Chapter 1

INTRODUCTION AND
OVERVIEW OF MANUFACTURING
Manufacturing Processes
© Fundamentals of Modern Manufacturing; Materials, Processes and Systems,
by M. P. Groover (Textbook)

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 INTRODUCTION AND
OVERVIEW OF MANUFACTURING

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems

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 1- What is manufacturing?
• Making things has been an essential activity of human
civilizations since before recorded history.
• Today, the term manufacturing is used for this activity.
• Manufacturing is the production of goods for use or sale
using labor and machines, tools, chemical and biological
processing.
• The term may refer to a range of human activity, from
handicraft to high tech, but is most commonly applied to
industrial production, in which raw materials are
transformed into finished goods on a large scale.

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 Manufacturing is Important

• Technologically
• Economically
• Historically

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Manufacturing - Technologically Important

What is technology?
Technology - the application of science to provide society
and its members with those things that are needed or
desired
Technology provides the products that help our society
and its members live better
What do these products have in common?
They are all manufactured
Manufacturing is the essential factor that makes technology
possible

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 Manufacturing - Economically Important

U.S. economy:

% of
Sector
GNP*
Manufacturing 20%

• Manufacturing is Agriculture, minerals, etc. 5%

one way by
Construction & utilities 5%
which nations
create material Service sector – retail, transportation, 70%
wealth banking, communication, education, and
government
* GNP= Gross Net Product

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Manufacturing - Historically Important
• Throughout history, human cultures
that were better at making things
were more successful

• Making better tools meant better

crafts & weapons

• To a significant degree, the history of

civilization is the history of humans'
ability to make things

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 What is Manufacturing?

• The word manufacture is derived from two Latin words

manus (hand) and factus (make); the combination means
“made by hand”

• Most modern manufacturing operations are accomplished by

mechanized and automated equipment that is supervised by
human workers

The three building blocks - materials, processes, and

systems - are the subject of modern manufacturing.

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 Manufacturing - Technologically

• Application of physical and chemical processes to alter the

geometry, properties, and/or appearance of a starting
material to make parts or products
• Manufacturing also includes assembly
• Almost always carried out as a sequence of operations

Figure 1.1 (a)

Manufacturing
as a technical
process

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 Manufacturing - Economically

• Manufacturing adds value to the material by

changing its shape or properties, or by combining it
with other materials (this is done by means of one
or more processing and/or assembly operations)

Figure 1.1 (b)

Manufacturing
as an economic
process

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 Manufacturing Industries
• Industry consists of enterprises and organizations
that produce or supply goods and services

Industries can be classified as:

Primary industries - those that cultivate and exploit natural
resources, e.g., farming, mining

Secondary industries - take the outputs of primary

industries and convert them into consumer and capital
goods - manufacturing is the principal activity, other
examples: construction, and electric power generation

Tertiary industries - service sector, eg banking

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Manufacturing Industries - continued

• Manufacturing includes several industries whose

products are not covered in this book; e.g.,
apparel, beverages, chemicals, and food
processing

• For our purposes, manufacturing means

production of hardware
– Nuts and bolts, forgings, cars, airplanes,
digital computers, plastic parts, and ceramic
products

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 Production Quantity Q

• The quantity of products Q made by a factory has an

important influence on the way its people, facilities,
and procedures are organized
• Annual production quantities can be classified into three ranges:

Production range Annual Quantity Q

Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of

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 Product Variety P

• Product variety P refers to different product

types or models produced in the plant.

• Different products have different features

– They are intended for different markets
– Some have more parts than others

• When the number of product types made in the

factory is high, this indicates high product
variety

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P versus Q in Factory Operations

• Figure 1.2 P-Q Relationship

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 P versus Q in Factory Operations
Examples:

Q P

Shampoo bottles:

Q is high (The company manufactures millions of shampoo bottles per year)

P is low (It only manufactures a couple of product types or models)

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 P versus Q in Factory Operations

Examples:

Q P

Aircrafts:
Q is low (The company manufactures few aircrafts per year)
P is high (Each aircraft has a lot of pieces or product types or models)

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More About Product Variety

• Although P is a quantitative parameter, it is much

less exact than Q because details on how much
the designs differ is not captured simply by the
number of different designs
• Soft product variety - small differences
between products, e.g., between car models
(Toyota Corolla and Camry) made on the same
production line, with many common parts among
models
• Hard product variety - products differ
substantially, e.g., between a small car and a
large truck, with few common parts (if any)

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2- Materials in
Manufacturing

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 Materials in Manufacturing

• Most engineering materials can be classified

into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
• Their chemistries and also their mechanical and physical
properties are different
• These differences affect the manufacturing
processes that can be used to produce products
from them

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 1. Metals

• Usually alloys, which are composed of two or more

elements, at least one of which is metallic

Two basic groups:

Ferrous metals - based on iron, comprises about
75% of metal tonnage in the world:
Steel = Fe-C alloy (0.02 to 2.11% C)
Cast iron = Fe-C alloy (2% to 4% C)

Nonferrous metals - all other metallic elements

and their alloys: aluminum, copper, magnesium,
nickel, silver, tin, titanium, etc.

