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Introduction to Manufacturing
- Part 1-
Darrell Wallace
Youngstown State UniversityDepartment of Mechanical and
Industrial Engineering
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man·u·fac·ture (v)
1. To make or process (a raw material) into a finished product, especially by means of a large-scale industrial operation.
2. To make or process (a product), especially with the use of industrial machines.
Latin:Manus (hand) + factus (make)
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Evolution of Manufacturing Just as today, the historical evolution of
manufacturing occurred as an exchange between material technology and processing capability
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Prehistoric Periods Stone Ages (~10,000,000 – 2,000 BC)
Time period varied geographically Three periods:
Paleolithic (old stone age) Mesolithic (middle stone age) Neolithic (new stone age)
Stone age likely led to wooden tools
Bronze Age (~2500-500 BC) Iron Age (~1500 BC-1000 AD)
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Manufacturing as Craft and Art Prior to about 1800, nearly all
manufacturing was “craftsmanship.” All products made as “one-offs” No standardization or mass-production
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Industrial Revolutions Major periods of Industrial growth beginning
around 1800 and continuing through modern day Transfer of expertise from person to process Improvements in processes
Automation Machine Tools Power Sources Materials Processing
Improvements in Infrastructure
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Some Key Components of the Industrial Revolutions Consumerism Military Development and Transfer of Technology
Manufacturing Tools and Processes Raw material processing (Whitney, Bessemer) Vertical integration (combined spinning / weaving) Mass Production (interchangeability, assembly lines) Machine Tools (Maudslay)
Power sources Steam Engines (Newcomb / Watt) IC Engines Electric machinery
Infrastructure Transportation Communication
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Year: 2004
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Educational services,health care, and social
assistance
Professional andbusiness services
Government
Finance, insurance,real estate, rental, and
leasing
Manufacturing
Contribution to U.S. GDP ($Billions)
Source: U.S. Bureau of Economic Analysis
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U.S. Manufacturing Employment FiguresSince 2001, Manufacturing employment has decreased significantly. However, contribution to the GDP has remained basically steady during that period. How is this possible?
Source: U.S. Bureau of Labor Statistics
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U.S. Manufacturing Productivity
M anufacturing SectorProductivity Index Per Capita
1987-2004
70
80
90
100
110
120
130
140
150
160
170
1985 1990 1995 2000 2005
Ou
tpu
t (N
orm
aliz
ed t
o 1
00%
in 1
992)
Source: BLS
50 years to Double Output
10 years to Double Output
25 years to Double Output
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Recent Shifts in U.S. Manufacturing 2001 Marked a major shift toward increased
productivity Employment in the manufacturing sector has
decreased sharply, but production has not. Productivity is at an all-time high Low-value-added processes appear to be offset
by improvements in higher-margin production Demand for employment will likely continue to
shift from unskilled laborers to individuals who can contribute to higher productivity.
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Engineering Skills Valued in Modern Manufacturing Environment Process Expertise
Improve process efficiencies Bridge gap be between design technology and production
technology
Design Expertise Adapt designs to make them more manufacturable
Logistics and Process Flow Maximize efficiency throughout the manufacturing process
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Course Objectives Show the relationship of manufacturing to other
engineering pursuits
Familiarize you with the most common manufacturing processes and some fundamental analyses
Encourage you to consider the many processes by which each product you encounter is manufactured
Provide fundamental background for future work and education in manufacturing and related fields