Manufacturing Engineering Technology in SI Units, 6th Edition
General Introduction
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Chapter Outline
1. What Is Manufacturing?
2. Product Design and Concurrent Engineering
3. Design for Manufacture, Assembly, Disassembly, and
Service
4. Green Design and Manufacturing
5. Selection of Materials
6. Selection of Manufacturing Processes
7. Computer-integrated Manufacturing
8. Quality Assurance and Total Quality Management
9. Lean Production and Agile Manufacturing
10. Manufacturing Costs and Global Competition
11. General Trends in Manufacturing
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What is Manufacturing?
Application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a starting
material to make parts or products
Manufacturing - Economic
Transformation of materials into items of greater value by one
or more processing and/or assembly operations
Economic Importance
U.S. Economy
Sector: %GDP
Agriculture and natural resources 5
Construction and public utilities 5
Manufacturing 15
Service industries* 75
100
includes retail, transportation, banking, communication, education, and government
18% working force; 40% US exports backbone of
industrialized nations
What Is Manufacturing?
Products around us consist of numerous individual pieces that shall
be built and assembled:
Clip one part
Lawn mower 300 parts
Grand piano ? parts
Automobile ? parts
Boeing 747-400 ? parts
Eli Whitney (US 1765-1825)
interchangeable parts (key: tolerance/
/precision engineering)
What Is Manufacturing? Example 1.1
Paper Clips
Functional and Service Requirement
Clamping forces (stiffness,
strength- permanent deformation; matl select: shape and size)
Corrosion resistance
Style and Cost
Metallic or plastic? What shape (round or else)? Its dia? Surface finish?
Production Consideration
How to shape (hand or machine)? Batch quantity
Bending without cracking or breaking
Easily cut without causing excessive wear on tooling
Produce smooth edge on the wire (burs not desire)
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What Is Manufacturing?
What Is Manufacturing?
Example 1.2
Incandescent Light Bulbs
Components of a common incandescent light bulb
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Manufacturing Steps in making an
incandescent light bulb (Prod. Rate >1000/min)
Filament manufacturing: Tungsten powder (sintering) Ingot (swaging)
Rods (drawing)- thin Wire (60W, 0.045 mm dia)
Wire dia. 1%less causes 25
? % life shortage (heated to 2200 to 3000 C)
Bulb vacuumed or filled w N2 or Argon gas (water drop causes 0.5m
blackened); coil spacing accuracy (heat concentration); position
accuracy heat deflection disk, and lead-in wire (Fe+Ni w Cu
coating)= glass thermal expansion coefficient
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Product Design and Concurrent Engineering
The Design Process
Design and manufacturing
activities take place
sequentially
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Product Design and Concurrent Engineering
The Design Process
It would be more desirable to:
1. Use a different material
2. Use the same material but in a different condition
3. Modify the design of a component
Concurrent Engineering
Also called simultaneous engineering
From the earliest stages of product design and
engineering, all are simultaneous
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Product Design and Concurrent Engineering
Concurrent Engineering
Any iterations will require a
smaller effort and less wasted
time would occur
1988(IDAInstitute of Defense Analyze)
(CEConcurrent Engineering)
()
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Product Design and Concurrent Engineering
Life Cycle
Life cycle of a new product consists of:
1. Product start-up
2. Rapid growth of the product in the marketplace
3. Product maturity
4. Decline
Life-cycle engineering requires that the entire life of a
product be considered
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Product Design and Concurrent Engineering
Role of Computers in Product Design
Product models are simplified through computer-
aided design (CAD) and computer-aided
engineering (CAE) techniques
CAD systems are capable of rapid and complete
analysis of designs
This is the process known as paperless design
Performance of structures can be analysed
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Product Design and Concurrent Engineering
Role of Computers in Product Design (Cont)
Computer-aided manufacturing involves all phases
of manufacturing
Performing tasks such as:
1. Programming for numerical control machines
2. Designing tools, dies, moulds, fixtures, and work-
holding devices
3. Maintaining quality control
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Product Design and Concurrent Engineering
Prototypes
A prototype is a physical model of an individual
component or product
Rapid prototyping use CAD/CAM and various
specialized technologies
Prototypes developed can review for
possible modifications to the original
design, materials, or production methods
/ 3D
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Product Design and Concurrent Engineering
Virtual Prototyping
It is a software-based method that uses advanced
graphics and virtual-reality environments
To allow designers to view and examine a part in detail
Also known as simulation-based design
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Design for Manufacture, Assembly, Disassembly,
and Service
Design for manufacture (DFM) integrate the design
process with production methods, materials, process
planning, assembly, testing, and quality assurance
Design for assembly (DFA), Design for manufacture
