1 Introduction to Manufacturing

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Dr. Sharifah Imihezri


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Method %

Quizzes 10

Assignments 10

Project 20

Mid-term Exam 20

Final Examination 40


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Involves a sequence of operations and

processes designed to create a specificproduct

Latin word manu factus meaning made by hand

The process of turning raw materials into a product


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5000-4000 BC :

Manufacturing started wood work,ceramics,stone and

metal work

600-800 AD

Steel production

1750s

Industrial Revolution : Machine tools run by invention of

steam engine

1965

Computer Controlled Machines


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1980s

The country witnessed a transition from

being a predominantly agriculturaleconomy to one that was industrial-based.

Lead agencies driving the expansion of manufacturing activities

MITIMinistry of International Trade and Industry

Ministry of Entrepreneur and Cooperative Development,

Ministry of Science, Technology and Innovation
http://www.mecd.gov.my/http://www.mosti.gov.my/http://www.mosti.gov.my/http://www.mecd.gov.my/


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Product should meet design requirement

Economical process

Quality should be built into the system Should be flexible and responsive to new technology

High productivity: Best utilization of man, material,

machine, capital and available resources.

Typicalproduct costbreakdown


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Material Selection

Processing Methods

Final Shape and Appearance

Dimensional and Surface Finish

Economics of Tooling

Design Requirements Safety and Environmental

Concerns


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Depending on the complexity of the

product and the type of materials used,

the time span between the original

concept and the marketing of the product

may range from a few months to many

years.

Requires a clear understanding of

the functions and the performance

expected of the product.


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Product Design Process

Eames chair: style and functional

First molded plastic chairs tobe mass-

produced. Initially molded in fiberglass

reinforced polyester and designed in 1948.

Stokke Chair: Comfort and safety1. Product needs/requirements


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Caption from LIFE. "Natural designs embodied in Mojave desert plants

fascinate Eames, who likes to mount them on the wall of his studio.

From them, he says he gets ideas for his own designs."

2. Product Conceptual Design

Product Design Process


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Heikki Naulap, 2004 student of the Royal College of Art, London

Product objective :

To create a vehicle which offered a new kind of experience while riding.

A mixture of the leaning characteristics associated with motorbikes, with a formula 1

style driving position and small sports car feeling.

Product Design Process2. Product Conceptual Design


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Copyright 2009

Innovative DesignEngineering, Inc.

Connector with

no load

Connector stress

when deformed

a. Design analysis using CAD software

b. Application of CAD/CAM to make sunglasses mold

(a) Computer model of thesunglass as designed andviewed on the monitor. (b) Machine the die cavity

using a computer numerical-control milling machine

(c) Final product.Source: Courtesy of

Mastercam/CNC

Software, Inc.

Product Design Process3. CAD/CAM


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Single

component(nail, bolt, fork,

coat hanger, etc.)

Multi-component

(ball point pens,automobiles, washing

machines, etc.)

Product


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Example of design changes as a function of time for an American and Japanese automobile.

Source: Engineering Modeling and Design, Chapman, Bahill & Wymore

Concurrent Engineering vs Traditional Engineering

In traditional engineering a relatively short time is spent defining the product.

A relatively long time is spent designing the product and a surprisingly long time

is often spent redesigning the product.

The key to shortening the overall design time is to betterdefine the product andbetter document the design process.


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Concurrent Engineering

quality, reliability and maintainability,

testability, manufacturing, drafting

and layout, and program

management.

Cross functional teamSystems engineering

Mechanical engineering

System/fabrication produceability

1. Concurrent Engineering brings together multidisciplinary teams,

Main objective :

To get things right as quickly as possible, and as early as possible.

To reduce the number of redesigns, especially those resulting from post-design

input from support groups

To find the optimum global design with respect to cost,quality and performance of

the whole system.


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CE

Input is obtained from as many functional areas as possible before the specifications

are finalized.

TRADE OFFS - between design features, part manufacturability, assembly

requirements, material needs, reliability issues, serviceability requirements, and cost

and time constraints.

This results in the product development team clearly understanding what the product

requires in terms ofmission performance, environmental conditions during operation,

budget, and scheduling.

