© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Manufacturing Processes Manufacturing Processes for Engineering Materials for Engineering Materials
(5(5thth Edition in SI Units) Edition in SI Units)
Chapter 1: IntroductionChapter 1: Introduction
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
What is Manufacturing?
• Manufacturing is the process of converting raw materials into products.
• Nations with largest GDP growth concentrated on high value-added products, such as automobiles and machinery.
• Labour intensive products such as clothing and toys are concentrated in countries where labour rates are lower.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Product Design and Concurrent Engineering• Traditionally design and
manufacturing activities have taken place sequentially.
• Design process requires a clear understanding of the functions and the performance expected of that product.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Product Design and Concurrent Engineering• Concurrent or simultaneous
engineering is a systematic approach integrating the design and manufacture of products.
• It optimizes all elements involved in the life cycle of the product.
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Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Design for Manufacture, Assembly, Disassembly & Service
• Design for manufacture (DFM) integrates product design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance.
• Assembly is an important phase of the overall manufacturing operation.
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Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Environmentally Conscious Design,Sustainable Manufacturing & Product Life Cycle
• Design for recycling (DFR) and Design for the environment (DFE) anticipates the negative environmental impact during initial stages of design.
• The basic guidelines for sustainable manufacturing are:1. Reducing waste of materials2. Reducing use of hazardous materials3. Proper disposal of all waste4. Improvements in waste treatment and in recycling
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Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Environmentally Conscious Design,Sustainable Manufacturing, & Product Life Cycle
Product Life Cycle (PLC)• Consists of the stages that a product goes through to its
ultimate disposal and recycling.
Product Life Cycle Management (PLCM)• It is defined as the strategies employed by the
manufacturer as the product goes through its life cycle.
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Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Selecting Materials
The following are the factors in selection of materials:1. Material Substitution2. Material Properties3. Cost and Availability4. Service Life and Recycling
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Selecting Manufacturing Processes
Processing methods for materials can be listed as follows:
1. Casting2. Forming and shaping3. Machining4. Joining5. Micromanufacturing and
nanomanufacturing6. Finishing
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Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Selecting Manufacturing Processes
Part Size and Dimensional Accuracy• Size, thickness and shape
complexity of a part have a major bearing on the process selected.
• The size and shape of manufactured products also vary widely.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Selecting Manufacturing Processes
Manufacturing and Operational Costs• Lead time required to begin production and the tool and
die life are of major importance.• Quantity of parts and production rates determine the
processes that are used and the economics of production.
Net-Shape Manufacturing• Additional finishing operations might be needed for
finished parts or products to desired specifications
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Integrated Manufacturing
Computer-integrated manufacturing has the capability for:1. improved responsiveness to demand and product
modification2. better use of materials and resources 3. better control of manufacturing operation 4. manufacturing of high quality products at a lower cost
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Integrated Manufacturing
Some examples:1. Computer numerical control (CNC)2. Adaptive control (AC)3. Industrial robots4. Automated handling5. Automated and robotic assembly systems6. Computer-aided process planning (CAPP)7. Group technology (GT)8. Just-in-time production (JIT)
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Lean Production and Agile ManufacturingLean production or lean manufacturing involves1. assessment of each activity regarding the efficiency and
effectiveness of its operations2. efficiency of the machinery and equipment used in the
operation 3. number of personnel involved in a particular operation 4. thorough analysis to reduce cost of each activity
Agile manufacturing is ensuring flexibility in manufacturing so that it can respond to changes in demand and customer needs.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Quality Assurance and Total Quality Management
• Product quality influences the marketability of a product and customer satisfaction.
• Product integrity is defined by the degree to which a product is suitable for its purpose, market need, life expectancy and ease of use.
• Human-factors engineering and ergonomics are also important in the design and manufacture of safe products.
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Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Manufacturing Costs and Global Competitiveness
• Cost of a product is taking into consideration the product’s marketability and customer satisfaction.
• Major impact on manufacturing includes:1. Global competition2. Market conditions fluctuated widely3. Customers demand4. Product complexity
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 1: IntroductionChapter 1: IntroductionManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
General Trends in Manufacturing
Materials• The trend is for better control of material overall
properties while keeping costs low.
Processes, Equipment, and Systems.• A major impact on the efficiency and reliability of all
manufacturing processes and equipment.
