LECTURE 2

INE 121: DR. GHADA MOHAMED

ELGOHARY

INTRODUCTION
Zagazig University, Industrial
Engineering Dep.

TO IE
1
 Book:
Introduction to Industrial & Systems
2 Engineering, 3rd edition
Authors: Wayne C. Turner et al.
Dr. Ghada Elgohary
 ONLINE/OFFLINE CHAPTER TOPIC

OFFLINE 17/10 INTRODUCTION DEFINITION & APPLICATION

OF IE

ONLINE 24/10 CHAPTER 3 MANUFACTURING

ENGINEERING

TimeLine
OFFLINE 31/10 CHAPTER 6 WORK DESIGN &
ORGANIZATION
PERFORMANCE

of ONLINE 7/11 CHAPTER 7 OPERATIONS PLANNING &

CONTROL

Lectures OFFLINE 14/11 CHAPTER 17 PROJECT MANAGEMENT

ONLINE 28/11 CHAPTER 4 FACILITIES LOCATION &

LAYOUT

OFFLINE 5/12 CHAPTER 5 MATERIAL HANDLING

ONLINE 12/12 CHAPTER 8 QUALITY CONTOL

OFFLINE 19/12 CHAPTER 11 HUMAN FACTORS

ONLINE 26/12 CHAPTER 12 RESOURCE MANAGMENT

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Chapter 3
Manufacturing
Engineering
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 • Manufacturing Engineering
• Product-Production Design
Interface
• Process Engineering

Outline • Product Structure

• Assessing Manufacturability
• Determining Process
Capability
• Evaluating Process Cost
• Determining Sequence of
Operations
• Documenting Process
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 • Ancillary Functions
• Tool, Jig, and Fixture
Design
Outline • Cost Estimating
• Maintenance Systems
Design
• Package Systems

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 1- Evaluating the manufacturability of
the product.

Manufacturing
2- Selecting processes and setting
process parameters as cutting tool,
size, shape, and so on.
Engineering 3- Designing work holding devices
(jigs & fixtures).
4- Estimating the cost of
manufacturing the product.
5- Assuring the quality of the part
produced.

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Product-Production Design Interface

▪ Part characteristics such as size, shape, strength,

reliability, safe operating and so on are evaluated
using the knowledge of physics.

▪ Manufacturing Engineer develops and evaluates the

cost of producing the part.

▪ Few industrial Engineers are trained in product

design, and few product designers are trained in
manufacturing engineering, this makes their
interaction is very important.

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 Continue
• The part designer wants the tolerances set
as small as possible to assure that the part
will function without problems.

• But manufacturing engineer wants the

largest possible tolerance to be specified as
this gives him a wider choice of processes
to be used in manufacturing.

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 Continue
• Ideally, a manufacturing engineer should
work with the product designer from
beginning to ensure producibility.
• If it isn’t possible to have this interaction,
the manufacturing engineer should inform
the design engineer of unusually costly
operations, by this information, the design
engineer can avoid certain costly
operations.
• This interaction must be happened early as
possible.

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 Process Engineering

It is concerned with the design the actual

process to be used in the manufacture of the
product.
The six steps for designing process:-
1. Product structure
2. Assessing manufacturability
3. Determining process capability
4. Evaluating the cost of process
5. Determining the sequence of operations
6. Documenting the process
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 1.Product structure

This is a chart defines “what goes into what?”

Meaning of Symbols;
R: Raw material
C: Component
SS: Sub-subassembly
S: Subassembly
&
Number in brackets ( ):
Needed units to form
one unit for higher
level.
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 product

S1 S2

C3 SS1 SS3

C1 C2 C4 C3

SS1 R2 R3 R5 R6

C1 C2 R4

R2 R3

R4

Fig. 3.1. Example Product Structure

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 Bill Of
Material
(BOM)

BookCase

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 Bill of Material

Product description: Bookcase, metal, 3 shelves.

