Selecting and Planning the Process of Manufacture

Dr. Pulak M. Pandey http://paniit.iitd.ac.in/~pmpandey

Introduction
The manufacturing process selected must be an economical balance of materials, manpower, product design, tooling and equipment, plant space, and many other factors influencing cost and practicality. The process must be selected in such a way that the produced product will be acceptable to the consumer functionally, economically and appearance-wise.

Fundamental Rules for the selection and Planning of a Manufacturing Process

1. 2. 3. 4. 5. 6.

The process must assure a product that meets all design requirements of quality, function and reliability Daily production requirement must be met Full capacity of the machine and its tooling should be utilized Idle operator and idle machine time must be reduced to minimum The process must provide the maximum utilization of the minimum amount of material The process should be flexible enough to accommodate reasonable changes in design

7.

8. 9. 10.

The process should be designed to eliminate any unnecessary operations and combine as many operations as are physically and economically practical Capital expenditure that must be amortized over short periods must be kept as low as possible. The process must be designed with the protection of both the operator and the workpiece in mind The process should be developed so that the final product will be produced at a minimum cost to the enterprise as a whole

The Engineering Approach

Establish the process objectives Collect all the facts about the problem Plan alternative processes Evaluate alternative processes Develop a course of action Follow up to assure action and check results

Using Materials More Economically

Better stock utilization through materials control Sale of scrap Re-usable materials Material cost balance sheet Process effects materials cost
Lack of proper workpiece control Wrong manufacturing process Improper stock selection Improper handling Incomplete inspection at early stages of manufacturing Incorrect operation sequence

Eliminating Operations

The cost of processing can be reduced by eliminating unnecessary operations. This can be achieved in number of ways and are accomplished through proper planning.
Changing product design. Changing the operation sequence. Changing the basic process. Combining operations.

Combining operations

By simulating
Simulation involves those combinations where two or more elements of an operation, or two or more operations are performed at the same time. Example: series of hole to be drilled simultaneously using a multiple spindle drill press. Cuter are specially designed.

By integrating
Where several individual elements of an operation or group of operations are combined in succession but not simultaneously. Taping is done after drilling hole on the same set up by just changing the tool. Typical example.

Both simulation and integration are employed profusely in todays highly mechanized and automated industry.

Advantages of combined operations

Improved accuracy Reduced labor cost Reduced plant fixed cost Less tooling required Less handling required Fewer setups Smaller in process inventory Less scrap Fewer inspection points required

Limitations of combined operations

Maintaining tool accuracy Possible higher tool costs Maintaining dimensions for several baselines Combination tooling subject to downtime More costly setups More costly scrap Compromises on operational speed Chip disposal

Selection of Proper Tooling

In selecting dies, jigs or fixtures for a given process, there are three essential considerations that demand the attention of process engineer
Quality of the product Total volume to be produced Required rate of production

Effect of operational speed on performance and economy

Cutting speed influences the rate of production and performance economy. Assuming product quality can be achieved is independent of the speed, there are two divergent opinions.
Greater is the machine speed, greater its output and lower product unit cost. Speed should be held so that longer tool life is achieved.

With the change in tool life due to change in operational speed the overall production time will be effected due to re-sharpening and resetting the tool. Minimum cost analysis and/or diminishing return analysis are carried out to evaluate the situation.

Minimum Cost Analysis

In minimum cost studies, it is found that when changes occur in a common variable (in this case it is operational speed), the change may modify other cost aspects of the problem in such a way that the combined effect produces a minimum value.

Diminishing Return Analysis

When the value of common variable (cutting speed) is increased, there will be a corresponding increase in the return (may be volume or profit) up to a point where return is no longer a proportional. This point is called the point of diminishing returns. Furthermore, if the common variable continues to increase, the return will ultimately reach a point beyond which its value will start to decrease. This point is called point of maximum returns.

The Make and Buy Decisions

The decision to manufacture a product in its entirely or to produce any part or all of it primarily dependent upon a combination of factors like:
1. 2. 3. 4. 5. 6. 7. Volume required Cost Life of the product Degree of product standardization Degree of manufacturing specialization Alternative source of supply Reliability of supplier

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Casting redesigned to eliminate foundry and machining operations

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Effect of cutting speed on volume, unit cost and total profit

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