Manufacturing technology

01 - Introduction

Manufacturing technology 1 01 - Introduction

Course description

Book and DVD

Manufacturing Technology:
• Lectures (36 hours) – oral exam with written preparation (75%)
• Lab sessions (26 hours) – continuous evaluation (25%)

Manufacturing technology 2 01 - Introduction

1
 WHAT IS MANUFACTURING?

• Making things has been an essential human activity

since before recorded history
• Today, the term manufacturing is used for this
activity
• Manufacturing is important
– Technologically
– Economically

Manufacturing technology 3 01 - Introduction

WHAT IS MANUFACTURING?

The word manufacture is derived from two Latin words:

• manus (hand)
• factus (make).
The combination means made by hand.

Word manufacture in English

• noun – 1567 AD
• verb – 1683 AD

Modern manufacturing → automated and computer-

controlled machinery

Manufacturing technology 4 01 - Introduction

2
 How are they made?

Manufacturing technology 5 01 - Introduction

Technology

Technology - the application of science to provide

society and its members with those things that are
needed or desired
• Technology provides the products that help our
society and its members live better
• What do these products have in common?
– They are all manufactured
• Technology is the essential factor that makes
manufacturing possible ().

Manufacturing technology 6 01 - Introduction

3
 Economy

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
- GDP – Gross Domestic Product

Manufacturing technology 7 01 - Introduction

Manufacturing - Technological

• Application of physical and chemical processes to

alter the geometry, properties, and/or appearance of
a starting material to make parts or products

Manufacturing technology 8 01 - Introduction

4
 Manufacturing - Economic

• Transformation of materials into items of greater value

by one or more processing and/or assembly operations

Manufacturing technology 9 01 - Introduction

Manufacturing Industries

• Industry consists of enterprises and organizations that

produce or supply goods and services
• Industries can be classified as:
1. Primary industries - cultivate and exploit natural
resources, e.g., agriculture, mining
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and
capital goods
3. Tertiary industries - service sector

Manufacturing technology 10 01 - Introduction

5
 Specific Industries in Each Category

Manufacturing technology 11 01 - Introduction

Manufacturing Industries - continued

• Secondary industries include manufacturing,

construction, and electric power generation
• Manufacturing includes several industries whose
products are not covered in this book; e.g., textiles,
beverages, chemicals, and food processing
• For our purposes, manufacturing means production of
hardware
– Nuts and bolts, forgings, cars, airplanes, digital
computers, plastic parts, and ceramic products

Manufacturing technology 12 01 - Introduction

6
 Manufactured Products

• Final products divide into two major classes:

1. Consumer goods - products purchased directly by
consumers
• Cars, clothes, TVs, tennis rackets
2. Capital goods - those purchased by companies to
produce goods and/or provide services
• Aircraft, computers, communication equipment,
medical apparatus, trucks, machine tools,
construction equipment

Manufacturing technology 13 01 - Introduction

Production Quantity Q

The quantity of products Q made by a factory has an

important influence on the way its people, facilities, and
procedures are organized
• Annual quantities can be classified into three ranges:
Production range Annual Quantity Q
Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of units

Manufacturing technology 14 01 - Introduction

7
 Product Variety P

• Product variety P refers to different product types or

models produced in the plant
• Different products have different features
– They are intended for different markets
– Some have more parts than others
• The number of different product types made each
year in a factory can be counted
• When the number of product types made in the
factory is high, this indicates high product variety

Manufacturing technology 15 01 - Introduction

P vs Q in Factory Operations

Manufacturing technology 16 01 - Introduction

8
 More About Product Variety

• Although P is quantitative, it is much less exact than Q because

details on how much the designs differ is not captured simply by
the number of different designs
• Soft product variety - small differences between products, e.g.,
between car models made on the same production line, with many
common parts
• Hard product variety - products differ substantially, e.g., between a
small car and a large truck, with few common parts (if any)

Manufacturing technology 17 01 - Introduction

Materials in Manufacturing

• Most engineering materials can be classified into one

of three basic categories:
1. Metals
2. Ceramics
3. Polymers
• Their chemistries are different, and their mechanical
and physical properties are different
• These differences affect the manufacturing processes
that can be used to produce products from them

Manufacturing technology 18 01 - Introduction

9
 In Addition: Composites

• Nonhomogeneous mixtures of the other three basic

types rather than a unique category

Manufacturing technology 19 01 - Introduction

1. Metals

• Usually alloys, which are composed of two or more

elements, at least one of which is metallic. Two basic
groups:
1. Ferrous metals - based on iron, comprises about
75% of metal tonnage in the world:
• Steel and cast iron
2. Nonferrous metals - all other metallic elements
and their alloys:
• Aluminum, copper, nickel, silver, tin, etc.

