MANUFACTURING

PROCESSES
 WHAT IS MANUFACTURING ?
The process of converting raw materials, components, or parts into finished
goods that meet a customer's expectations or specifications. Manufacturing commonly employs a man-
machine setup with division of labor in a large scale production.
Manufacturing technology provides the tools that enable production of all manufactured goods. These
master tools of industry magnify the effort of individual workers and give an industrial nation the power to
turn raw materials into the affordable, quality goods essential to today’s society.
• Input/Raw materials
A resource required for the manufacture of a product or service
• Conversion System/Processes
Making output/products from Inputs/raw materials by various processes, machinery and operations
following a well-organized plan for each activity required
• Output/Products
Actual product/output having VALUE (as a monetary worth or marketable price) OUTPUT may be,
DISCRETE PRODUCTS/Individual parts or part pieces (nails, gears, engine blocks etc.)
CONTINUOUS PRODUCTS/May be cut into individual pieces (a spool of wire, metal or plastic
sheet, tubes, pipes etc.)
MANUFACTURING AND PRODUCTION ?
DIFFERENCE
Often used interchangeably as well as,
Manufacturing is a process of converting raw material in to finished product by using various
processes, machines and energy. it is a narrow term. Manufacturing isn't just when producing the
product, it includes other stages such as design, sales, management and marketing also.
e.g. Making a tire from raw material, making frame body of a bicycle from pipes etc

Production is a process of converting inputs in to outputs. it is a broader term.

every type of manufacturing is production but every production is not a manufacturing.
A film/drama/advertisement maker is producer, and making a film is
production
An agricultural farm has various crops as products
 MANUFACTURING PROCESSES
This refers to science and technology of manufacturing products effectively, efficiently,
economically and environment-friendly (Sustainable Development)
It is extremely difficult to tell the exact number of various manufacturing processes existing
and are being practiced presently because a spectacularly large number of processes have been
developed till now and the number is still increasing exponentially with the growing demands and
rapid progress in science and technology.
However, all such manufacturing processes can be broadly classified in four major groups as follows:
Shaping or forming
Joining process
Removal process
Regenerative manufacturing

Additional classifications include,

•Assembly
•Surface Treatments (Finishing)
•Heat Treating
•Others
MANUFACTURING PROCESSES DESCRIPTION
1. Shaping or forming
Manufacturing a solid product of definite size and shape from a given
material taken in three possible states:
• in solid state – e.g., forging rolling, extrusion, drawing etc.
• in liquid or semi-liquid state – e.g., casting, injection moulding etc.
• in powder form – e.g., powder metallurgical process.
2. Joining process, Welding, brazing, soldering etc.
3. Removal process, Machining (Traditional or Non-traditional), Grinding etc.
4. FINISHING PROCESSES (honning, lapping, polishing, burnishing, deburring, surface treating,
coating, plating)
5. Regenerative manufacturing, Production of solid products in layer by layer from raw materials
in different form:
• liquid – e.g., stereo lithography
• powder – e.g., selective sintering
• sheet – e.g., LOM (laminated object manufacturing)
• wire – e.g., FDM. (Fused Deposition Modelling)
Out of the aforesaid groups, Regenerative Manufacturing is the latest one which is generally
accomplished very rapidly and quite accurately using CAD and CAM for Rapid Prototyping and
Tooling.
MANUFACTURING PROCESSES contd.

CONCURRENT ENGINEERING – a systematic approach integrating the design and

manufacture of products with the view of optimizing all elements in the life cycle of the product
LIFE CYCLE – all aspects of a product such as design, development, production, distribution,
use and its ultimate disposal and recycling, are considered simultaneously
RAPID PROTOTYPING – relies on CAD/CAM and various manufacturing techniques (using
polymers or metal powders) to produce prototypes in the form of a solid physical model of a
part rapidly and at a low cost.
DESIGN FOR MANUFACTURE AND ASSEMBLY (DFM)-A comprehensive approach to
production of goods and integrates the design process with materials, manufacturing
methods,process planning, assembly and quality assurance.
DESIGN FOR ASSEMBLY (DFA) & DESIGN FOR DISASSEMBLY
Assembly - Ease, speed and cost of putting parts together Disassembly Products are taken
apart for maintenance, servicing or recycling of their components.