Thapathali Campus, Institute of Engineering
Manufacturing
Engineering
lecture - 1 & 2
Introduction to manufacturing
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Introduction to manufacturing
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
What is manufacturing?
Although the basis of manufacturing can be traced back as far as 50004000 BC, the
word manufacture did not appear until 1567, with manufacturing appearing over 100
years later in 1683 A.D
the Latin words manus meaning hand & facere meaning to make
manufactus meaning made by hand or hand-made
factory was derived from the now obsolete word manufactory
manufacturing is defined as (DeGarmoet al., 1988): the conversion of stuff into things.
Collins English Dictionary(1998): processing or making (a product) from raw materials, especially as a large scale operation
using machinery.
In a modern context: the making of products from raw materials using various processes, equipment, operations and
manpower according to a detailed plan.
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Historical Development of Material and Manufacturing Process
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
History of Manufacturing (1700-1960)
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
History of Manufacturing (1960-2000s)
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Assignment 1
Describe briefly about
I. Forming and shaping Technique
II. Joining Process technique
III. Tools and manufacturing system.
which are mentioned in the lecture slide titled Historical Development of
Material and Manufacturing Process
You should include the working principle and field of applications with
essential figures/ diagrams.
Submission Date 9th Jestha, 2074
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
What is a manufacturing system?
A system in which raw materials are processed from one form into another, known as a product, gaining a higher
or added value in the process and thus creating wealth in the form of a profit.
Basic model of manufacturing system adding value
Added value can be defined as (ICMA, 1974): The increase in market value resulting from an alteration of the
form, location or availability of a product, excluding the cost of materials and services. form of a profit.
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Inputs and outputs of a manufacturing
system
Inputs and outputs of a manufacturing system
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Common characteristics of a
manufacturing system
Regardless of the nature of the manufacturing organization or the
product being manufactured, all manufacturing systems have a
number of common characteristics, which are:
I. All systems will have specific business objectives to meet in the
most cost-effective manner.
II. All systems consist of an integrated set of sub-systems, usually
based on functions, which have to be linked according to the
material processing.
III. All systems must have some means of controlling the sub
systems and the overall system.
IV. To operate properly, all systems need a flow of information and
a decision-making process.
It is must to be incorporated into the manufacturing system to
allow stable operation in the rapidly changing global market. The manufacturing system
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Developing a manufacturing strategy
Developing a manufacturing strategy
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Manufacturing organizational structures
Sales and marketing:
to ensure a steady flow of orders and consolidate and expand the
organizations share of the market
Addition job : sales forecasting, order processing, market research, servicing
and distribution.
Engineering:
product design, research and development (R&D) and the setting of
specifications and standards.
Human resources
recruitment, training and development, labor relations, job evaluations and
wages.
Finance and accounts
Capital financing, budget setting and investment analysis.
with the keeping of financial records including cost accounting, financial
reporting and data processing.
Purchasing
acquisition of materials, equipment and service, satisfy the supply need
ensure the quality and quantity of supplies through vendor rating.
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Manufacturing organizational structures
Manufacturing
Production planning manufacturing plans such as the master production
schedule (MPS) and the materials requirements plan (MRP).
Quality assurance to ensure that products are being made to the required
specification.
Plant maintenance with the responsibility of ensuring that all equipment
and machinery is maintained at an appropriate level for its use.
Industrial engineering responsibilities include the determination of work
methods and standards, plant layouts and cost estimates.
Manufacturing engineering whose responsibilities includes manufacturing
systems development, process development, process evaluation and
process planning.
Production/materials control coordinate the flow of materials and work
through the manufacturing plant (work-in-progress). Stores will usually be
included in this function.
Production whose responsibility it is to physically make the product.
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
A functional structure
A functional structure
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Organizational management levels
Strategic level
This level is usually associated with senior management.
Involves the setting of short- and long-term business objectives that will
give the organizational competitive advantage over other similar
organizations.
Tactical level
This level is associated with middle management.
The main function of this level is to develop the plans by which the
business objectives can be met using the organization resources.
Operational level
This level is the frontline management and the main function of this
level is to ensure the everyday operations are planned and monitored.
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Categories of manufacturing system
1. Continuous process manufacturing
1. Discrete manufacturing.
1. project manufacture
2. jobbing shop manufacture
3. batch manufacture
4. mass/flow manufacture
Continuous manufacture
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Product variety versus quantity for traditional
manufacturing systems
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Processing strategies
process decision is further linked to four distinct
strategies within manufacturing
make to stock (MTS)
assemble to order (ATO)
make to order (MTO)
engineer to order (ETO).
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Comparison of MTS, ATO and MTO/ETO
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Processing strategies
Relationship between manufacturing system, product variety and processing strategy
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Comparison of MTS, ATO and MTO/ETO
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Plant layout
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Plant layout
The physical arrangements of departments, workgroups within
departments, workstations, machines and stock-holding points within a
manufacturing facility.
Plant layout design
Plant facility systems design considers the
structural systems, heating, ventilation and air
conditioning (HVAC) and general services, that
is, water, electrics, lighting, etc.
Considers equipment and machinery within
the production area, all production related
areas and often personnel areas within the
facility.
Material handling systems design considers
the materials, personnel and equipment
handling systems required to support
production.
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Objective of Plant layout
The Minimize overall production time.
Minimize investment in equipment.
Utilize existing space most effectively.
Provide for employee convenience, safety and comfort.
Maintain flexibility of arrangement
Minimize Material handling cost.
Minimize variation in types of material handling equipment.
Facilitate the manufacturing process.
Facilitate the organizational structure
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Types of plant layout
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Product-focused layout
Product-focused layout
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Product-focused layout
Product-focused layout
Smooth and logical flow lines.
Small in process inventories.
Total production time/unit short.
Reduced material handling
Little operator skill, training simple.
Simple production planning & control .
Less space for work in transit and temporary
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Process-focused layout
Process-focused layout
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Process-focused layout
Process-focused layout
Better utilization of machines, hence fewer m/cs needed.
High degree of FLEXIBILITY with regard to equipment or manpower
allocation for specific tasks
Comparatively low investment in machines required.
Greater job satisfaction for operator.
Specialized supervision is possible.
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Hybrid layout
Hybrid layout
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Fixed position layout
Fixed position layout
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Production Space requirement
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Systematic Layout Planning(SLP) Muther (1961)
Data gathering
1 Identify Flow of 2 Activity Relationship
material
Analysis
3 Relationship
4 Space diagram 5 Space
requirements available
6 Space relationship
diagram
Search 7 Reasons to 8 Restrictions
modify
9 Layout alternatives
Selection 10 Evaluation
Department of Mechanical Engineering
Thapathali Campus, Institute of Engineering
Assignment 2
Design a plant layout for a manufacturing company.
You have liberty to choose the company
Final product can be
Juice, Vehicle ( Car, Bus, Heavy equipment), cigarette,
Aero plane, mobile phones, soap, cement, shoe, tyre,
beverage and so on
Repairing workshops for heavy equipment
Metal workshop for hydro power.
Prepare a report submit word file (hard copy is optional)
Submission date: 16th Jestha, 2074
Department of Mechanical Engineering
