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Engr 241 - Introduction to Manufacturing

Engr 241 - Introduction to Manufacturing. Introduction and Fundamentals. What is Manufacturing?. AKA “Production” Process of converting raw materials into products.

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Engr 241 - Introduction to Manufacturing

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  1. Engr 241 - Introduction to Manufacturing Introduction and Fundamentals

  2. What is Manufacturing? • AKA “Production” • Process of converting raw materials into products. • “Manufacturing is a collection of interrelated activities that includes product design and documentation, material selection, planning, production, quality assurance, management, and marketing of goods” (Rehg & Kraebber, 2005, p.4). Engr 241

  3. What is Manufacturing? • “…manufacturing is a value-adding activity, where the conversion of materials into products adds value to the original material” (Black & Kohser, 2008, p. V). • “Assembly is an important phase of the overall manufacturing operation and requires consideration of the ease, speed, and cost of putting parts together” (Kalpakjian & Schmid, 2005, p. 15). Engr 241

  4. Materials in Manufacturing • Metals - Ferrous (contain iron) and Nonferrous • Non-Metals – Plastics, Ceramics, Graphite, Diamond • Composite Materials. Engr 241

  5. Typical Manufacturing Processes • Casting/Molding (expendable & permanent molds) • Forming and Shaping (rolling, forging, extrusion and drawing, sheet forming, powder metallurgy) • Machining (material removal – cutting, turning, boring, drilling, milling, planing, grinding, etc.) • Joining (welding, brazing, soldering, diffusion bonding, adhesive bonding, mechanical joining) • Finishing (honing, lapping, polishing, deburring, surface treating, coating, plating) Engr 241

  6. Historical Milestones • 1712, Thomas Newcomen develops steam engine • 1775, Boring machine developed by Wilkinson (England) to produce cylinders for James Watt’s steam engine • 1785, Concept of interchangeable parts in guns by LeBlanc (France), however Eli Whitney (cotton gin, 1794) credited for IP concept in 1798 • 1800, Aessandro Volta (Italy) develops the battery Engr 241

  7. Historical Milestones • 1853, Sam Colt produced one of the largest gun mfg. co. with 1400 machine tools • 1876, Telephone by Alexander Graham Bell • 1879, Thomas Edison’s 40 hr light bulb • Early 1900’s, Henry Ford creates efficient assembly lines – first example of lean production Engr 241

  8. Historical Milestones • In the 1920s, Ford Motor Company’s operation embodied the key elements of scientific management (Frederick W. Taylor, 1856-1915): • standardized product designs • mass production • low manufacturing costs • mechanized assembly lines • specialization of labor • interchangeable parts • Fords centralized management approach led to the decline of FMC in the 1930’s – GM became the auto leader Engr 241

  9. Historical Milestones • 1920’s, John Baird develops Television • 1927-1932, researchers in the Hawthorne Studies realized human factors affect production • 1950’s – 1960, Lean Manufacturing revolution is born (Taiichi Ohno, Toyota’s chief production engineer) • 1961, Unimate, First robot in production – part of the automation revolution, human replacement concept • Early 1970’s, microprocessor technology developed Engr 241

  10. Traditional Design/Manufacturing (U.S.) • Sequentially, rather than concurrently (simultaneously) • Profits FIRST • Short Term Production • Top heavy Management • Machines are the solution to every problem – Automate your way to success • People need to be told what tasks to do, how to do tasks, and when to do tasks Manufacturing Design Engr 241

  11. Modern Design/Manufacturing (U.S.) • Long-Range Planning: set goals that provide the best ROI • Concurrent Engineering: Design and manufacturing are encompassed together • Lean Production: Elimination wasteful practices • Agile/Flexible Manufacturing: Ability to rapidly change from one part/product to another, quick response to demand Engr 241

  12. Modern Design/Manufacturing (U.S.) • Benchmarking: Set goals with respect to competition • Design for Manufacturing and Assembly (DFMA): Integrates design process with materials, manufacturing methods, process planning, assembly and testing, quality assurance. • Rapid Prototyping: Techniques to produce and analyze part models at low costs quickly • Trained people can make decisions and respond to manufacturing problems quicker than a hierarchical approach. Engr 241

  13. Modern Design/Manufacturing • Design for environment (DFE)/Design for Recycling (DFR): reduce waste, hazardous materials, reuse • Computer-Integrated Manufacturing: Supplier contact – monitoring system information as occurring • Autonomation – Mix of humans and automation Engr 241