Sometimes, only design engineers and manufacturing engineers are involved in

concurrent engineering. In other cases, the cross-functional teams include

representatives from purchasingmarketing, production

quality assurance

customers and suppliers
http://www.google.co.uk/url?sa=i&source=images&cd=&cad=rja&docid=UpXHt0ctDPnf9M&tbnid=2HxrACJHhNEU6M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fvirtual.vtt.fi%2Fvirtual%2Fproj6%2Fproce%2Fcee.html&ei=tHkLUabTF4b9rAfa_YDwAQ&psig=AFQjCNG_LSuiDkB3LEknUZ54BQM5sLWxJA&ust=1359792948443007http://www.google.co.uk/url?sa=i&source=images&cd=&cad=rja&docid=UpXHt0ctDPnf9M&tbnid=2HxrACJHhNEU6M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fvirtual.vtt.fi%2Fvirtual%2Fproj6%2Fproce%2Fcee.html&ei=tHkLUabTF4b9rAfa_YDwAQ&psig=AFQjCNG_LSuiDkB3LEknUZ54BQM5sLWxJA&ust=1359792948443007http://www.google.co.uk/url?sa=i&source=images&cd=&cad=rja&docid=UpXHt0ctDPnf9M&tbnid=2HxrACJHhNEU6M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fvirtual.vtt.fi%2Fvirtual%2Fproj6%2Fproce%2Fcee.html&ei=tHkLUabTF4b9rAfa_YDwAQ&psig=AFQjCNG_LSuiDkB3LEknUZ54BQM5sLWxJA&ust=1359792948443007http://www.google.co.uk/url?sa=i&source=images&cd=&cad=rja&docid=UpXHt0ctDPnf9M&tbnid=2HxrACJHhNEU6M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fvirtual.vtt.fi%2Fvirtual%2Fproj6%2Fproce%2Fcee.html&ei=tHkLUabTF4b9rAfa_YDwAQ&psig=AFQjCNG_LSuiDkB3LEknUZ54BQM5sLWxJA&ust=1359792948443007http://www.google.co.uk/url?sa=i&source=images&cd=&cad=rja&docid=UpXHt0ctDPnf9M&tbnid=2HxrACJHhNEU6M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fvirtual.vtt.fi%2Fvirtual%2Fproj6%2Fproce%2Fcee.html&ei=tHkLUabTF4b9rAfa_YDwAQ&psig=AFQjCNG_LSuiDkB3LEknUZ54BQM5sLWxJA&ust=1359792948443007


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Advantages:

The major iterations that do occur will

occur before the design becomes final.

The overall time taken to design and

manufacture a new product can be

substantially reduced if the design activities

are carried out together rather than in

series.

The reductions in design cycle time that

result from concurrent engineering

invariably reduce total product cost.


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The foundations of CE were built on the concepts of design for manufacturing(DFM) and design for assembly (DFA)

Must be able to assess the impact of design modifications on

manufacturing process selection

assembly

inspection

tools and dies

product cost

DFMDFA

CECE

CE

CECE

CE

CE

CE

Design for Manufacture (DFM)


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Examples of the wide variety of

materials

and geometries for paper clips.

Questions for consideration:

What material properties are required?

Which manufacturing process wouldproduce the lowest cost?

Would the material and processing

strategy change if the desired quantity

was 10,000 vs. 1 million per day?

Design for Manufacture (DFM)


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Design for Assembly (DFA)Products are designed with ease of assembly in mind.

Why????

Product contains fewer parts it will take less time to

assemble,Parts are provided with features which make it easier to

grasp, move, orient and insert them.

In addition products must be design for ease of disassembly.

Why????

Maintenance, servicing, recycling of components

reduce assembly timeassembly costs.


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The machines permit technicians to control the height and rotation of the vehicle, permittingeven the undersides to be worked on with ease.

Factory tour in Maranello, Italy

The 'new assembly line' makes use of pincer machines designed by Italian robot manufacturersComau that permit easy access to all sides of the vehicle. The cars are placed at the best height for each worker, and can

be rotated to permit work to be done on its underside.