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 2. Ceramics
Compounds containing metallic (or semi-metallic) and
nonmetallic elements.
• Typical nonmetallic elements are oxygen, nitrogen,
and carbon

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2. Ceramics

 For processing, ceramics divide into:

1. Crystalline ceramics – includes:
 Traditional ceramics, such as clay
(hydrous aluminum silicates)
 Modern ceramics, such as alumina
(Al2O3)

2. Glasses – mostly based on silica (SiO2)

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 3. Polymers

Compound formed of repeating structural units called

mers, whose atoms share electrons to form very large
molecules

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 3- Polymers
 Three categories:
1. Thermoplastic polymers - can be
subjected to multiple heating and
cooling cycles without altering
molecular structure
2. Thermosetting polymers - molecules
chemically transform (cure) into a rigid
structure – cannot be reheated
3. Elastomers - shows significant elastic
behavior

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 In addition- Composites
• Nonhomogeneous mixtures of the other three basic types rather
than a unique category

Figure 1.3 Venn diagram of

three basic material
types
plus composites

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 Composites
• Material consisting of two or more phases that are
processed separately and then bonded together to achieve
properties superior to its constituents
Phase - homogeneous mass of
material, such as grains of identical
unit cell structure in a solid metal

Usual structure consists of particles or

fibers of one phase mixed in a second
phase

Properties depend on components,

physical shapes of components, and
the way they are combined to form
the final material

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 Composites

The Composites Institute (IVW) manufactures this ultra-light

Canyon F10 has been the basis for developing the lightest
roadworthy racing bike in the world.

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 INTRODUCTION AND
OVERVIEW OF MANUFACTURING

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production System

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3- Manufacturing Processes

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Manufacturing Processes
• Two basic types:
1. Processing operations - transform a work
material from one state of completion to
a more advanced state
– Operations that change the geometry,
properties, or appearance of the
starting material

2. Assembly operations - join two or more

components to create a new entity

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Figure 1.4 Classification of manufacturing processes

D
2

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Processing Operations

• Alters a material’s shape, physical properties, or

appearance in order to add value
• Three categories of processing operations:
1. Shaping operations - alter the geometry of
the starting work material
2. Property-enhancing operations - improve
physical properties without changing shape
3. Surface processing operations - to clean,
treat, coat, or deposit material on exterior
surface of the work

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A
Shaping Processes – Four Categories

1. Solidification processes - starting material is a

heated liquid or semifluid
2. Particulate processing - starting material
consists of powders
3. Deformation processes - starting material is a
ductile solid (commonly metal)
4. Material removal processes - starting material
is a ductile or brittle solid

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 A
1- Solidification Processes

• Starting material is heated sufficiently to transform it into a

liquid or highly plastic state
• Examples: metal casting, plastic molding

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 A
2- Particulate Processing
• Starting materials are powders of metals or
ceramics
• Usually involves pressing and sintering, in which
powders are first compressed and then heated to bond
the individual particles
Steps: Pressing and sintering

Sintering is a method for making

objects from powder, by heating the
material (below its melting point) until its
particles adhere to each other.
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 A
3- Deformation Processes

• Starting workpart is shaped by application of forces that

exceed the yield strength of the material
• Examples: (a) forging, (b) extrusion

A press machine performs extrusion.

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A
4- Material Removal Processes
• Excess material removed from the starting piece so
what remains is the desired geometry
• Examples: machining such as turning, drilling, and
milling; also grinding and nontraditional processes

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A
Waste in Shaping Processes

• Desirable to minimize waste in part shaping

– Material removal processes are wasteful in unit
operations, simply by the way they work
– Most casting, molding, and particulate processing
operations waste little material

• Terminology for minimum waste processes:

– Net shape processes - when most of the starting
material is used and no subsequent machining is
required
– Near net shape processes - when minimum amount of
machining is required

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 B
Property-Enhancing Processes

• Performed to improve mechanical or physical properties

of work material
• Part shape is not altered, except unintentionally
– Example: unintentional warping of a heat treated part

• Examples:
– Heat treatment of metals and glasses
– Sintering of powdered metals and ceramics

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C
Surface Processing Operations

