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

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introduction to manufacturing

Introduction to Manufacturing

General Manufacturing Processes Engr.-20.2710

Instructor - Sam Chiappone

introduction to manufacturing2
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)
slide3

1910’s

1920’s

1930’s

1900’s

Society & Manufacturing

1940’s

1990’s

1950’s

1980’s

1960’s

1970’s

types of goods
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
products
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.
manufacturing a product
Manufacturing a Product
  • Production systems include
    • People
    • Money
    • Equipment
    • Materials
    • Supplies
    • Markets
    • Management
    • Manufacturing System
    • All aspects of commerce
manufacturing a product7
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.

manufacturing a product8
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
roles of people in mfg
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
roles of people in mfg10
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
roles of people in mfg11
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
aspects of a manufacturing system
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.
characteristics of process technology
Characteristics of Process Technology
  • Mechanics
  • Economics or costs
  • Time Spans
  • Constraints
  • Uncertainties and process reliability
  • Skills
  • Flexibility
  • Process capability
aspects of a manufacturing system14
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
aspects of a manufacturing system15
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.

aspects of a manufacturing system16
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
factory layouts
Factory Layouts
  • Job Shop
  • Flow Shop
  • Linked-Cell Shop
  • Project Shop
  • Continuous Process
factory layouts18
Factory Layouts

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

seven basic processes
Seven Basic Processes
  • Casting
  • Forming
  • Machining
  • Joining and Assembly
  • Surface Treatment
  • Heat Treatment
  • Other
casting
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
forming shearing
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
metal removal machining
Metal Removal - Machining
  • Seven basic processes
    • Shaping
    • Turning
    • Drilling
    • Milling
    • Sawing
    • Broaching
    • Abrasive machining
    • Non-Traditional
      • Examples: EDM & Water-Jet
joining
Joining
  • Mechanical Fastening
  • Welding
  • Adhesive bonding
  • Assembly
surface treatment
Surface Treatment
  • Aesthetic requirements
    • Painting
  • Product requirements
    • Safety
      • Burrs
    • Surface treatment
      • chemical plating to resist rust
heat treatment
Heat Treatment
  • Altering the mechanical properties of a material.
    • Strength
    • Wear resistance
    • Resistance to penetration
other
Other
  • Inspection
  • Packaging
  • Transportation
  • Waste disposal
    • Scrap
    • Chemical by-products
changing world competition
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
new manufacturing systems
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
how do we plan for manufacturing
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