  14. Manufacturing Goal? • The goal of any manufacturing organization is to make money. • To increase net profit - simultaneously increase both Return On Investment (ROI) and cash flow…to improve “The bottom line”. Engr 241

  15. Manufacturing’s #1 Task? *Customer Satisfaction* • Customers must be informed about products • Customers must be motivated to purchase products • Customers must be satisfied with the quality/performance of products • Customers must be satisfied with the price of products • Customers must be satisfied with product service *Companies will fail without these* Engr 241

  16. Manufacturing Trends • 1. Outsourcing – U.S. companies typically take advantage of lower labor costs found in other countries • 2. Manufacturing companies are restructuring to become lean producers – to respond faster to customer wants, to make goods cheaper and faster, to reduce labor-related injuries, to increase product quality. Companies that cannot adapt are out of business the next day. • 3. Products are becoming more varied/specialized while lot sizes are reducing. Long-term stocking of finished products is becoming less common. Engr 241

  17. Manufacturing Trends • 4. Consumer expectations include better quality, reliability – this drives the implementation of processes that can be controlled. Control = predictable outcomes and reduction of defects. • 5. Lead time reduction. Reducing time-to-market requires products to be designed for easy manufacturing and assembly. Flow approaches are becoming common. • 6. Worldwide competition. Products purchased today may be made anywhere in the world. Engr 241

  18. Manufacturing Trends • 7. Quality materials in = Quality out. Emphasis is being placed on materials that are safe to process, safe to consumers, pure and free of defects, recyclable, easy to process, and are reliable/predictable. • 8. An emphasis on continuous improvement of processes, materials, people, suppliers, quality, product. • 9. Computer advances have significantly influenced control and inspection systems in automated production, information technology communication/supplier relations, design platforms, machine reliability, and machine flexibility. Engr 241

  19. Questions to consider • 1. How important is manufacturing to the economy and your future? • 2. What are perceptions of manufacturing? • 3. What is continuous improvement in people? • 4. What are lead times? How are they reduced? • 5. What is value? • 6. What is quality? • 7. What is waste? Engr 241

  20. Countries Lacking Manufacturing Suffer Economically Impacting SOL • “Converting materials from one form to another adds value to them. The more efficiently materials can be produced and converted into the desired products that function with the prescribed quality, the greater will be the companies’ productivity and the better will be the standard of living of the employees.” (Black & Kohser, 2008, p. 1). • “A nation’s level of manufacturing activity is related directly to its economic health; generally, the higher the level of manufacturing activity in a country, the higher the standard of living of its people.” (Kalpakjian & Schmid, 2006, p. 1). Engr 241

  21. Manufacturing • Mfg companies contribute roughly 20% of GNP (value of goods & services produced) (Black & Kohser, 2008). Engr 241

  22. Manufacturing Requires & Therefore Creates Service Jobs: • Advertising/Marketing/Sales • Education/Training • Health Care & Insurance • Communication & • Distribution/Transportation • Utilities • Banking/Finance • This is evident in most metropolitan areas and select countries (goods and services are available – SOL is impacted) Engr 241

  23. Manufacturing Cost • “…manufacturing costs represent about 40% of a product’s selling price” (Kalpakjian & Schmid, 2006, p. 40). (Black & Kohser, 2008, p. 2). Engr 241

  24. Manufacturing – Relative People Costs • While cutting labor is often viewed as a cost-reduction practice, “Reductions in direct labor will have only marginal effects on the total people costs” (Black & Kohser, 2008, p. 3). Engr 241

  25. Manufacturing Product Lifecycle • Every product has a lifecycle – the stage of the lifecycle (maturity of the product) determines the form of manufacturing system in place (Job Shop –> Mass Production) • The demand for a product changes during the lifecycle –Demand is commonly known as Order Winning Engr 241

  26. Manufacturing Product Lifecycle (Rehg & Kraebber, 2005, p. 13). Engr 241

  27. Order Winning Criteria • “… are the minimal operational capabilities required to get an order” (Rehg & Kraebber, 2005, p. 13) • Typical OWC include Price, quality/reliability, delivery speed, innovation, after-sale service, flexible financing Engr 241

  28. Order Winning Criteria & Product Lifecycle • Order-winning criteria change during the product lifecycle • 1) In Startup/Introduction, product is new – low volume, customers enticed to become acquainted with products • 2) In Growth, innovation is typically the OWC, D>C, demand stresses company capacity, new buyers, corporate entry Engr 241