and assembly (DFMA), and Design for disassembly
(DFD) are all important for manufacturing
Assembly requires a consideration of the ease, speed,
and cost of individual components of a product
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Green Design and Manufacturing
Manufacturing operations produce waste like:
1. Chips from machining and trimmed materials
2. Slag from foundries and welding
3. Additives in sand used in sand-casting
4. Hazardous waste and toxic materials
5. Lubricants and coolants
6. Liquids from heat treating
7. Solvents from cleaning operations
8. Smoke and pollutants from furnaces
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Green Design and Manufacturing
Environmentally conscious design and manufacturing
considers all possible adverse environmental impacts of
materials, processes, operations and products
Design for recycling (DFR) - two basic activities
1) Biological cycle
- Organic materials degrade and lead to new soil that
sustain life
2) Industrial cycle
- Product that can be recycled and reused continuously
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Green Design and Manufacturing
Cradle-to-cradle Production emphasizes:
1. Sustainable and efficient manufacturing activities
2. Waste-free production
3. Using recyclable and nonhazardous materials
4. Reducing energy consumption
5. Using renewable energy
6. Maintaining ecosystems
7. Using available materials and energy sources
8. Exploring the reuse and recycling of materials
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Green Design and Manufacturing
Guidelines for Green Design and Manufacturing
1. Reduce waste of materials
2. Reduce hazardous materials products and processes
3. Investigate environmental-friendly manufacturing
technologies
4. Improvements in methods of recycling and reusing
5. Minimize energy use
6. Encourage recycling
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Selection of Materials
General types of materials used:
1. Ferrous metals
2. Nonferrous metals
3. Plastics (polymers)
4. Ceramics, glasses
5. Composite materials
6. Nanomaterials
7. Shape-memory alloys, amorphous alloys,
semiconductors and superconductors
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Selection of Materials
Properties of Materials
1. Mechanical properties
2. Physical properties
3. Chemical properties
4. Manufacturing properties
5. Appearance
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Selection of Materials
Availability
If materials are not available in the desired quantities,
shapes, dimensions, and surface texture, substitute
materials can be considered
Reliability of supply is important in order to meet
production schedules
A countrys self-reliance on resources is a political goal
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Selection of Materials
Service Life
A shortened service life of a product is due to:
1. Improper selection of materials
2. Improper selection of production methods
3. Insufficient control of processing variables
4. Defective parts or manufacturing-induced defects
5. Poor maintenance
6. Improper use of the product
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Selection of Materials
Material Substitution in Products
We would want to consider the following substitutions:
1. Metal vs. wooden handle for a hammer
2. Aluminium vs. cast-iron lawn chair
3. Aluminium vs. copper wire
4. Plastic vs. steel car bumper
5. Plastic vs. metal toy
6. Alloy steel vs. titanium submarine hull
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Selection of Materials
Example 1.2
Baseball Bats
Cross sections of baseball
bats made of aluminium and
composite material
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Selection of Materials
Example 1.3
U.S. Pennies
Materials used undergone changes throughout history
due to periodic material shortages and the cost of
appropriate raw materials
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Selection of Manufacturing Processes
Some examples of manufacturing methods are:
1. Casting
2. Forming and shaping
3. Machining
4. Joining
5. Finishing
6. Microfabrication and nanofabrication
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Selection of Manufacturing Processes
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Selection of Manufacturing Processes
Copyright 2010 Pearson Education South Asia Pte Ltd
Selection of Manufacturing Processes
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Selection of Manufacturing Processes
Process Selection
Selection of process depends on geometric features of
the parts and workpiece material and properties
Some mechanical tools are
being replaced by laser cutting
Size of manufactured products
are getting smaller such as
microscopic gears
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Selection of Manufacturing Processes
Net-shape and Near-net-shape Manufacturing
Part is made in only one operation to the final desired
dimensions, tolerances and surface finish
Difference between the two is the degree of how close the
product is to its final dimensional characteristics
Examples of net-shape manufacturing are precision
casting, forging, forming sheet metal, powder metallurgy,
injection molding of metal powders and injection molding
of plastics
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Selection of Manufacturing Processes
Ultraprecision Manufacturing
Advantages are dimensional accuracies and mirror-like
surfaces on metals
Types of Production
Job shops: less than 100
Small-batch production: 10 to 100
Batch production: 100 and 5000
Mass production: over 100,000
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Selection of Manufacturing Processes
