Introduction to
Manufacturing
Lecturer: Dian Daruis
Email: dian@upnm.edu.my
Introduction to Manufacturing
Observe the objects around you:
– How did they become what they are?
What important role does manufacturing play in
society?
People involved?
How do we define manufacturing?
– From Latin word manu factus ~ made by hand, also
used is production engineering.
– Manufacturing is the ability to make goods and services
to satisfy societal needs
» Manufacturing processes are strung together to create a
manufacturing system (MS)
– It is the process of converting raw materials (changing)
into products which encompasses design and
manufacture following a well-organized plan for each
activity required.
Design process
Product design is a critical activity, 70-80% of the cost of
product development & manufacture occurs at this stage.
(refer Figure 6 in text book).
Product design is no longer a sequential process but rather
a concurrent process. (read: concurrent engineering or
simultaneous engineering).
– CE is a systematic approach integrating the design and
manufacture of products with view of optimizing all elements
involved in the life cycle of the product. Basic goals – to minimize
product design & engineering changes, hence time & costs.
Life cycle – all aspects of a product (design, development,
production, distribution, use, disposal and recycling.
Success determinants for CE;
– Full support from the upper management
– A multifunctional and interactive teamwork and support groups
– Utilizing all available technologies ; CAD, CAE, CAM, rapid
prototyping
Overdesigns – surveys indicated that many products in the
past have been overdesigned; too bulky, materials of too
high quality, unwarranted precision and quality for the
intended uses.
DFMA
A comprehensive approach to production of goods
and integrates the design process with materials,
manufacturing methods, process planning,
assembly, testing and quality assurance at low cost
(economically).
You can read more on DFMA at
http://www.dfma.com/ and
http://www.npd-solutions.com/dfmguidelines.html
Material selection and process
selection
Materials engineer
How the materials will be processed?
How the process will affect the materials?
Time and cost effects consideration to
manufacture the materials
Types of Goods
Consumer Goods
– Items which are purchased directly by consumers
» Consumer electronics
» Clothing
Producer Goods
– Items which are manufactured for other companies to
produce products from
» Sheet metals etc.
» Machine tool builders
» Automotive suppliers
Products
Fabricating - Manufacturing of products from
components, pieces, or sub-assemblies. Separate
discrete items such as machined parts, bolts, nuts
etc. are fabricated.
Processing - Manufacturing a product in a
continuous series of operation . Examples include
wire, beverages, chemicals etc.
Manufacturing a Product
Production systems include
– People
– Money
– Equipment
– Materials
– Supplies
– Markets
– Management
– Manufacturing System
– All aspects of commerce
Manufacturing a Product
The Manufacturing System
The functions and systems of the production system, which includes (and services) the manufacturing
system. The functional departments are connected by formal and informal information systems
designed to service the manufacturing system that produces the goods.
Manufacturing a Product
The Manufacturing System
– Collection of operations and processes to produce a
desired product or component
– Design or arrangement of the manufacturing processes
Roles of People in Mfg.
Design engineer responsibilities
– What the design is to accomplish
– Assumptions that can be made
– Service environments the product must withstand
– Final appearance of the product
– Product designed with the knowledge that certain
manufacturing processes will be used
Roles of People in Mfg.
Manufacturing engineer responsibilities
– Select and coordinate specific processes and equipment
– Supervise and manage their use
Industrial (Manufacturing) engineer
– Manufacturing systems layout
Materials engineers
– Specify ideal materials
– Develop new and better materials
Roles of People in Mfg.
Technicians
– QC, machine set-up, machine maintenance, machine
repair, and system integration
Machinist and Tool Makers
– Producing close tolerance parts and tooling to
specifications
Operators
– Running production parts and quality
Aspects of a Manufacturing System
Mfg. Processes
– The method (s) used to convert a product from one form to
another- example metal removal. A process typically
involves a sequence of steps or operations.
Characteristics of Process
Technology
Mechanics
Economics or costs
Time Spans
Constraints
Uncertainties and process reliability
Skills
Flexibility
Process capability
Aspects of a Manufacturing System
Operations
– Distinct action to produce a desired result or effect
– Categories of operations
» Materials handling and transport
» Processing
Drilling, tapping, turning, milling, injecting
» Packaging
» Inspecting and testing
» Storing
Aspects of a Manufacturing System
Figure 1-6 The component called a pinion
shaft is manufactured by a “sequence of
operations” to produce various geometric
surfaces.
Aspects of a Manufacturing System
Job and station
– Job is a group of related operations generally done at one station
– Station is the location or area where production is done
Treatments operate continuously on a workpiece
– Heat treating, curing, galvanizing, plating, finishing, chemical
cleaning, painting
Tools, tooling and workholders
– Lowest mechanism in the production is a tool
» Used to hold, shape or form the unfinished product
Tooling for measurement and inspection
– Rulers, calipers, micrometers, and gages
– Precision devices are laser optics or vision systems that utilize
electronics to interpret results
Factory Layouts
Job Shop
Flow Shop
Linked-Cell Shop
Project Shop
Continuous Process
Factory Layouts
Figure 1-15 Different manufacturing
system designs produce goods at different
production rates.
Seven Basic Processes
Casting
Forming
Machining
Joining and Assembly
Surface Treatment
Heat Treatment
Other
Casting
Molten metal fills a cavity in a mold.
Quick method to transform a raw material into a
desired shape.
Two types of casting methods:
– Expendable mold
» Sand casting
– Permanent mold
» Die casting
Plastic, composite manufacturing, and PM
Forming & Shearing
Changing materials into a desired shape by:
– Squeezing
– Bending
– Shearing
– Drawing
Utilizes Materials that have been previously cast or
molded
Performed at “cold” or “hot” temperatures
– cold = room temp to .3 of the melt temperature material
– hot = above .3 of the melt temperature of the material
Metal Removal - Machining
Seven basic processes
– Shaping
– Turning
– Drilling
– Milling
– Sawing
– Broaching
– Abrasive machining
– Non-Traditional
» Examples: EDM & Water-Jet
Joining
Mechanical Fastening
Welding
Adhesive bonding
Assembly
Surface Treatment
Aesthetic requirements
– Painting
Product requirements
– Safety
» Burrs
– Surface treatment
» chemical plating to resist rust
Heat Treatment
Altering the mechanical properties of a material.
– Strength
– Wear resistance
– Resistance to penetration
Other
Inspection
Packaging
Transportation
Waste disposal
– Scrap
– Chemical by-products
Product Life Cycle Cost
Changing World Competition
Globalization has impacted manufacturing
– Worldwide competition for global products and their
manufacture
– High tech manufacturing for advanced technology
– New manufacturing systems, designs, and management
China as the next manufacturing superpower? (as
reported by Deloitte 2010).
How Do We Plan For
Manufacturing?
Definition of a need
Conceptual design
Review of initial design
Design Prototype
Production plan
Resource specifications
Manufacturing Prototype
Manufacturing
Inspection--quality checks
Packaging - shipping
Customer response
New Manufacturing Systems
Toyota Production System (just in time philosophy
and practice) (since 1948-1975)
– Lean manufacturing system
– 100% good units flow without interruption
– Integrated quality control
– Responsibility for quality is given to manufacturing
– Constant quality improvement
– Continuous improvement
New issues -Environmental issues /
sustainability
Recently, concern for the environment has led
manufacturing industry to take a proactive role in
the development of cleaner manufacturing
processes and the design of recyclable products.
The goal is sustainable development, where the
waste from one process becomes the raw material
for another in a large cycle which imitates the
natural food chain.