  29. Order Winning Criteria & Product Lifecycle • 3) In Maturity (maximum profits), D=C, price is often the OWC – standard designs of products. Companies try to lengthen the Maturity phase to increase ROI, Repeat buyers, corporate rivalry, intense marketing strategies • 4) In Commodity/Decline, demand for the standard product begins to drop and are replaced by newer improved products, company dropout, sales stabilize or fall Engr 241

  30. Manufacturing Product Lifecycle (Black & Kohser, 2008, p. 22). Engr 241

  31. Manufacturing Product Lifecycle (Black & Kohser, 2008, p. 22). Engr 241

  32. Manufacturing Product Lifecycle Examples Treated Lumber = Commodity Camera Film = Decline Diamond Ring = Commodity Computer Mouse = Commodity PEX Pipe = Maturation CD Player = Decline HDV Camcorders = Growth Engr 241

  33. Manufacturing Product Lifecycle Examples Cereal = Commodity LCD HD Televisions = Growth/Maturation Styrofoam Cups = Commodity/Decline Steel-Framed Bicycle = Decline/Obsolescence Auto-Nav Systems = Growth New Software, Food, Video Game = Introduction/Growth Engr 241

  34. Product Volume vs Production Method (Black & Kohser, 2008, p. 25). Engr 241

  35. Manufacturing Product Lifecycle “It is crucial to achieve this integration [of manufacturing and assembly] during the design phase because about 70% of the life-cycle cost of a product is determined when it is designed” (Black & Kohser, 2008, p. 22). • Design choices include materials, fabrication methods, material handling, assembly and inspection methods Engr 241

  36. Questions to consider • 1. Can the product life cycle be changed/altered? If so, how do manufacturers alter the product life cycle? • 2. What are a manufacturer’s reasons for dropping a product/operations? What does a manufacturer do (in terms of product development) to stay in business? • 3. What is the role of the manufacturing engineer in the product life cycle? Engr 241

  37. Product Life Cycle Considerations • Manufacturers desire a long life cycle (growth is good) • Manufacturers must be concerned with price is OWC • Manufacturers may outsource operations if price is dominant OWC to stay in business • Manufacturers must be concerned when product life is at the end of maturation or in decline • If the lifecycle is near the end, companies must diversify in what they produce or potentially go out of business • Manufacturers work with customers, develop R&D programs, pilot test new products to experience re-growth Engr 241

  38. Product Life Cycle Considerations • Manufacturers drop products/operations where liability/safety is an issue (production, environment, personnel, customer, government regulations) • Manufacturers drop products/operations when product demand is lacking (decline/obsolescence/commodity) – raises costs to make those products • Manufacturers drop products/ops. when producing those products increases more than the actual return • Manufacturers may drop products/outsource operations if they do not have capability • Manufacturers may drop products if other products are in the growth phase or entering another market is possible Engr 241

  39. Manufacturing Engineers: CRA • May coordinate and supervise processes/equipment to be utilized, choose machines/equipment for tasks (as part of design) • “Industrial or manufacturing engineers are responsible for manufacturing systems design (or layout) of factories. They must take into account the interrelationships of the design and the properties of the materials that the machines are going to process as well as the interaction of the materials and processes.” (Black & Kohser, 2008, p. 10). • May design specialized tooling, work-holding devices • May work with design engineers to facilitate economical production of goods Engr 241

  40. Manufacturing Engineers: CRA • Determine how a product is to be made (specific mfg processes) • May design or select instruments/tools to perform quality inspections • May select tools and tool materials to carry out machining/forming processes of materials • May make modifications to the manufacturing system to decrease the cost-per-unit without sacrificing 3F’s • May serve as a liaison to foreign suppliers • May serve as the primary contact for cost reduction strategies in the production of products Engr 241

  41. Supporting Information • http://www.industryweek.com/ReadArticle.aspx?ArticleID=13312 • http://www.industryweek.com/ReadArticle.aspx?ArticleID=10867&SectionID=10 • http://www.bls.gov/iag/manufacturing.htm • http://www.bls.gov/news.release/ecopro.t01.htm • See Standard of Living report • http://www.sme.org/gmn/data/docs/018834 Engr 241

  42. Future Topics for Discussion • Materials and their properties • Processing materials • 3F’s of Product Design • Over-engineering/Overdesign and Value Engineering • Lean-related topics Engr 241

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