Example 1.4
Saltshaker and Pepper Mill
The two metal pieces for the
pepper mill are made by
powder-metallurgy techniques
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Computer-integrated Manufacturing
Computer-integrated manufacturing (CIM) integrates
computer graphics, computer-aided modelling, and
computer-aided design and manufacturing activities
Capable of making possible
1. Responsiveness to rapid changes
2. Better use of materials, machinery, and personnel
3. Reduction in inventory
4. Better control of production
and management
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Computer-integrated Manufacturing
Various elements in CIM include:
1. Computer numerical control (CNC)
2. Adaptive control (AC)
3. Industrial robots
4. Automated materials handling
5. Automated assembly systems
6. Computer-aided process planning (CAPP)
7. Group technology (GT)
8. Just-in-time production (JIT)
9. Cellular manufacturing (CM)
10. Flexible manufacturing systems (FMS)
11. Expert systems (ES)
12. Artificial intelligence (AI)
13. Artificial neural networks (ANN)
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Computer-integrated Manufacturing
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Computer-integrated Manufacturing
Example 1.5
Mold for Making Sunglasses Frames
Machining a mold cavity for making sunglasses
Computer model of the sunglasses as designed and
viewed on the monitor
Machining of the die cavity using a computer numerical-
control milling machine
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Quality Assurance and Total Quality Management
Product quality influences customer satisfaction
Quality must be built into the product from its initial design
Quality assurance and total quality management (TQM)
are the responsibility of everyone involved in the design
and manufacture of products and their components
Product integrity define the degree to which a product
1. Functions reliably
2. Suits its intended purposes
3. Can be maintained with relative ease
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Quality Assurance and Total Quality Management
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Quality Assurance and Total Quality Management
At six sigma, defective parts are reduced to only 3.4 per
million parts made.
Level reached only through manufacturing process
capabilities to reduce variability in product quality
Quality Standards
Global manufacturing and competitiveness
lead to international quality control methods
Thus the establishment of ISO 9000
and QS 9000 standards
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Quality Assurance and Total Quality Management
Human-factors Engineering
Human-factors approach results in ergonomics design
Defined as the study of a workplace and the design of
machinery and equipment
Product Liability
Involved with product design, manufacture and marketing
Products malfunction or failure can cause bodily injury or
even death
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Lean Production and Agile Manufacturing
Lean production involves a thorough assessment of each
activity of a company
Lean production focuses on:
1. Efficiency and effectiveness of each and every
manufacturing operation,
2. Efficiency of the machinery and equipment used
3. Activities of the personnel involved in each operation
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Lean Production and Agile Manufacturing
Agile Manufacturing
Agile manufacturing is ensuring agility and flexibility
Methodologies of both lean and agile production require
that a manufacturer benchmarks its operations
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Manufacturing Costs and Global Competition
Manufacturing cost is about 40% of its selling price
Total cost of manufacturing a product consists of:
1. Materials
2. Tooling
3. Fixed Costs
4. Capital
5. Labour
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General Trends in Manufacturing
Global manufacturing trends
1. Product variety and complexity continue to increase
2. Product life cycles are becoming shorter
3. Markets have become multinational
4. Market conditions fluctuate widely
5. Customers are demanding
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General Trends in Manufacturing
Materials
6. Material composition, purity, and defects
7. Selection of materials for improved recyclability
8. Developments in nano-technology for materials
9. Testing methods and equipment
10. Increasing control over the thermal treatment
11. Higher strength-to-weight and stiffness-to-weight ratios
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General Trends in Manufacturing
Manufacturing operations
12. Predictive models of the effects of material processing
parameters
13. Ultraprecision manufacturing
14. Computer simulation and modelling
15. Rapid-prototyping technologies
16. Optimization of manufacturing processes
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General Trends in Manufacturing
Manufacturing systems
17. Computer software and hardware
18. Control systems and automated inspection
19. Lean production and information technology
Goals in manufacturing
20. View manufacturing activities not as individual
21. Meet all design requirements, product specifications
22. Build quality into the product
23. Economical and environmentally friendly (green)
manufacturing methods
General Trends in Manufacturing
Goals in manufacturing
24. Evaluate advances in materials, production methods, and
computer integration
25. Adopt flexible production methods
26. Achieving higher levels of productivity
27. Continuous improvement of a companys products
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