Stock Number:1
Component Quantity Source
Stock No. Description Required

3 Shelf 3 Manufacturing
4 Leg 4 Manufacturing
5 Inserts 8 Purchasing
6 Screws 12 Purchasing

Bill of Material
Product description: Bookcase, metal, 6 shelves.
Stock Number:2
Component Quantity Source
Stock No. Description Required

3 Shelf 6 Manufacturing
4 Leg 8 Manufacturing
5 Inserts 8 Purchasing
6 Screws 24 Purchasing
7 Connectors 4 Purchasing
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 Bill of Material
Product description: Shelf
Stock Number:3
Component Quantity Source
Stock No. Description Required

8 Sheet metal 3 square feet Purchasing

Bill of Material
Product description: Leg
Stock Number:4
Component Quantity Source
Stock No. Description Required

3 Sheet metal 2 square feet Purchasing

Fig. 3.2. Bill of material

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 2.Assessing
Manufacturability

• The manufacturability of
an item is a measure of
the relative ease or
difficulty of producing the
item within tolerance.

• The tighter the tolerance

the more expensive the
item will be as shown in
Fig. 3.3.

• Item is Standard-sized or
not.
Fig. 3.3. relationship of cost and
tolerance
17 Dr. Ghada Elgohary
 Tolerance

Tolerance in Dimensions

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3.Determining Process
Capability

Fig. 3.4. Tolerance for various processes

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Fig. 3.4. Tolerance for various processes
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 Surface finish
Relative production time

Surface finish

Fig. 3.5. Relative production time versus surface finish

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 4.Evaluating Process Cost

Evaluating the cost of using each process, there are two

types of cost, fixed costs and variable costs.
Examples of Fixed costs: purchase cost of machines,
the installing cost, the design and fabrication
cost, holding devices , and the cost of spaces of
machines.

Examples of Variable costs: the cost of operator per

time, the cost of running machine per time, the
cost of cutting tool , and the cost of material used
in manufacturing per time per part.

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 Continue
Total cost = Fixed Cost + Variable cost * number of units

* Fig. 3.7 indicates Total Variable cost

relationship between cost per unit
Number of units Produced produced
and Total Cost.
* If a number of alternative
processes are being considered,
their costs can be plotted in Fixed
same graph. cost

Number of units produced

Fig. 3.7. Total cost

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 Continue
Example, suppose that three processes are under
consideration and the following costs:-
Process A Process B Process C
Fixed cost $0 $2,000 $8,000
Cost/unit 10 8 5

Produced Used Process

units
<1000 Process A
>2000 Process C
>=1000 Process B
<=2000
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 Continue
Solution:
Determine the break-even
point
Total cost(A) = 0 + 10X
Total cost(B) = 2000 + 8X
Then X =1,000.

The total costs for both

processes must be equal
at the break-even point.

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 5.Determining Sequence of
Operations
The determination of the sequence of operations
that will be used to transform the material into its
desired final shape depends on some considerations
such as:

1. Minimization of part handling.

2. Assuring sequence to avoid scratches.
3. Performing as many operations on each machine as
possible so that close tolerance can be maintained
for high quality (repeat before go until fit
tolerance).

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 6.Documenting Process

• Recording information of any process

is done by Constructing
An Operations Process Chart .

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 Ancillary Functions
The production or manufacturing engineer performs
many other functions such as
Tool, jig, and fixtures design,
Cost estimating, and
Maintenance systems design, and
Packing systems.

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Tool, Jig, and
Fixture Design

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 Cost Estimating
Three items of cost:
▪ Material—Direct material such as wood, paper,
and Indirect material such as cleaning compounds
for sweeping floors and paint thinner for cleaning
brushes.
▪ Labor—Direct labor such as lathe labor, Painter,
and Indirect labor is all other factory labor such as
maintenance man, foremen, and inspector.
▪ Overhead– overhead is all cost of production other
than direct labor or direct material. Indirect material
and indirect labor are overhead items.

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 Maintenance Systems Design

1. Periodic maintenance/
Preventive maintenance
2. Emergency maintenance.

Fig. 3.26 is an example checklist

used for periodic preventive
maintenance of automotive
vehicles.
The design of these checklists
and determination of frequency
of their functions of production-
manufacturing engineer.
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3
4
 Package Systems

• Packaging is the last phase of production—

manufacturing engineering.

• The package of the finished product must be

designed to protect it during transit and to ensure
that the product will arrive undamaged.

• The package designer must be familiar with the

various materials for packaging, the techniques of
package design, and the cost of various packages.

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Package
Systems

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 Assignment 2
Prob. 1
Choose a manufacturing
product, and then draw and
explain its (Product
Structure & Bill of Materials).

Prob. 2
Make a checklist
maintenance sheet for any
device at your home.

Prob.3
Draw an operations process
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chart for a chosen product
Dr. Ghada Elgohary
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