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Introduction to
Manufacturing

Basic Manufacturing Concepts

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WHY MANUFACTURING ?

Manufacturing is in Europe:
1st Non-financial economy sector, in terms of employees and
added value (in Italy it employs approximately 20% of the
workforce)
1st Sector for export (more than 80% of total export)
1st Sector for private investments in Research & Development
(66% of total private investments)
1st Sector for innovation level
1st Sector for productivity growth

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MANUFACTURING IN ITALY

Made in
ITALY

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MANUFACTURING IN ITALY

“4A”:
§ Alimentari-vini (Food and beverage);
§ Abbigliamento-moda (Fashion);
§ Arredo-casa (Furniture and home appliance);
§ Automazione-meccanica-gomma-plastica (Automation and machinery).

In 2017, Italy is among the three top countries worldwide in the production of 922
product categories out of 5206 (1st in 240, 2nd in 380, 3rd in 302). Italy is 4th
after P.R. of China (2461), Germany (1394) and USA (1015).
Surplus from Trade 2017
§ Automation and machinery: + 81 billion € (+81 in 2016, +84 in 2014)
• Top 369 products
§ Fashion: + 31,6 billion € (+33,4 in 2016, +25 in 2014)
• Top 277 products
§ Furniture and home appliance: + 15,6 billion € (+14,6 in 2016, +12 in 2014)
• Top 44 products
§ Food and beverage: + 22,7 billion € (+19,4 in 2016, +7 in 2014)
• Top 80 products
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WHY COMPUTER AIDED MANUFACTURING ?
Traditionally, industrial equipment and machinery
companies have focused on selling hardware (e.g.,
machines, components), and many of them have
based their business models and success on the
outstanding quality of their products.
These days may be coming to an end as three
powerful, mutually reinforcing developments are
emerging across the industrial equipment and
machinery sector requiring players to fundamentally
rethink their current business models:
§ intensifying global competition,
§ commoditization of hardware,
§ and a seismic shift in technology stack value
pools due to customers’ increasing demand for
digital services.

Digital McKinsey
August 2018
Copyright © McKinsey & Company
www.mckinsey.com
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INDUSTRY 4.0

1760-1830 1870-1914 1950-1995 2014-

Other names used in different countries:

§ Smart Manufacturing
§ Smart Factories
§ Industrial Internet of Things

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4TH INDUSTRIAL REVOLUTION

GTAI - German Trade and Invest

Industry 4.0 Smart Manufacturing for the Future, 2014
Cyber-Physical Systems (CPS) are enabling technologies which bring
the virtual and physical worlds together to create a truly networked
world in which intelligent objects communicate and interact with
each other.
The merging of the virtual and the physical worlds through cyber-
physical systems and the resulting fusion of technical processes and
business processes are leading the way to a new industrial age best
defined by the INDUSTRIE 4.0 project’s “smart factory” concept.
The deployment of cyber-physical systems in production systems
gives birth to the “smart factory”. Smart factory products, resources
and processes are characterized by cyber-physical systems; providing
significant real-time quality, time, resource, and cost advantages in
comparison with classic production systems.
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CYBER-PHYSICAL SYSTEMS

Fundamental Principles

§ Self Identification
Who am I ?
§ Services Exploration
What do I offer ?
§ Autonomous Networking
Who are my partners ?
= a valve
(from prof. Detlef Zuhlke)

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CYBER-PHYSICAL SYSTEMS

Traditional service/business model.

(from prof. Detlef Zuhlke)

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CYBER-PHYSICAL SYSTEMS

Thanks to availability of new services, new business models could appear.

(from prof. Detlef Zuhlke)

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SUBSEA HIPPS 11
(HIGH INTEGRITY PRESSURE PROTECTION SYSTEM)

ADVANCED
TECHNOLOGY
VALVE

HIPPS made by two T.C. Slab Gate valves 5 1/8” class API 15000
fitted in a single block with pressure sensors and injection valves
First subsea HIPPS qualified and delivered for the GOM
(water depth 3000 m)
EXXON JULIA (2015) (USA)

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CYBER-PHYSICAL SYSTEMS

New services
Services for decision- Algorithms

making

Topology
Models and
Cloud data of physical Documents

objects 3D Models
available in the Process Data
network …

Physical
Objects

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CYBER-PHYSICAL SYSTEMS

Industry 3.0 Industry 4.0

(from Martin Hankel, Bosch Rexroth)

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CYBER-PHYSICAL SYSTEMS

[Source: Liu and Xu 2016]

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INDUSTRY 4.0

The nine technological pillars

of INDUSTRIE 4.0

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INDUSTRY 4.0 INITIATIVES IN THE WORLD

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ITALIAN INDUSTRY 4.0 ENABLING TECHNOLOGIES

[Fonte: MISE]

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EU – MANUFUTURE VISION 2030

European manufacturing in 2030 will be a globally

leading, interconnected, and adaptive sociotechnical
value creation system that ensures sustainable growth
and social welfare in a resource-constrained world.

