Introduction to Manufacturing Processes and Product Development

1. Introduction to Industrial Engineering Yosef Manik Department of Industrial Engineering President University School of Engineering yosef.manik@president.ac.id

2. Manufacturing Process

3. Customer Suppliers Marketing/ Sales Product Design Process Design Delivery Planning Production Planning Material Planning Shipping of F/G Fabrication Receiving of R/M Quality Control Process Control

4. What is Manufacturing? Manufacturing is the process of converting raw materials into products.

5. Product Development: from Design to Completion • 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.

6. Product Life Cycle

7. Product Development: from Design to Completion • 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.

8. Selecting Materials • Metal • - Ferrous materials (carbon steels, etc) • - Nonferrous materials (aluminum, magnesium, copper, etc.) • (2) Plastics : thermoplastics, thermoset, and elastomers (rubbers) • (3) Ceramics: glass ceramics, glasses, graphite, diamond • (4) Composite materials : reinforced plastics, metal-matrix and ceramic-matrix composites

9. Selecting Materials • The following are the factors in selection of materials: • Material Substitution • Material Properties • Cost and Availability • Service Life and Recycling

10. Parts can be made using various manufacturing processes… e.g., Casting vs. Metal forming process Selecting an Appropriate Manufacturing Process is Important!!

11. Selecting Mfg. 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.

12. Selecting Mfg. 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

13. Function in Prod. System Basic Processes : giving the work material initial form; e.g.: metal casting, plastic molding Secondary Processes : giving the work material its final desired geometry; e.g.: machining (turning, drilling, milling, etc.) Operation to enhance physical properties: Improving physical properties of the material (e.g.: hardness), without changing the material geometry, instead; e.g.: heat treatment Finishing operations: improving appearance or protecting the surface of the work-part; e.g.: painting, coating Assembling: joining components into a final product; e.g.: mechanical fastening, welding

14. Case Study: Alloy Wheel

15. Environmental Consideration • 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: • Reducing waste of materials • Reducing use of hazardous materials • Proper disposal of all waste • Improvements in waste treatment and in recycling