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My dream car


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What is DFM? The objective of DFM is to identify product concepts that are

easy to manufacture DFM is the first step in which a team approach is taken

to develop the product

DFM is an umbrella which covers a variety of tools andtechniques to accomplish a manufacturable product

Why DFM? Lower development cost

Shorter development time

Faster manufacturing start of build

Lower assembly and test costs Higher quality


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DFM Method Estimate the manufacturing costs.

Reduce the costs of components.

Reduce the costs of assembly.

Reduce the costs of supporting production. Consider the impact of DFM decisions on other

factors.


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DFM MethodEstimate the Manufacutring

Costs

Consider the Impact of DFM

Decisions on Other Factors

Recompute the

Manufacturing Costs

Reduce the Costs of

Supporting Production

Reduce the Costs of

Assembly

Reduce the Costs of

Components

Good

enough

?

N

Y

Acceptable Design

Proposed Design


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Ease of Assembly Part is inserted from the top of the assembly

Part is self-aligning

Part does not need to be oriented

Part requires only one hand for assembly Part requires no tools

Part is assembled in a single, linear motion

Part is secured immediately upon insertion


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Consider Customer Assembly Customers will tolerate some assembly

Design product so that customers can easily andassemble correctly

Customers will likely ignore directions


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DFM Tools: DFA Guidelines Summary of DFA Guidelines

Minimize the number of parts Standardize and use as many common parts as possible Design parts for ease of fabrication (use castings without

machining and stampings without bend) Use standard cutters, drills, tools

Minimize assembly directions Maximize compliance; design for assembly Minimize handling Eliminate adjustments Use repeatable, well understood processes Design parts for efficient testing Use Guide features Incorporate symmetry in both axis Avoid designs that will tangle. Design parts that orient themselves


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Design for ProductionGeneral Principles1. Use Common Sense2. Plan and Define

3. Consider Available Facilities

4. Consider Available Tools5. Consider Available Worker Skills

6. Employ Simplicity

7. Standardize


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Design for Production Guidelines (Cont.)8. Minimize assembly direction (Top down

direction preferred)9. Maximize compliance in assembly10. Minimize handling in assembly11. Minimize complexity of design12. Maximize common jigs and fixtures13. Optimize work position14. Ease access


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Manufacturing Costs Defined Sum of all the expenditures for the inputs of the

system (i.e. purchased components, energy, rawmaterials, etc.) and for disposal of the wastesproduced by the system


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Elements of the Manufacturing Cost of aProductManufacturing Cost

OverheadAssemblyComponents

Standard Custom Labor Equipment

and ToolingSupport

Indirect

Allocation

Raw

MaterialProcessing Tooling


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Manufacturing Cost of a Product Component Costs (parts of the product)

Parts purchased from supplier Custom parts made in the manufacturers own plant or

by suppliers according to the manufacturers designspecifications

Assembly Costs (labor, equipment, & tooling)

Overhead Costs (all other costs) Support Costs (material handling, quality assurance,

purchasing, shipping, receiving, facilities, etc.)


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Environmentally Conscious Design and SustainableManufacturingDesign for recycling

Design for the environment

Green design - environmentally safe and friendly

- considers the possible negative environmental impact

of materials, products and processes

Sustainable manufacturingCapable of being continued with minimal long-term effect on the

environment

reducing waste materials

reducing the use of hazardous materials

proper handling and disposal of all waste

improvements in waste treatment and in recycling/ruse of

materials
http://www.google.co.uk/url?sa=i&source=images&cd=&cad=rja&docid=LvWUH7SneT92cM&tbnid=MRLwx6VgypavIM:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fwww.gbb.org%2Fnews%2Fgreen-conventions-find-one-attend-one-plan-one%2F&ei=pTAPUaq0C8SOrgfKoYGgDQ&psig=AFQjCNGNyf_mcHUYsMECUC_vYq1oVHxCmw&ust=1360036389216696


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Whats in my PC?Material Proportion

PlasticFerrous metalsNon-ferrous metalsElectronic boardsGlass

23%32%18%12%15%

The complex mixture of materials make PCs very difficult to recycle!http://www.recycling-guide.org.uk

Ultracompact PC is Dell's smallest and

most environmentally conscious computer

to date. It's one-fifth the size of standard

desktops and uses about 70% less energy.

http://www.time.com


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Classified as a bicycle in all 50 states, 'ELF', the

three-wheeled solar and pedal powered electricassist velomobile by American organic transit

hybridizes the advantages of bicycle and

automotive transportation into a waterproof body

Made with 45% recycled

aluminum and a vacuum formed

trylon (composite of 85% recycled

ABS and solarcote) frame.

