Disadvantages
The major disadvantages of this layout as compared with process layout are It is very difficult to increase production beyond
the capacities of the production lines.
▪ When single inspector has to look after many machines, inspection becomes difficult
▪ This layout is very less flexible for product change.
▪ The rate or pace rate of working depends upon the output rate of the slowest machine and hence leading to excessive
idle time for other machines if the production line is not adequately balanced.
▪ Machines being put up along the line, more machines of each type have to be installed for keeping a few as stand by,
because if on machine in the line fails, it may lead to shut down of the complete production line. That is why the line or
product layout involves heavy capital investments
Applications
It is used in assembly work.
4. Combination Layout
It is also known as group layout. A combination of process and product layouts combines the
advantages of both types of layouts.

Most of the manufacturing sections are arranged in process layout with manufacturing lines
occurring here and there scattered wherever the conditions permit.
These days, the most of manufacturing industries have adopted this kind of layout. In this type of
layout, a set of machinery or equipment is grouped together in a section, and so on, so that
each set or group of machines or equipment is used to perform similar operations to produce a
family of components. A combination layout is possible where an item is being made in
different types and sizes.

Typical combination layout

In such cases, machinery and manufacturing equipment are arranged in a process layout but a group of number of similar
machines is then arranged in a sequence to manufacture various types and sizes of products. In this layout, it is noted
that, no matter the product varies in size and type, the sequence of operations remain same or similar. This layout is
suitable when similar activities are performed together thereby avoiding wasteful time in changing from one unrelated
activity to the next. It focuses on avoiding unnecessary duplication of an effort. It is preferable for storing and retrieving
information changing related to recurring problems thereby reducing the search in understanding information and
eliminating the need to solve the problem again. It is also useful when a number of items are produced in same sequence
but none of the items are to be produced in bulk and thus no item justifies for an individual and independent production
line. There are some advantages, disadvantages and application of this layout which are given as under:

Advantages
The advantages of this type of layout are:
▪ Reduction in cost of machine set-up time and material handling of metals.
▪ Elimination of excess work-in-process inventory which subsequently allows the
reduction in lot size.
▪ Simplification of production planning functions, etc.
Disadvantages
The major disadvantages of this layout are:
▪ Change of the existing layout is time consuming and costly.
▪ Inclusion of new components in the existing component requires thorough analysis.
▪ Change of input component mix may likely to change complete layout structure.
▪ Change of batch size may change number of machines.
Application
Manufacturing circular metal saws, hacksaw, wooden saw, files and crank shaft
PRINCIPLES OF PLANT LAYOUT
1. Principle of minimum distance or movement
2. Principle of flow
3. Principle of cubic space
4. Principle of satisfaction and safety
5. Principle of flexibility
6. Principle of overall integration
7. Principle of minimum investment
STEPS IN PLANT LAYOUT PLANNING
Guiding fundamentals:
1. Plan the whole and then the details.
2. Plan the ideal and then the practical
3. Follow the cycle of layout development and overlap the phases
4. Plan the process and machinery around the material requirement.
5. Plan the layout around the process and the machinery/equipment.
6. Plan the building around the layout.
7. Plan with the aid of clear visualization.
8. Plan with the help of others
9. Check the layout.
10. Sell the layout.
TYPES OF FLOW PATTERN
Flow pattern means the path followed by the work through the plant, starting from
raw material up to finished product. As each plant layout is unique, there is no best
way to layout of a flow pattern.

However, the flow pattern should be such that it:

There are six basic flow patterns:
1. Straight line: Most suited for product layout.
2. L- Flow: Similar to straight line but economizes on floor spaces.
3. U-Shaped: The raw materials enter and the finished products leave the plant at the same
end. This pattern results in better space utilization and easier inspection.
4. S-Flow: Still better space utilization and simpler inspection. However the material enters the
plant at one end and the finished products leave the plant from the other end. It is normally
used when production line is very long.
5. Circular or O-Flow: Easier supervision and minimum back-tracking of work. This flow is
suited where the operations are carried out on rotary tables or where the starting point abd
the
finishing point are the same, for example, mechanized foundry.
6. Convoluted: This pattern has the same characteristics as the S-Flow pattern.
Thank you