• Cleaning - chemical and mechanical processes

to remove dirt, oil, and other contaminants
from the surface
• Surface treatments - mechanical working such
as sand blasting, and physical processes like
diffusion
• Coating and thin film deposition - coating
exterior surface of the workpart

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D
Assembly Operations
• Two or more separate parts are joined to
form a new entity
• Types of assembly operations:
1. Joining processes – create a permanent
joint
 Welding, brazing, soldering, and
adhesive bonding
2. Mechanical assembly – fastening by
mechanical methods
 Threaded fasteners (screws, bolts and
nuts); press fitting, expansion fits

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Production Systems

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 Production Systems
• People, equipment, and procedures used for the
combination of materials and processes that
constitute a firm's manufacturing operations
• A manufacturing firm must have systems and procedures
to efficiently accomplish its type of production

Two categories of production systems:

1. Production facilities
2. Manufacturing support systems

Both categories include people (people make the systems work)

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 Production systems

Production systems

Manufacturing
Production facilities
support systems
Low production: Job shop
Manufacturing engineering
Medium production: Batch production
Production planning and
and cellular manufacturing
control
High production: quantity production
Quality control
and flow line production

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 1- Production Facilities

• The factory, production equipment, and material

handling systems
• Production facilities "touch" the product
• Includes the way the equipment is arranged in the
factory - the plant layout
Equipment usually organized into logical groupings, called
manufacturing systems

Examples:
Automated production line
Machine cell consisting of an industrial robot and
two machine tools

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 Facilities versus Product Quantities
• A company designs its manufacturing systems and
organizes its factories to serve the particular mission
of each plant

• Certain types of production facilities are recognized as the most

appropriate for a given type of manufacturing:
1. Low production – 1 to 100
2. Medium production – 100 to 10,000
3. High production – 10,000 to >1,000,000
• Different facilities are required for each of the three quantity
ranges

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 Low Production
• Job shop is the term used for this type of production
facility
• A job shop makes low quantities of specialized and
customized products
– Products are typically complex, e.g., space capsules,
prototype aircraft, special machinery
• Equipment in a job shop is
general purpose

• Labor force is highly skilled

• Designed for maximum

flexibility

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 Medium Production
• Two different types of facility, depending on product
variety:

Batch production:
– Suited to hard product variety
– Setups required between batches

Cellular manufacturing:
 Suited to soft product variety
 Worker cells organized to process parts
without setups between different part styles

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 High Production

• Often referred to as mass production

– High demand for product
– Manufacturing system dedicated to the production
of that product

• Two categories of mass production:

1. Quantity production
2. Flow line production

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 Hard vs Soft Product variety
• Hard product variety is when the products differ
substantially.
• In an assembled product, hard variety is
characterized by a low proportion of common
parts among the products; in many cases, there
are no common parts.
• Soft product variety is when there are only small
differences between products.
• There is a high proportion of common parts
among assembled products whose variety is soft.
 Quantity Production

Mass production of single parts on single machine or small

numbers of machines

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 Quantity Production

 Typically involves standard machines equipped with

special tooling

 Equipment is dedicated full-time to the production of one

part or product type

 Typical layouts used in quantity production are process

layout and cellular layout

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 Flow Line Production

Multiple machines or workstations arranged in sequence, e.g.,

production lines

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 Flow Line Production

 Product is complex
 Requires multiple processing and/or assembly
operations
 Work units are physically moved through the sequence to
complete the product
 Workstations and equipment are designed specifically for
the product to maximize efficiency

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A spectacular scene in steelmaking is charging of a basic oxygen furnace, in
which molten pig iron produced in a blast furnace is poured into the BOF.
Temperatures are around 1650°C (3000 ° F).

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A machining cell consisting of two horizontal machining centers supplied by
a in-line pallet shuttle (photo courtesy of Cincinnati Milacron).

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Metal chips fly in a high
speed turning operation
performed on a computer
numerical control turning
center (photo courtesy of
Cincinnati Milacron).

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Photomicrograph of the cross section of multiple coatings of
titanium nitride and aluminum oxide on a cemented carbide
substrate (photo courtesy of Kennametal Inc.).

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 A batch of silicon wafers enters a furnace heated to 1000°C
(1800°F) during fabrication of integrated circuits under clean room
conditions (photo courtesy of Intel Corporation).

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Two welders perform arc
welding on a large steel
pipe section (photo
courtesy of Lincoln Electric
Company).

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Automated dispensing of
adhesive onto component
parts prior to assembly
(photo courtesy of EFD, Inc.).

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Assembly workers on an
engine assembly line
(photo courtesy of Ford Motor
Company).

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Assembly operations
on the Boeing 777
(photo courtesy of Boeing
Commercial Airplane Co.).

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