Environmentally Conscious Design and SustainableManufacturing
http://www.organictransit.com/index.htmlhttp://www.organictransit.com/index.html


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Selecting manufacturing process

General classification of shapes *

*M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.


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Selecting manufacturing processProcessMaterial matrix

with the dot indicating a

compatibility between

the material and the

correspondingmanufacturing process. *



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Selecting manufacturing processProcessShape matrix with the dot

indicating a compatibility between

the shape and the corresponding

manufacturing process. *



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Dr. Sharifah Imihezri


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Stage One - Computer Aided Design. A product is designed totally on

computer. When complete it is tested or its functions simulated on screenbefore even a prototype is made. If a circuit is involved it is designed by using

software and tested on screen. Improvements / alterations are made to the

design using the same CAD software.

Stage Two - Prototype Manufacture. Prototypes are manufactured on

machines such as 3D printers which produce an accurate 3D model. CNCrouters and laser cutters may also be used to produce a realistic model.

Sometimes working models are manufactured.

Stage Three - The computer system controlling the plant works out the most

efficient method of manufacture. It calculates costs, production methods,

numbers to be manufactured, storage and distribution.


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Stage Four- The computer system orders the necessary materials to

manufacture the product. Keeping costs to a minimum. The just in time

philosophy is applied. This means that materials / components are ordered asneeded. Very little is stored at the factory. Usually only enough materials are

stored to keep the factory going for a small number of days. Materials are

automatically reordered when required, to keep the factory working smoothly

and continuously.

Stage Five - Manufacturing begins with the product being made using CAM(Computer Aided Manufacture). Computers control CNC machines such as

laser cutters, CNC routers and CNC lathes.

Stage Six - Quality control is applied at every stage. The product is tested

using computer control inspections. For instance, the accuracy of

manufacture is tested automatically. This ensures that the product ismanufactured to the correct sizes.


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Stage Seven - The product is assembled by robots. This is automated

(controlled) by the computer system.

Stage Eight. The product is quality checked before being stored for

distribution to the customer. All storage is automated. This means that

computer controlled vehicles move the finished product from the

manufacturing area to storage. The computer systems keep track of everyindividual product. Products are bar coded which are constantly scanned and

recorded by the computer system.

Stage Nine - The product is automatically moved from store to awaiting

lorries / trucks for distribution to the customer.

Stage Ten - Financial accounts are updated, bills chased up and paid by the

computer system.


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Greek word : automatos self acting


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Goals of automation

1. Integrate various aspects of manufacturing operationsimprove product quality

minimise cycle times reduce labor cost

2. Improve productivity

3. Reduce human involvement : boredom human error

4. Reduce workpiece damage manual handling of parts

5. Economise on floor space

5. Increase the level of safety for personnel hazardous working conditions


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Machines are grouped according to function into

machine centers.

Orders for individual products are routed through the

various machine centers to obtain the required

processing.

This layout may be appropriate when there are many

different products, each with a low volume of

production.

Skilled labour

Job shop Layout - work travelsto dedicated process centers

Milling

Assembly& Test

Grinding

Drilling Plating

Similar resources placed

together

T T T CG CG

T T T SG SG

M M D D D

M M D D D


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Note the various

machining operations

Also known as fixed-position automation

Produce standardized products e.g engine block, valve, gear

Specialized machines and lack flexibility

Machines cant be modified to a significant extent to accommodate

a variety of products

This automation approach is best suited for mass production of the same

product with few alterations or change-overs.

straight circular


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Also known as flexible automation or programmable automation

Has greater flexibility through computer control

This method is ideal for handling small batches of product and product changes.

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1 Introduction to Manufacturing

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