Chapter I

Manufacturing
A branch of industry is the application of tools and processes for the
transformation of raw materials into finished products.

The term manufacturing system refers to a collection or arrangement of

operations and processes used to make a desired product or component. In a
manufacturing system, there is a change or disturbance in the system, the
system should accommodate or adjust itself and continue to function efficiently.

Physical Elements Measurable Parameters

Machines for processing Production rate
Computer - Systems Work in process inventory
Material handling equipment Percentage of defects
People Percentage on time delivery
Daily/weekly/monthly production
volume
Total cost

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MANUFACTURING COMPONENTS

Production Machines: Machines can be classified according to worker

participation in the task, as:

 Manually-operated
 Semi-automated
 Fully automated.

Manually operated machines

Controlled or supervised by a worker or operator, there is a clear division of

labor, whereby the machine provides the power for the operation and the
worker provides the control. Conventional machine tools (such as lathes, milling
machines, drill presses etc.) fit this category. The worker must attend the
machine continuously during the work cycle.

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Semi-Automated Machine

This performs a portion of the work cycle under programme control, and then a
worker assumes control for the remainder of the cycle. An example of a
machine in this capacity is a CNC lathe, where the CNC machine performs its
processing operation as per the programme, and then the worker unloads and
reloads the machine for the next work cycle. The worker must attend the
machine every cycle, but need not be continuously present.

Fully-Automated Machine

This has the capability to operate with no human attention for periods of time
that are longer than one work cycle. Some form of machine tending will be
required periodically, however; for example, to replenish the machine with raw
material etc.

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Material Handling System
In loading the workstation is supplied with the correct type and amount of
work units so that the processing operation can be performed. Loading,
positioning, and unloading work units are a group of actions that are regularly
performed together at individual workstations.

Positioning requires the work unit to be oriented or locate correctly within the
processing machine, so that the processing action can be performed upon n
the work unit accurately.

Unloading involves the removal of the processed work units from the workstation
often for further material handling processes to occur.

Material transport systems involve passing work units between workstations by

hand or in batches, by means of manual techniques or by using appropriate
material transport systems.

2 General Types of Work Transport

Fixed routing

– uses the same sequence of workstations to process identical work units as

they passed through the system

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Variable routing
- work units are transported through a variety of different station sequences to
allow for variable processing to be performed on transported work units.

Computer Control Systems

Computer systems are required to control fully-automated and semi-automated
equipment and participate in overall co-ordination and management of the
manufacturing system.

Computer system functions for automated manufacturing

o Communicate instructions to workers
o Download workpart programmes
o Control material handling system
o Schedule production
o Diagnose failures
o Monitor safety
o Maintain quality control
o Manage operations

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Human Resources

Direct labour
Humans perform some value-added work on work units

Physical labour
that results in an increase in value of the processed work unit.

Indirect labour
manage and support the system as computer programmers, operate and direct
computer activities and maintain and repair the automated manufacturing
system.

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Chapter II
MATERIALS TYPES AND PROPERTIES

Metals
Combination of one or more metallic elements. Alloy- combination of metal
and non-metal.
o Steel
o Aluminum
o Copper
o Brass
Properties
o Strong
o Dense
o Ductile
o Electrical and heat conductor
o Opaque

Ceramics
Inorganic materials with non-metallic properties usually processed at high
temperature
o Structural ceramics
o Refractories
o Porcelain
o Glass
Properties
o Lower density then metals
o Strong
o Low ductility (brittle)
o Low thermal conductivity
o Corrosion resistant

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Polymers
 Contains many chemically bonded parts or units to form a solid
o Plastics (synthetic)
o Nylon
o Liquid crystal
o Elastomers (rubber)
 Properties
o Low density
o Poor conductors of electricity and heat
o Different optical properties
Composites
 Two or more distinct substances are combined to produce a new material
o Fiberglass (glass and a polymer)
o Plywood (layers of wood and glue)
o Concrete (cement, sand and pebble)

 Properties
o Depends on the amount of distribution of each type of materials
o Collective set of properties are more desirable and possible than with any
individual material

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PROPERTIES OF MATERIALS

Physical Properties
Those which can be observed without change of identity of materials
o density
o color
o shape and size
o specific gravity of materials
o porosity

Chemical Properties
Properties that describe how a substance changes into completely different
substance
o Flammability
o Corrosion/oxidation resistance
o Reaction with water/acid

Thermal Properties
Related to conductivity of heat refers to characteristic behavior of materials
under thermal load
o Thermal conductivity
o Thermal expansion
o Melting point
o Thermal diffusivity

Electrical Properties
Ability to conduct electrical current
o Electrical resistivity
o Electrical conductivity
o Temperature coefficient of resistivity
o Dielectric strength
o Thermoelectricity

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Manufacturing Properties
are highly desirable in shaping, forming and fabrication of materials
o Machinability
o Weldability
o Castability
o Formability
o Malleability

Magnetic Properties
Ability of material to be suitable for a particular magnetic application
o Permeability
o Retentivity or Magnetic Hysteresis
o Coercive force
o Reluctance
Optical Properties
Define material response to incident radiation

o Transmissivity
o Reflection
o Absorption

Mechanical Properties
Measure how materials behave under load. Reflect relationship between its
response to and deformation from an applied load or force
o Strength
o Hardness
o Ductility
o Toughness
o Fatigue resistance
o Creed

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Chapter III
MANUFACTURING & MARKETING PRODUCTS

What is marketing?
Marketing is the action or business of promoting and selling products or services,
including market research and advertising.

