CHAPTER 1 Innovations sustaining technology

Sustaining technology serve to continually bring more value to the consumer

Materials, Manufacturing, and the Standard of Living of existing products and services
Manufacturing is critical to a countrys economic welfare and standard of living
in any society is determined, primarily, by the goods and services that are Maturity
available to the people
- contributes 20% of the GNP (Gross National Project)

Volume/unit time
Decline
Classes of Manufactured Goods: Growth
1. Producer goods goods manufactured for other companies to use
either producer or consumer goods
2. Consumer goods those purchased directly by the consumer or the
general public Introduction
- converting materials from one form to another
Nature and Importance of Materials and Manufacturing
Time

Materials
- Properties Selling Price
- Reliability
- Processing
- Cost

51%

DESIGN PROCESSING
- Loads - Equipment
- Use conditions - Effect on
processes available materials
- Material selection - Configuration Manufacturing cost selling price of a product
- Quantity - Tooling
Manufacturing and Production Systems
Manufacturing the economic term for making goods and services available to
satisfy human wants
Product Life-cycle - it implies creating value by applying useful mental or physical labor
Development/creation PRODUCTION SYSTEM THE ENTERPRISE
Growth Production system refers to the total company (or enterprise)
Maturity/optimization - all aspects of workers, machines, and information, considered
Decline collectively, needed to manufacture parts or products; integration of all units of
the system is critical
MANUFACTURING SYSTEMS JOB AND STATION
Manufacturing system (MS) design or arrangement of the manufacturing Job the total of the work or duties a worker performs. It is a group of related
process operations and tasks performed at one station or series of stations in cells
- the collection of manufacturing processes and operations resulting in Station a position or location in a machine or process where a production
a specific end products; an arrangement or layout of many processes, materials- worker performs specific operation, tasks, or job
handling equipment, and operators
MANUFACTURING PROCESSES OPERATION
Manufacturing process converts unfinished materials to finished products Operation a distinct action performed to produce a desired result
often using machines or machine tools Functions of Operations:
Example: injection molding, die casting, progressive stamping, milling, arc 1. Material handling changes in position of the product
welding, painting, assembling, testing, pasteurizing, homogenizing, and 2. Processing change in volume and quality; including assembly and
annealing disassembly; can include packaging
Machine tool an assembly of related mechanisms on a frame or bed that 3. Packaging special processing; may be temporary or permanent for
together produce a desired result shipping
Goods refer to material things 4. Inspecting and testing comparison to the standard or check of
Services nonmaterial things that people buy to satisfy wants, needs, or desires process behavior
Service production system (SPSs) - includes transportation, banking, finance, 5. Storing time lapses without further operations
savings and loan, insurance, utilities, health care, education, communication, 6.
entertainment, sporting events, etc. TREATMENTS
Process sequence of operations and processes/ steps for production of goods Treatments usually after or modify the product-in-process without tool
and services contact. It usually adds value to the part but does not alter the operation.
Examples:
PRODUCTION SYSTEM Heat treating Chemical cleaning
Curing Painting
Galvanizing Finishing
Plating

MANUFACTURING SERVICE PRODUCTION TOOLS, TOOLING, AND WORKHOLDERS

PRODUCTION SYSTEM SYSTEM Tools used to hold, cut, shape, or form the unfinished product
Common hand tools:
Saw Sandpaper
Hammer Drill
MANUFACTURING PROCESS Screwdriver Torch
Chisel Grindstone
Types of Services Industries: Tooling includes jigs, workholders, and fixtures. They are purchased
1. Advertising and marketing separately from machine tools
2. Communication (telephone, computer networks)
3. Education TOOLING FOR MEASUREMENT AND INSPECTION
4. Entertainment (radios, TV, movies, plays) Common examples:
5. Equipment and Furniture control Rulers Micrometers
6. Financial (banks, investment companies, loan companies) Calipers Gages
7. Health care
8. Insurance
9. Travel (hotel, motel, cruise lines, airlines)
PRODUCTS AND FABRICATIONS BASIC MANUFACTURING PROCESSES
Products can be manufactured by: Casting, Foundry, or Molding Processes
1. Fabricating is the manufacture of a product from pieces - involve introducing liquid, granular, or powdered material into a
- usually in plants, factory or mill previously prepared mold cavity
2. Processing used to refer to the manufacture of a product by Farming or Metalworking Process
continuous means, or by continuous series of operations (plant/refinery) - modifying the shape, size, and physical properties of the material
- products that flow (liquids, gases, grains, or powders) Machining (material removal) Process
Continuous-process-industries sometimes called processing industries or flow - removal of certain selected areas from a part in order to obtain a
industries desired shape or finish
Construction is making goods by means other than manufacturing or - drilling, turning, milling, sawing
processing in factories Joining and Assembly
Agriculture, fisheries, and commercial fishing produce real goods from useful Mechanical fastening Press, shrink, or snap fittings
labor Soldering and brazing Adhesive bonding
Welding Assembly processes
WORKPIECE AND ITS CONFIGURATION Surface Treatments (Finishing)
In the manufacturing of goods, the primary objective is to produce a component - processes that involves cleaning, removing burrs left by machining, or
having a desired geometry, size, and finish providing protective and/or decorative surfaces on workpieces
Types of surfaces: - Examples:
1. Plane or flat Deburring Galvanizing
2. Cylindrical (external or internal) Painting Anodizing
3. Conical (external or internal) Plating Chemical and mechanical cleaning
4. Irregular (curved or warped) Buffing
Rapid Prototyping
ROLES OF INDUSTRIAL ENGINEERS IN MANUFACTURING - an additive process that produces prototypes directly from the software
1. Responsible for manufacturing systems design (or layout) of factories using specialized machines driven by computer-aided design packages
2. They must take into consideration the interrelationships of the design - Value-adding capability the ability to produce components with great
and the properties of the materials that the machines are going to precision and accuracy
process Heat Treating
3. They must consider the inter-reaction of the materials and the - heating and cooling of a material for the specific purpose of altering its
processes properties
- Examples:
MANUFACTURING SYSTEMS DESIGNS Annealing
Job shop characterized by large varieties of components, general-purpose Tempering
machines, and a functional layout
Lot or batch materials moved from machine to machine in carts or containers
Flow shops characterized by larger volumes of the same part or assembly,
special-purpose machines and equipment, less variety, and more mechanization
Linked-cell shop composed of manufacturing and subassembly cells
connected to final assembly using a unique form of inventory and information
control
Kanban a unique form of inventory and information control
Project shop characterized by the immobility of the item being manufactured
Continuous processes used to manufacture liquids, oils, gases, and powders.
The manufacturing engineers in these factories are often a chemical engineer.