Dr. HABEEB ALANI Office: BN-Block, Level-3, Room-088 Email: hbuni61@yahoo Ext. No.: 7292

1. Dr. HABEEB ALANI Office: BN-Block, Level-3, Room-088 Email: hbuni61@yahoo.com Ext. No.: 7292 Lecturer: Dr. HABEEB ALANI

2. University TENAGA National College Of EngineeringMechanical DepartmentAcademic Year – 2009-2010 Lecture Note Lecturer: Dr. HABEEB ALANI

3. Introduction To Manufacturing andManufacturing Systems Lecturer: Dr. HABEEB ALANI

4. Japanese sword reworked for hard and soft metal parts Lecturer: Dr. HABEEB ALANI

5. Space Shuttle Lecturer: Dr. HABEEB ALANI

6. The Transistor Lecturer: Dr. HABEEB ALANI

7. Everyday products Lecturer: Dr. HABEEB ALANI

8. Manufacturing derived from: “Manufacturing” (derived from Latin)= “manus” (hand) + “factus” (made) = “made by hand” Lecturer: Dr. HABEEB ALANI

9. Definition of Manufacturing: Manufacturing is an industrial activity that converts raw materials to useful products by the means of machines. Lecturer: Dr. HABEEB ALANI

10. Development of Manufacturing depends on: Materials 1 Machine-Tools 2 Computer-aided Design (CAD)&Computer-aided mfg (CAM). 3 Robotics 4 Electronics 5 Lecturer: Dr. HABEEB ALANI

11. Evolution of the Enterprise 1-1 Evolution Steps: Hand Tool 1 Animals 2 Water Power 3 Steam Engines 4 Electrical Motors 5 Lecturer: Dr. HABEEB ALANI

12. The MFG System: OUTPUT INPUT PROCESS Lecturer: Dr. HABEEB ALANI

13. INPUT Energy Customer Demand HR Material Education Money R & D Lecturer: Dr. HABEEB ALANI

14. PROCESS Design Production Management Lecturer: Dr. HABEEB ALANI

15. OUTPUT Consumer Goods Capital Goods Quality Cost Effectiveness Lecturer: Dr. HABEEB ALANI

16. INPUT ` Money - Working Capital (Money for employee) • Fixed Capital (For machine tools and buildings) Lecturer: Dr. HABEEB ALANI

17. INPUT Energy - Electricity To run the machines - Compressed airTo run the pneumatic systems and clean machines and products - Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.) - GasTo use it in Furness, welding operations and boilers. Lecturer: Dr. HABEEB ALANI

18. PROCESS Design - Creating plans for new products • Lowering the product cost at maintained high quality Lecturer: Dr. HABEEB ALANI

19. PROCESS Production - Designated at the design stage - Machine tools types - Machining processes - People are selected at the design stage Lecturer: Dr. HABEEB ALANI

20. OUTPUT Products Goods - Consumers goods: People use them (Food, Cars, ….) - Capital goods: Products used to make other consumer goods (Machine tools, Plant, ….) Lecturer: Dr. HABEEB ALANI

21. TheClassification of basic Manufacturing 1-2 Job-lot Mass production Moderate a b c Lecturer: Dr. HABEEB ALANI

22. Mass Production Features: a - Goods are produced at a high volume for considerable period of time ( >100.000 parts per year). - Machine are not flexible (They are not able to produce other types of products). - Products of this type of mfg are the cheapest. Lecturer: Dr. HABEEB ALANI

23. Moderate production Features: b - Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year). - Multipurpose machine tools and CNC machine tools are usually used in this type of mfg. - Product Ex.: Tools, Moulds, Radio transmitters. Lecturer: Dr. HABEEB ALANI

24. Job-lot production Features: c - The plant does not any specific type of products but it is able to produce any type of product that the market is in need of. - Products move in lots between mfg processes (10-500 parts per lot). - Machine are more flexible and universal. - Product Ex: Airplanes, Automobile parts, and Plastic products . Lecturer: Dr. HABEEB ALANI

25. Organization for Manufacturing -A plant needs an affective organizing method for manufacturing in order to manage its resources / Employees Money Power Materials Machines . *A good mfg strategy is needed.See table 1.1 (Evolution of strategy mfg sys.. 1 2 3 4 5 Lecturer: Dr. HABEEB ALANI

26. Concurrent Engineering CE • It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes simultaneously. CE is not an enginee- ring discipline.- CE Objective: Optimizing the use of companyresources and reducingtime to market cycle. Lecturer: Dr. HABEEB ALANI

27. General CE phases for a new project: Technology and concept development: Ph.-1 Definition of customer requirement implementation. a Assessment of primary alternatives processes. b Development of required resources. c Preparation of product plan. d Lecturer: Dr. HABEEB ALANI

