Introduction to Manufacturing

1. Introduction to Manufacturing General Manufacturing Processes Engr.-20.2710 Instructor - Sam Chiappone

2. Introduction to Manufacturing • Observe the objects around you: • How did they become what they are? • What important role does manufacturing play in society? • How do we define manufacturing? • Manufacturing is the ability to make goods and services to satisfy societal needs • Manufacturing processes are strung together to create a manufacturing system (MS)

3. 1910’s 1920’s 1930’s 1900’s Society & Manufacturing 1940’s 1990’s 1950’s 1980’s 1960’s 1970’s

4. Types of Goods • Consumer Goods • Items which are purchased directly by consumers • Consumer electronics • Clothing • Producer Goods • Items which are manufactured for other companies to produce products from • Steel Mills - coil stock • Machine tool builders - Milling Machines • Automotive suppliers - Taillight assemblies

5. Products • Fabricating - Manufacturing of products from components, pieces, or sub-assemblies. Separate discrete items such as machined parts, bolts, nuts etc. are fabricated. • Processing - Manufacturing a product in a continuous series of operation . Examples include wire, beverages, chemicals etc.

6. Manufacturing a Product • Production systems include • People • Money • Equipment • Materials • Supplies • Markets • Management • Manufacturing System • All aspects of commerce

7. Manufacturing a Product • The Manufacturing System Figure 1-4 The functions and systems of the production system, which includes (and services) the manufacturing system. The functional departments are connected by formal and informal information systems designed to service the manufacturing system that produces the goods.

8. Manufacturing a Product • The Manufacturing System • Collection of operations and processes to produce a desired product or component • Design or arrangement of the manufacturing processes

9. Roles of People in Mfg. • Design engineer responsibilities • What the design is to accomplish • Assumptions that can be made • Service environments the product must withstand • Final appearance of the product • Product designed with the knowledge that certain manufacturing processes will be used

10. Roles of People in Mfg. • Manufacturing engineer responsibilities • Select and coordinate specific processes and equipment • Supervise and manage their use • Industrial (Manufacturing) engineer • Manufacturing systems layout • Materials engineers • Specify ideal materials • Develop new and better materials

11. Roles of People in Mfg. • Technicians • QC, machine set-up, machine maintenance, machine repair, and system integration • Machinist and Tool Makers • Producing close tolerance parts and tooling to specifications • Operators • Running production parts and quality

12. Aspects of a Manufacturing System • Mfg. Processes • The method (s) used to convert a product from one form to another- example metal removal. A process typically involves a sequence of steps or operations.

13. Characteristics of Process Technology • Mechanics • Economics or costs • Time Spans • Constraints • Uncertainties and process reliability • Skills • Flexibility • Process capability

14. Aspects of a Manufacturing System • Operations • Distinct action to produce a desired result or effect • Categories of operations • Materials handling and transport • Processing • Drilling, tapping, turning, milling, injecting • Packaging • Inspecting and testing • Storing

15. Aspects of a Manufacturing System Figure 1-6 The component called a pinion shaft is manufactured by a “sequence of operations” to produce various geometric surfaces.

16. Aspects of a Manufacturing System • Job and station • Job is a group of related operations generally done at one station • Station is the location or area where production is done • Treatments operate continuously on a workpiece • Heat treating, curing, galvanizing, plating, finishing, chemical cleaning, painting • Tools, tooling and workholders • Lowest mechanism in the production is a tool • Used to hold, shape or form the unfinished product • Tooling for measurement and inspection • Rulers, calipers, micrometers, and gages • Precision devices are laser optics or vision systems that utilize electronics to interpret results

17. Factory Layouts • Job Shop • Flow Shop • Linked-Cell Shop • Project Shop • Continuous Process

18. Factory Layouts Figure 1-15 Different manufacturing system designs produce goods at different production rates.

19. Seven Basic Processes • Casting • Forming • Machining • Joining and Assembly • Surface Treatment • Heat Treatment • Other

20. Casting • Molten metal fills a cavity in a mold. • Quick method to transform a raw material into a desired shape. • Two types of casting methods: • Expendable mold • Sand casting • Permanent mold • Die casting • Plastic, composite manufacturing, and PM

21. Forming & Shearing • Changing materials into a desired shape by: • Squeezing • Bending • Shearing • Drawing • Utilizes Materials that have been previously cast or molded • Performed at “cold” or “hot” temperatures • cold = room temp to .3 of the melt temperature material • hot = above .3 of the melt temperature of the material

22. Metal Removal - Machining • Seven basic processes • Shaping • Turning • Drilling • Milling • Sawing • Broaching • Abrasive machining • Non-Traditional • Examples: EDM & Water-Jet

23. Joining • Mechanical Fastening • Welding • Adhesive bonding • Assembly

24. Surface Treatment • Aesthetic requirements • Painting • Product requirements • Safety • Burrs • Surface treatment • chemical plating to resist rust

25. Heat Treatment • Altering the mechanical properties of a material. • Strength • Wear resistance • Resistance to penetration

26. Other • Inspection • Packaging • Transportation • Waste disposal • Scrap • Chemical by-products

27. Product Life Cycle Cost

28. Changing World Competition • Globalization has impacted manufacturing • Worldwide competition for global products and their manufacture • High tech manufacturing for advanced technology • New manufacturing systems, designs, and management

29. New Manufacturing Systems • Toyota Production System • Lean manufacturing system • 100% good units flow without interruption • Integrated quality control • Responsibility for quality is given to manufacturing • Constant quality improvement

30. How Do We Plan For Manufacturing? • Definition of a need • Conceptual design • Review of initial design • Design Prototype • Production plan • Resource specifications • Manufacturing Prototype • Manufacturing • Inspection--quality checks • Packaging - shipping • Customer response