Introduction to Introduction to ManufacturingManufacturing

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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Society & Manufacturing

1930’s1920’s 1910’s

1900’s

1990’s

1950’s

1940’s

1960’s 1970’s1980’s

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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