Manufacturing technology 20 01 - Introduction

10
 1. Metals

Charging a
basic oxygen
furnace (BOF)
in steelmaking:
molten pig iron
is poured into
the BOF.
Temperatures
are around
1650°C
(3000°F).

Manufacturing technology 21 01 - Introduction

2. Ceramics

Compounds containing metallic (or semi-metallic) and

nonmetallic elements.
• Typical nonmetallic elements are oxygen, nitrogen,
and carbon
• For processing, ceramics divide into:
1. Crystalline ceramics – includes:
• Traditional ceramics, such as clay, and modern
ceramics, such as alumina (Al2O3)
2. Glasses – mostly based on silica (SiO2)

Manufacturing technology 22 01 - Introduction

11
 3. Polymers

Compound formed of repeating structural units called

mers, whose atoms share electrons to form very large
molecules. Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without altering
molecular structure
2. Thermosetting polymers - molecules chemically
transform into a rigid structure – cannot reheat
3. Elastomers - shows significant elastic behavior

Manufacturing technology 23 01 - Introduction

4. Composites

Material consisting of two or more phases that are

processed separately and then bonded together to
achieve properties superior to its constituents
• Phase - homogeneous mass of material, such as
grains of identical unit cell structure in a solid metal
• Usual structure consists of particles or fibers of one
phase mixed in a second phase
• Properties depend on components, physical shapes
of components, and the way they are combined to
form the final material

Manufacturing technology 24 01 - Introduction

12
 Overview

Manufacturing technology 25 01 - Introduction

4. Overview of manufacturing technologies

Pencils

Manufacturing technology 26 01 - Introduction

13
 Classification of manufacturing processes

Manufacturing technology 27 01 - Introduction

Classification of manufacturing processes

Manufacturing technology 28 01 - Introduction

14
 Classification of manufacturing processes

Manufacturing technology 29 01 - Introduction

Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 30 01 - Introduction

15
 Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 31 01 - Introduction

Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 32 01 - Introduction

16
 Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 33 01 - Introduction

Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 34 01 - Introduction

17
 Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 35 01 - Introduction

Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 36 01 - Introduction

18
 Casting &
moulding

Forming

Shearing &
machining

Joining

Coating

Changing of
mat. prop.
Manufacturing technology 37 01 - Introduction

Manufacturing technology 38 01 - Introduction

19
 • Manufacturing costs
– One-time-only costs
– Repeating costs
– Recurring costs (Regular cost incurred repeatedly, or for each item produced
or each service performed.)
• Production speed
• Flexibility
• Quality
• Environmental impact

• A lot is design dependent

– Flat, thin parts cannot be cast
– Complex products cannot be forged cheaply
– Hot-working results in worse surface quality and accuracy
– Some casting processes produce a better surface finish than others because
of the mold material used

Manufacturing technology 39 01 - Introduction

Manufacturing technology 40 01 - Introduction

20
 Manufacturing method?

Manufacturing technology 41 01 - Introduction

Marketing Sales
EE5 project

Quality
control
Design Production

Process
planning
Manufacturing technology

Manufacturing technology 42 01 - Introduction

21
 Practicalities

Goals
• Knowing terminology of the manufacturing jargon
• Understanding the most important manufacturing technologies and
machinery
• Insight in the link between material-function-shape-production technology

Handbook
• M.P.Groover, Principles of Modern Manufacturing, Wiley, Hoboken, 2010.

Literature
• S. Kalpakjian, S. Schmid, Manufacturing Engineering and Technology,
5th Ed., Pearson Prentice Hall, Signapore, 2006.
• M.P.Groover, Fundamentals of Modern Manufacturing - Materials,
processes, and Systems, Wiley, Hoboken, 2007.

Exam
• Oral with written preparation, closed book
Manufacturing technology 43 01 - Introduction

Manufacturing technology 44 01 - Introduction

22