According to the American marketing association, it is “the activity, set of

institutions, and processes for creating, communicating, delivering, and
exchanging offerings that have value for customers, clients, partners, and
society at large

The term developed from the original meaning which referred literally to going
to market with goods for sale. From a sales process engineering perspective,
marketing is “a set of processes that are interconnected and interdependent
with other functions of a business aimed at achieving customer interest and
satisfaction”

Three phases of marketing

o Promoting
o Advertising
o Selling

Product Marketing
A process of promoting and selling product to a customer and also defined as
being the intermediary function between product developments and increasing
brand awareness.

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Product Marketing Responsibilities
Market Position
 Competitive analysis
 Market gaps
 Customer purchasing data
 Customer needs

Pricing & Packaging

 Product revenue goals and plans
 Pricing strategy
 Packaging that conveys the value of the product
 Packaging design to drive sales

Marketing & promotion plan

 messaging and positioning
 collateral and website
 materials for sales staff
 key marketing channels

Customer response
 maximized buying process
 sales and revenue monitoring
 customer feedback
 customer support staffing

Eight types of product marketing

 paid advertising
 cause marketing
 relationship marketing
 undercover marketing
 word of mouth
 internet marketing
 transactional marketing
 diversity marketing

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What is manufacturing?
Manufacturing is the making of articles on a large-scale using machinery;
industrial production

Manufacturing is the use of labor, goods and machines to produce goods for
use or for sale. Manufacturing sector covers work performed in:

o Electronics industry
o Mechanical industry
o Energy industries
o Food and beverage industries
o Plastic industry
o Metalworking industries

There are four primary types of manufacturing products

o Molding
o Machining
o Joining
o Shearing and Forming

The Four C, Four P and Four A

Complementary tools to remember in product marketing

4Cs
o Communication
o Cost
o Consumer value
o Convenience

4Ps
o Promotion
o Price
o Product
o Place

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4As
o Accessibility
o Affordability
o Acceptability
o Awareness

The 7Ps of Marketing Mix

 Product
 Promotion
 Price
 Place
 People
 Process
 Physical evidence

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Chapter IV
TYPES OF PRODUCTION SYSTEM

Intermittent Production System

 Production system is flexible
 Design of the product can be change time to time
 We can adjust production system according to the order

Types of Intermittent Production System

Project Production
 made to order
 low volume type of production
 fixed position assembly type of layout
 the sequence of operation is unique to each project
 involved many agencies
 complex in nature
 specific time period and expenditure

Examples: roads/highways, bridges, dam, airport, ship, school project

Job Shop Production

 Manufactures only or few quantities of products and procedures as per
the specification of the customers within prefixed time & cost.
 The distinguishing feature of this is low volume and high variety of
products
 Use of general-purpose machines arranged into different departments
 Highly skilled and competent operators
 Detailed planning is essential
 Large inventory of materials, tools, parts, etc.

Examples: cake, technology, customization, prototypes, parts, bespoke

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Batch Production
 American production and inventory control society (APICS) defines
batch production as a form of manufacturing in which the job through
the functional departments in lots or batches and each lot may have a
different routing. It was characterized by the manufacture of limited
number of products produced at regular intervals and stocked
awaiting sales
 Shorter production runs
 Plant & machinery is flexible. Plant & machinery set up is used for the
production of item in a batch & change of set up is required for
processing the next batch
 Manufacturing lead-time and cost are lower as compared to job order
production
 Examples: pandesal, pharmaceutical products, appliances,
cellphones, laptops

Continuous Production System

 Continuous production generally means the machines creating the
product run 24/7, which means there are NO interruptions during
production. The less interruptions, the more made, and the more made =
more to go out, ultimately creating more profit. A drawback, though, is
that if there is one problem, all the production will be disturbed.

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Types of Continuous Production System

Mass Production
 Considers the volume produced
 Mass production is generally used to refer to the quantities of
production
 Requires specialist machinery
 Large volume of products
 Shorter cycle time
 Involves the product going through many stages of a production line
 One at a time production of goods
 It is used only if the product is standardized
 High capital investment
Examples: unilever products, paperclips

Process Production
 Single type of product is produced in very large quantities
 Make to stock production system
 Capital invested is very huge
 The flexibility of these plants is almost zero
 Production planning and scheduling can be decided well in advance
 The full production system is designed to produce only one specific
type of item
 Semi-skilled workmen and skilled technicians are required
 Highly mechanized system
 Cost per unit may be lower

Examples: oil refinery, steel, asphalt, cement, etc.

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