28. Product and Process Development and Prototype validation -CE Function: Ph.-2 This is the phase in which the CE team will Product improvement for assembly andmfg a Development the mfg and assembly processes b Establish baseline process technology c Establish program goals and risk-reduction plans freezing d Lecturer: Dr. HABEEB ALANI

29. Cont…… Ph.-2 Generally other project elements are addressed I this phase , such as financial business plans, product concept demonstration, freezing of engineering content, and final project approval. Note: Ph.-2 Lecturer: Dr. HABEEB ALANI

30. Process Validation and Product Design Confirmation : Ph.-3 This is the execution phase where The Production process and methods are finalized a Simulation and pilot runs are conducted to test critical steps b Machine and equipment are validated for production readiness, quality and performance c Lecturer: Dr. HABEEB ALANI

31. Production and continuous improvement : Ph.-4 - This face is the Acceleration of production floor into “ Full rated capacity”. This means: Attaining high product quality at the lowest costs. Lecturer: Dr. HABEEB ALANI

32. Design, Material and Production 1-3 • According to the existing machine tools and the designed product we choose the raw materials.On the other hands, according to the existing materials and required quality we choose the machine tools. Lecturer: Dr. HABEEB ALANI

33. - Efficiency of production : • In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive. Lecturer: Dr. HABEEB ALANI

34. Cont….. Efficiency of production • The quality and accuracy must be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable). Lecturer: Dr. HABEEB ALANI

35. - Economical production is determined by: A functional simple design that has appropriate quality (no more or less). 1 A material choice that represents the best compromise among physical properties, cost, and machinability. 2 The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost. 3 Lecturer: Dr. HABEEB ALANI

36. Engineering Materials Materials Metallic Non-Metallic Ferrous Organic Non-Ferrous Non- Organic Lecturer: Dr. HABEEB ALANI

37. Materials Application Chain Processing * SELECTION is the Critical Step for Technologists. Structure Properties Performance Selection Field Application Lecturer: Dr. HABEEB ALANI

38. Stress & Strain Dislocations & Deformation Elasticity & Plasticity Elastic Constants Mechanical Properties Lecturer: Dr. HABEEB ALANI

39. Mechanical Testing Mechanical Properties Strengthening Mechanisms Failure Analysis Tests Lecturer: Dr. HABEEB ALANI

40. Resistivity & Conductivity Electronic-Band Structure Semiconductivity Refraction & Reflection Transmission Electrical Properties Electrical Properties Lecturer: Dr. HABEEB ALANI

41. The Evolution of Materials Lecturer: Dr. HABEEB ALANI

42. Classes of Materials Basic Metals Ceramics Polymers Advanced Biomaterials Semiconductors Composites Lecturer: HABEEB ALANI

43. Materials that are normally combinations of "metallic elements". Metals usually are good conductors of heat and electricity. Metals are quite strong but malleable and tend to have a lustrous look when polished Metals Lecturer: Dr. HABEEB ALANI

44. Ceramics • Ceramics are generally compounds between Metallic and NONmetallic elements and include such compounds as: -Oxides -Nitrides -Carbides Ceramic materials developed for gas turbine rotors are used in aircraft and diesel engine parts. • Typically they are insulating and resistant to high temperatures and harsh environments. Lecturer: HABEEB ALANI

45. Plastics • Plastics (or polymers) are generally compounds based upon carbon and hydrogen (Organic Compounds). • They are very large molecular structures. • Usually they are low density and are not stable at high temperatures. Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, high-contrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for the backlight required in display technologies such as liquid crystal displays (LCDs). Lecturer: Dr. HABEEB ALANI

46. Semiconductors • SEMIconductors have electrical properties intermediate between Metallic conductors and Ceramic insulators. • Also, the electrical properties are strongly dependent upon small amounts of Impurities. Lecturer: Dr. HABEEB ALANI

47. Composites • Composites consist of more than one material type. • Fiberglass, a combination of glass and a polymer, is an example. Concrete and plywood are other familiar composites. • Many new combinations include ceramic fibers in a metal or polymer matrix. Lecturer: Dr. HABEEB ALANI

48. Composites Lecturer: Dr. HABEEB ALANI

49. Composites Hand bag Ghost airplane Graphite MatrixComposite Shaft Liquid MetalFacePlate Golf Clubs Lecturer: Dr. HABEEB ALANI

50. BioMaterials • Materials compatible with an organism (e.g. Humans) that can be used to make implants, prostheses, and surgical instruments. • Designed not to provoke rejection by our bodies (skin, blood, bone, etc.), they can be natural (collagen, cellulose, etc.) or synthetic (metallic, alloy, ceramic, plastic, and others). • Dental crowns and contact-lenses use biomaterials. Lecturer: Dr. HABEEB ALANI