MET 449 / ME 448 – Design for MET 449 / ME 448 – Design for Manufacturing and ToolingManufacturing and Tooling

Introduction to Production Introduction to Production SystemsSystems

The Production System The Production System (Big Picture)(Big Picture)

Purchasing

Design Engineering

Quality Control

Accounting / Finance R&D

Production Planning and

Control

Transportation / Distribution

Customer

Manufacturing System

Production System

Source: Materials and Processes in Manufacturing, ninth ed. (DeGarmo, Black, & Kohser, 2003)

Manufacturing System

Bigggggger Picture!Bigggggger Picture!

Economic System (Capitalism)

Production System

Economic SystemEconomic System

An An economic systemeconomic system is a particular set of is a particular set of social institutionssocial institutions which deals with the which deals with the productionproduction, , distributiondistribution and and consumptionconsumption of goods and services in a particular of goods and services in a particular society. The economic system is society. The economic system is composed of people and institutions, composed of people and institutions, including their relationships to productive including their relationships to productive resources, such as through the convention resources, such as through the convention of property. It addresses the problems of of property. It addresses the problems of economics, such as the allocation of economics, such as the allocation of scarce resources in a given economy. scarce resources in a given economy.

Source: http://en.wikipedia.org/wiki/Economic_system (Jan. 2008)

The Production SystemThe Production SystemAll aspects of workers, machines, and information, considered collectively, needed to manufacture parts or products; integration of all units of the system is critical.

Source: Materials and Processes in Manufacturing, ninth ed. (DeGarmo, Black, & Kohser, 2003)

The Manufacturing SystemThe Manufacturing SystemThe collection of manufacturing processes and operations resulting in specific end products.

An arrangement or layout of many processes, materials-handling equipment, and operators.

Source: Materials and Processes in Manufacturing, ninth ed. (DeGarmo, Black, & Kohser, 2003)

Examples:

Manufacture of AutomobilesManufacture of AirplanesManufacture of Fast Food

Discussion TopicDiscussion Topic

What automobile do you currently What automobile do you currently drive?drive?

What motivated each of you to What motivated each of you to purchase that particular automobile?purchase that particular automobile?

Do you ever think about what it takes Do you ever think about what it takes to “manufacture” that automobile?to “manufacture” that automobile?

Example: Car ManufactureExample: Car Manufacture

Source: Materials and Processes in Manufacturing, ninth ed. (DeGarmo, Black, & Kohser, 2003)

What is “Value”?What is “Value”?

Value = Product Function and Performance

Cost of Product

Examples:

Cars

Bikes

Shoes

Ski Equipment

Staplers

Design to BuildDesign to Build

Functional RequirementsFunctional Requirements Customer RequirementsCustomer Requirements CostCost MaintenanceMaintenance AssemblyAssembly ManufacturabilityManufacturability Prototype and TestPrototype and Test Detail to Assembly FlowDetail to Assembly Flow

PRODUCT DESIGN

Material PropertiesMaterial Properties– MechanicalMechanical– PhysicalPhysical– Etc.Etc.

Manufacturing Manufacturing ProcessesProcesses

Availability and CostAvailability and Cost Service LifeService Life Material CompatibilityMaterial Compatibility

MATERIALS SELECTION

PRODUCT DESIGN

PRODUCT DESIGN

MANUFACTURING PROCESSES SLECTION

Material CharacteristicsMaterial Characteristics Workpiece CharacteristicsWorkpiece Characteristics Dimensional RequirementsDimensional Requirements Tolerance RequirementsTolerance Requirements Surface Finish Surface Finish

RequirementsRequirements Production VolumeProduction Volume Production RateProduction Rate Lead TimeLead Time CostCost

PRODUCT BUILD

Operations SequencingOperations Sequencing ToolingTooling

– DesignDesign– Build Build – Installation and TestInstallation and Test

Facilities and MachinesFacilities and Machines Continuous ImprovementContinuous Improvement

PRODUCT DESIGN

MATERIALS SELECTION

PRODUCT BUILD

MANUFACTURING PROCESSES SLECTION

VALUE ENGINEERING

Tied all together through Tied all together through “Value Engineering”“Value Engineering”

Value Engineering: A system that evaluates each step in product design, materials selection, process selection and operations of fabrication so as to manufacture a product that performs its intended functions and has the lowest possible cost.

Manufacturing Processes FlowManufacturing Processes FlowRaw

Materials

Primary Processes

Secondary Processes

Finishing Processes

Finished Product

Operations SequencingOperations Sequencing

Machinery and FacilitiesMachinery and Facilities

What machines are required for build What machines are required for build of each designed component?of each designed component?

Make of Buy?Make of Buy? Will assembly be automated?Will assembly be automated? Where will machines be located?Where will machines be located? Etc.Etc.

Operations SequencingOperations Sequencing

ToolingTooling

ObjectiveObjective – Increase productivity – Increase productivity while decreasing cost and while decreasing cost and maintaining or improving overall maintaining or improving overall quality of the product.quality of the product.

What tooling is required to support What tooling is required to support the overall manufacturing process?the overall manufacturing process?– DetailDetail– AssemblyAssembly

Operations SequencingOperations Sequencing

Measurement ParametersMeasurement Parameters

What set-up time is associated with What set-up time is associated with production of each detail part and production of each detail part and assembly?assembly?

What cycle time is associated with each What cycle time is associated with each step in the build cycle for each part and step in the build cycle for each part and assembly?assembly?

What productivity measurements are What productivity measurements are being used to continuously improve the being used to continuously improve the product design and the build process?product design and the build process?

Operations SequencingOperations Sequencing

Design of ToolingDesign of Tooling

Conclusion Conclusion

Product Build is a precision controlled Product Build is a precision controlled process of making and assembling process of making and assembling detail parts or components, all tooled detail parts or components, all tooled to exacting tolerances, into a final to exacting tolerances, into a final product of total tolerance product of total tolerance accumulation equal to, or closer than accumulation equal to, or closer than engineering requirements. engineering requirements.

Conclusion Conclusion

The overall accuracy of a The overall accuracy of a manufactured product is determined manufactured product is determined by the accuracy of the tooling by the accuracy of the tooling designed and built to aid the build designed and built to aid the build process of each detail component process of each detail component and the assembly tooling designed and the assembly tooling designed and built to hold the components in and built to hold the components in the correct relation until they are the correct relation until they are assembled.assembled.

Conclusion Conclusion

Fit, Performance, and Service Life Fit, Performance, and Service Life requirements of a product are defined in requirements of a product are defined in the design stage.the design stage.

Manufacturing Processes and Tooling Manufacturing Processes and Tooling ultimately ultimately controlscontrols::– Fit = How efficiently a product can be Fit = How efficiently a product can be

assembledassembled– Performance = Both if and how a product Performance = Both if and how a product

worksworks– Service Life = How long a product worksService Life = How long a product works

PRODUCT DESIGN

MATERIALS SELECTION

PRODUCT BUILD

MANUFACTURING PROCESSES SLECTION

VALUE ENGINEERING

Design-to-Build InterrelationshipsDesign-to-Build Interrelationships

Value Engineering: A system that evaluates each step in product design, materials selection, process selection and operations of fabrication so as to manufacture a product that performs its intended functions and has the lowest possible cost.

Questions?Questions?

Comments?Comments?