1st Vision 2010: Competitiveness

2nd Vision 2020: Sustainability
3rd Vision 2030: Resilience

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EU – MANUFUTURE VISION 2030

Research Priority Domains

1. Manufacturing Technologies and Processes
2. Digital Transformation
3. Robotics and Flexible Automation
4. Nano-Technology and New Materials
5. Biological Transformation of Products, Processes, and Value Creation
6. Customer Driven Manufacturing
7. Human Centered Manufacturing
8. Agile Manufacturing Systems Design and Management
9. Circular Economy, Resource and Energy Efficiency
10.New Business Logics and Models

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MANUFACTURING

Requirements

Design

Production
Raw Material / Product
Components

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TYPES OF MANUFACTURING

Continuous The elements composing the final

product cannot be easily identified.
The process is not reversible.
Examples: Production of Iron, Paper,
Chemicals, Pharmaceuticals, Food, …

Finite number of components.

Discrete Two main phases:
§ Fabrication phase: set of processes
for modifying shape, dimensions, and
surface state of a single part.
§ Assembly phase: set of processes
for joining single parts to obtain a
(assembled) product.
Examples: Production of Cars, Computers,
Appliances, Shoes, Toys, Phones, …

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DISCRETE MANUFACTURING

pencil sharpener

coffee maker
(moka)

clothes peg

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DISCRETE MANUFACTURING

M. De Lucchi
(Artemide)
table lamp

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DISCRETE MANUFACTURING

motorcycle

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DISCRETE MANUFACTURING

https://youtu.be/lJx6cF-H__I
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A SIMPLIFIED MODEL OF MANUFACTURING PROCESS

“The manufacturing process begins when raw materials are

transported to a place – a factory – where labor, know-how,
technology, equipment and energy are used to physically
and/or chemically transform these materials into a product.

This product is then transported either to another factory,

where these same inputs are again applied, or to a place,
where those who wish to own it (consumers or other
businesses that use the product for their activities) can
purchase it.”
A Framework for Revitalizing American Manufacturing
Barack Obama - December 2009

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TRANSFORMATION PROCESS

Modification of a set of product properties obtained by

means of selected elementary processes.

f
( Property)

ff Final state

Transformation
Trajectory

fi
Initial state
t (time)

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RELEVANT TRANSFORMATION

• Shape and dimension (macro-geometry)

• Surface finishing (micro-geometry)
• Mechanical characteristics (stiffness, ductility, etc)
• State, temperature

Fish Kettle
(stainless steel 304, thickness 1,2 mm)

(courtesy of Serafino Zani, Lumezzane Gazzolo (BS))

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TRANSFORMATION - SCHEME

Information
Technological
Raw part/ Managerial WIP/ Finished
WIP
Material Material product

Other materials Scrap / Reject

Energy Energy
Transformation Heat

Information
Process feedback
Machines
Resources Tools Info within the object
Fixturing

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METHODS OF TRANSFORMATIONS: CASTING

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METHODS OF TRANSFORMATIONS: FORMING AND SHAPING

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METHODS OF TRANSFORMATIONS: FORMING AND SHAPING

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METHODS OF TRANSFORMATIONS: FORMING AND SHAPING

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METHODS OF TRANSFORMATIONS: MACHINING

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METHODS OF TRANSFORMATIONS: JOINING

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EXAMPLE – ASSEMBLY

https://youtu.be/5F6dlts1a34
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EXAMPLE – CHAIN OF TRANSFORMATIONS

https://youtu.be/8_lfxPI5ObM
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SCALES OF TRANSFORMATIONS

10 m

1m

0,1 m

10 mm

1 mm

0,1 mm

10 μm

1 μm

0,1 μm

10 nm

1 nm

0,1 nm = 1Å
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TECHNICAL FEASIBILITY

Transformations (manufacturing processes)

should guarantee:

• Technical specifications

• Production time
Feasibility and
• Environmental regulations Sustainability
• Operating safety

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TECHNICAL FEASIBILITY

Ashby Chart

Tolerance (mm)

Surface Roughness, Rq (μm)

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PRODUCTION TIME

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PROFITABILITY

Economical feasibility

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CHOICE OF MANUFACTURING PROCESS

Technological
feasibility Profitability

Manufacturing Process

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LEARNING TARGETS

This course introduces the student to the

fundamentals of manufacturing processes used in
discrete-part fabrication along with their needs in
terms of automation and computer-based
intelligence, according to the smart manufacturing
paradigm.

Main Topics:
1. Introduction to Manufacturing
2. Industrial Geometrical Metrology
3. Manufacturing Processes
4. CNC Machine Tools and Computer-Aided Manufacturing

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LEARNING TARGETS

Lectures and other didactic activities will allow students to:

§ know the structure and behaviour of engineering materials;
§ understand the basic design requirements of a product, and in
particular geometrical product specification and verification;
§ know the basics of manufacturing and transformation theory;
§ understand the classification of manufacturing processes and systems;
§ know the basic principles, tools, and machines of the considered
processes;
§ design feasible manufacturing and inspection processes for a product;
§ know the computer numerical control (CNC) and the CNC machines;
§ understand the needs and the benefits of the adoption of
CAD/CAM/CAPP techniques;
§ understand the need for automation and computer-based intelligence in
manufacturing.

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LEARNING TARGETS

Requirements

Material Behaviour
Product requirements
Design Process Planning
CAD/CAM/CAPP

Production
Raw Material / Product
Manufacturing Processes
Components CNC Machine Tools
Industrial
Material Behaviour Geometrical
Smart Manufacturing Metrology

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Q&A

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