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Introduction and Overview of Manufacturing
Introduction and Overview of Manufacturing
OVERVIEW OF MANUFACTURING
1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
5. Manufacturing Economics
6. Recent Developments in Manufacturing
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing is Important
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Technological Importance
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Technological Importance
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Economic Importance
U.S. Economy
Sector: %GDP
Agriculture and natural resources 5
Construction and public utilities 5
Manufacturing 12
Service industries* 78
100
* includes retail, transportation, banking,
communication, education, and government
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
What is Manufacturing?
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing - Technological
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing - Economic
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing Example:
Artificial Heart Valve
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing Industries
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing Industries -
continued
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufactured Products
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Production Quantity Q
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Product Variety P
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P vs Q in Factory Operations
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More About Product Variety
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing Capability
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
1. Technological Processing
Capability
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
3. Production Capacity
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Materials in Manufacturing
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
1. Metals
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
2. Ceramics
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
3. Polymers
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
4. Composites
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Classification of
Manufacturing
Processes
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Processing Operations
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Four Categories of
Shaping Processes
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Solidification Processes
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Particulate Processing
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Deformation Processes
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Material Removal Processes
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Waste in Shaping Processes
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Property-Enhancing Processes
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Surface Processing Operations
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Assembly Operations
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Production Machines and
Tooling
▪ Manufacturing operations are accomplished using
machinery and tooling (and people)
▪ Types of production machines:
▪ Machine tools - power-driven machines used to
operate cutting tools previously operated manually
▪ Other production equipment:
▪ Presses
▪ Forge hammers,
▪ Plastic injection molding machines
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Production Systems
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Model of the Production System
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Production Facilities
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Facilities vs Product Quantities
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Low Production
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Fixed-Position Plant Layout
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Medium Production
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Cellular Plant Layout
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High Production
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Quantity Production
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Flow Line Production
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Product Plant Layout
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Manufacturing Support Systems
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Typical Cost Breakdown for a
Manufactured Product
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Recent Developments
in Manufacturing
▪ Microelectronics
▪ Computerization in manufacturing
▪ Flexible manufacturing
▪ Microfabrication and Nanotechnology
▪ Lean production and Six Sigma
▪ Globalization and outsourcing
▪ Environmentally conscious manufacturing
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Microelectronics
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Computerization of
Manufacturing
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Flexible Manufacturing
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Microfabrication and
Nanotechnology
▪ Microfabrication
▪ Processes that make parts and products whose
feature sizes are in the micron range (10-6 m)
▪ Examples: Ink-jet printing heads, compact disks,
microsensors used in automobiles
▪ Nanotechnology
▪ Materials and products whose feature sizes are in
the nanometer range (10-9 m)
▪ Examples: Coatings for catalytic converters, flat
screen TV monitors
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Lean Production and Six Sigma
▪ Lean production
▪ Doing more work with fewer resources, yet
achieving higher quality in the final product
▪ Underlying objective: elimination of waste in
manufacturing
▪ Six Sigma
▪ Quality-focused program that utilizes worker
teams to accomplish projects aimed at improving
an organization’s organizational performance
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Globalization
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Outsourcing
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Environmentally Conscious
Manufacturing
▪ Determining the most efficient use of materials and
natural resources in production, and minimizing the
negative consequences on the environment
▪ Associated terms: green manufacturing, cleaner
production, sustainable manufacturing
▪ Basic approaches:
1. Design products that minimize environmental
impact
2. Design processes that are environmentally
friendly
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Examples
1 A stamping press produces sheet-metal stampings in batches. The press is operated by a worker
whose labor rate = $15.00/hr and applicable labor overhead rate = 42%. Cost rate of the press =
$22.50/hr and applicable equipment overhead rate = 20%. In one job of interest, batch size = 400
stampings, and the time to set up the die in the press takes 75 min. The die cost $40,000 and is
expected to last for 200,000 stampings. Each cycle in the operation, the starting blanks of sheet metal
are manually loaded into the press, which takes 42 sec. The actual press stroke takes only 8 sec. Cost
of the starting blanks = $0.43/pc. The press operates 250 days per year, 7.5 hours per day, but the
operator is paid for 8 hours per day. Assume availability = 100% and scrap rate = 0. Determine (a)
cycle time, (b) average production rate with and without setup time included, and (c) cost per
stamping produced.
▪ Solution: (a) Cycle time Tc = 42 + 8 = 50 sec = 0.833 min
▪ (b) Including setup time, Tp = 75/400 + 0.833 = 1.021 min
▪ Rp = 60/1.021 = 58.78 pc/hr
▪ Excluding setup time, Rc = 60/0.833 = 72.03 pc/hr
▪ (c) Equipment cost rate Ceq = 22.50(1.20)/60 = $0.45/min.
▪ Die cost per piece Ct = 40,000/200,000 = $0.20/pc
▪ Labor cost rate CL = 15.00(1.42)/60 = $0.355/min
▪ This labor cost should be adjusted for the fact that although the press operates 7.5 hr/day, the
operator is paid for 8 hr. CL = 0.355(8/7.5) = $0.379
▪ Finally, cost per stamping Cpc = 0.43 + (0.379 + 0.45)(1.021) + 0.20 = $1.48/pc
Example 3