Introduction
to
Manufacturing
Origin
Manufacture
Manus Factus
= hand = make
“Made by hand” accurately described the
fabrication methods that were used when the
English word “manufacture” was first coined
around 1567 A.D.
Industrial Revolution
Manufacturing Process Flow
Manufacturing Process Flow –
ISO 9001 (2008)
- Quality Management system
ISO/TS 16949 (2009)
- QMS for Automotive Production &
Relevant Service Parts Organizations
ISO 50001 (2011)
- Energy Management
ISO 14000 (2004)
- Environmental Management
Manufacturing in Economic Sense
Transformation of a material into a greater value
by processing it.
Main types of Industries
Primary Secondary Tertiary
Final Product
i. Consumer goods
- products purchased directly by consumers
e.g. Cars, clothes, TVs, tennis rackets
ii. Capital goods
- those purchased by companies to produce
goods and/or provide services
e.g. Aircraft, industrial computers, communication
equipment, medical apparatus, trucks, machine
tools, construction equipment
* For our purposes in this module, manufacturing
means production of selected parts / products.
e.g. Nuts and bolts, forgings, cars, airplanes, digital
computers, plastic parts, and ceramic products.
Other products which are manufactured include clothes,
books, food and etc. will not be covered in our current
module
Manufacturing Process Flow
Components of a Manufacturing Industry
•Mechanized equipments
•Automated equipments
Processes •Supervised by human workers
Systems
Modern
Manufacturing Plant
Material
Starting Materials
Metals
•Usually Alloys… What are alloys ?
•Ductile & Malleable
•Metal is divided into two basic groups:
1. Ferrous metals
Steel and cast iron
2. Nonferrous metals
Aluminum, copper, nickel, silver, tin, etc.
Charging a basic
oxygen furnace
in steelmaking:
Molten pig iron is
poured into the
furnace.
Temperatures
~1650°C.
Pig iron
Ceramics
- Advanced Ceramics such as alumina (Al2O3).
- Harder than metals but brittle.
Polymers
- Elastomers, thermoplastics, thermosetting
polymers.
Composites
Material consisting of 2 or more phases that are
processed separately and then bonded together to
achieve properties superior to its constituents
Components of a Manufacturing Industry
•Mechanized equipments
•Automated equipments
Processes •Supervised by human workers
Systems
Modern
Manufacturing Plant
Material
Classification of
Manufacturing Processes
I. Processing operations
or
II. Assembly operations
I. Processing operations
Three categories of processing operations:
Shaping operations - alter the geometry of
1.
the starting work material
Property enhancing operations - improve
2.
physical properties without changing shape
Surface processing operations - clean, treat,
3.
coat, or deposit material on surface of work
Solidification Particulate
processes - starting processing –
material is a heated starting material
liquid or semi fluid consists of
powders
a. Shaping Processes
Deformation Material removal
processes processes
- starting material -starting material
is a ductile solid is a ductile or
(commonly metal) brittle solid
Solidification Process
•Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
Casting process Product of Casting
Particulate Processing
Starting materials are (1) metal or ceramic powders,
•
which are (2) pressed and (3) sintered
Deformation Process
•Starting work part is shaped by application of
forces that exceed the yield strength of the material
• Examples:
(a) Forging and (b) Extrusion
Material Removal Process
Excess material removed from the starting piece
•
so what remains is the desired geometry
• Examples:
(a) Turning, (b) Drilling, & (c) Milling
CNC Milling
Metal chips fly in a
high speed turning
operation performed
on a computer
numerical control
turning center
(photo courtesy of Cincinnati
Milacron).
b. Property Enhancing Processes
Processes that improve mechanical or physical
properties of work material
• Examples:
Heat treatment of metals and glasses
▫
(tempered glass)
Cleaning
c. Surface Processing
Operations
Coating & Thin film
Surface deposition
-Electroplating
Treatments -PVD
-Painting
Photomicrograph of the cross section of multiple coatings
of titanium nitride and aluminum oxide on a cemented
carbide substrate (photo courtesy of Kennametal Inc.)
II. Assembly
Operations
Joining Processes
-Welding
-Brazing
Mechanical Assembly
- Threaded fasteners
-Soldering
-Adhesive Bonding
Two welders
perform arc
welding on a
large steel pipe
section (photo
courtesy of
Lincoln Electric
Company)
Automated
dispensing of
adhesive onto
component parts
prior to assembly
(photo courtesy of EFD, Inc.).
Components of a Manufacturing Industry
•Mechanized equipments
•Automated equipments
Processes •Supervised by human workers
Systems
Modern
Manufacturing Plant
Material
Production Systems
A manufacturing firm must have systems and
procedures to efficiently accomplish its production
• People
• Equipment
• Procedures
Used for the materials and processes that constitutes a firm’s
manufacturing operations
Production Systems
Production Manufacturing
Support
Facilities Systems
People make the system works!!!
Production Machines and Tooling's
Machine tools - power-driven machines used to
▫
operate cutting tools previously operated manually
Other production equipment:
▫
Presses
Forge hammers,
Plastic injection molding machines
A robotic arm performs
unloading and loading
operation in a turning
center using a dual
gripper
(photo courtesy of Cincinnati Milacron)
Production Facilities
Include the factory, production equipment, and
material handling systems
• Overall plant layout, arrangement of equipments.
Equipment usually organized into logical groupings,
•
called manufacturing systems.
Examples:
•
▫Automated production line
▫Machine cell consisting of an industrial robot and two
machine tools
Facilities vs Product Quantities
•Manufacturing systems of each plant is designed
to serve its purpose
[Link] production – 1 to 100
[Link] production – 100 to 10,000
[Link] production – 10,000 to >1,000,000
Manufacturing capability
is limited by:
i. Technological processing capability
ii. Physical product limitations
iii. Production capacity
i. Technological processing capability
Certain manufacturing processes are suited to
certain materials.
A machine shop cannot roll steel
▫
A steel mill cannot build cars
▫
ii. Physical Product Limitations
There are size and weight limitations on the parts
•
or products that can be made in the plant
• Product size and weight affect:
Production equipment
▫
Material handling equipment
▫
iii. Production Capacity
•Defined as the maximum quantity that a plant can
produce in a given time period
• Usually measured in terms of output units.
• Also called plant capacity
