Introduction to Manufacturing

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Introduction to Manufacturing

• General Manufacturing Processes Engr.-20.2710
• Instructor - Sam Chiappone

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Introduction to Manufacturing

• Observe the objects around you
• How did they become what they are?
• What important role does manufacturing play in
  society?
• How do we define manufacturing?
• Manufacturing is the ability to make goods and
  services to satisfy societal needs
• Manufacturing processes are strung together to
  create a manufacturing system (MS)

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1910s
1920s
1930s
1900s
Society Manufacturing
1940s
1990s
1950s
1980s
1960s
1970s
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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
• Steel Mills - coil stock
• Machine tool builders - Milling Machines
• Automotive suppliers - Taillight assemblies

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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.

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Manufacturing a Product

• Production systems include
• People
• Money
• Equipment
• Materials
• Supplies
• Markets
• Management
• Manufacturing System
• All aspects of commerce

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Manufacturing a Product

• The Manufacturing System

Figure 1-4 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.
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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

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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

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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

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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

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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.

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Characteristics of Process Technology

• Mechanics
• Economics or costs
• Time Spans
• Constraints
• Uncertainties and process reliability
• Skills
• Flexibility
• Process capability

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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

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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.
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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

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Factory Layouts

• Job Shop
• Flow Shop
• Linked-Cell Shop
• Project Shop
• Continuous Process

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Factory Layouts
Figure 1-15 Different manufacturing system
designs produce goods at different production
rates.
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Seven Basic Processes

• Casting
• Forming
• Machining
• Joining and Assembly
• Surface Treatment
• Heat Treatment
• Other

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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

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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

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Metal Removal - Machining

• Seven basic processes
• Shaping
• Turning
• Drilling
• Milling
• Sawing
• Broaching
• Abrasive machining
• Non-Traditional
• Examples EDM Water-Jet

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Joining

• Mechanical Fastening
• Welding
• Adhesive bonding
• Assembly

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Surface Treatment

• Aesthetic requirements
• Painting
• Product requirements
• Safety
• Burrs
• Surface treatment
• chemical plating to resist rust

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Heat Treatment

• Altering the mechanical properties of a material.
• Strength
• Wear resistance
• Resistance to penetration

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Other

• Inspection
• Packaging
• Transportation
• Waste disposal
• Scrap
• Chemical by-products

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Product Life Cycle Cost
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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

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New Manufacturing Systems

• Toyota Production System
• Lean manufacturing system
• 100 good units flow without interruption
• Integrated quality control
• Responsibility for quality is given to
  manufacturing
• Constant quality improvement

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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