MEM 560: MANUFACTURING PROCESSES

TOPIC 1

OVERVIEW OF
MANUFACTURING
PROCESSES & TECHNOLOGY

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Compiled by:
Norliana Mohd Abbas, PhD
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 OVERVIEW

Sustainable manufacturing
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Role of manufacturing
in nation’s economy

2 4 Industrial revolution and

virtual manufacturing

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Competitiveness aspects in
Introduction to manufacturing processes
manufacturing
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 1 What is manufacturing?

the process of converting raw materials into products

 Also involves activities in which the manufactured product itself, is used
to make other products e.g. sewing machine to make clothing.

 Manufacturing is a complex activity involving variety of resources and

activities viz.:
1. Product design
2. Machinery and tooling
3. Process planning
4. Materials
5. Production control
6. Support services
7. Marketing etc… 3
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1 What is essential in manufacturing?

1. Design requirement, products specifications & standard

2. Economical & environmental friendly
3. Quality
4. Flexible
5. Materials, production methods & comp. integration
6. System
7. Continuous product improvement
8. Productivity

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1 Types of Production

1. Low-Quantity Production @ Job shop production

1-100 units/year
e.g. air craft, ship

2. Medium-Quantity Production @ Batch production

100-10 000 units/year
e.g. team jersey

3. High-Quantity Production @ Mass production

10 000-millions units/year
e.g. car 5
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1 Product Life Cycle

A well designed product are:

1. Functional (design)
2. Well manufactured (production)
3. Well packaged (arriving safely to the customer)
4. Durable (function effectively for its intended purpose) 6
5. Maintainable
6. Resource efficient (can be disassembled for recycle)
1 Design for X

1. Design for Manufacture (DFM)

Integrates process with materials, mfg methods, process planning,
assembly, testing & quality assurance

2. Design for Assembly (DFA) & disassembly

Easy to assemble & disassemble the product

3. Design for Service

Individual parts @ sub-assemblies in a product be easy to reach & service

4. Design for Manufacture & Assembly (DFMA)

Correlation between mfg of component & their assembly into final
product
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 Product design process &
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concurrent engineering
 Product design:
A critical activity since 70-80% of the cost of the product development &
manufacture is determined by the decision made in the initial design stage.

The design of a product first requires a thorough understanding of the function

and the expected performance of the product

Product design involves constructing & studying analytical models through the
use of product design tools:

CAD CAE CAM

technology concerned
technology concerned technology concerned
with the use of computer
with the use of computer
systems to assist in with the use of systems to plan, manage
creation, modification, computer systems to 8
& control manufacturing 8
analysis, and optimization analyze CAD geometry operations
of a design
 Product design process &
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concurrent engineering
 concurrent engineering = simultaneous engineering

An approach where all discipline are involved in the early design stage so,
the iterationresult in less wasted effort and time. Integrates the design &
manufacture of a product with a view toward optimizing all elements
involved in life-cycle of a product

Key: well organized communication within various discipline

➢ Concurrent engineering reduces:

1. Changes in product design & engineering
2. Time & cost from design concept to marketplace
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 Product design process & concurrent
1 engineering

(Left) Chart showing various steps

involved in design and
manufacturing a product.
Depending on the complexity of
the product and the type of
materials used, the time span
between the original concept and
the marketing of a product may
range from a few months to many
years,

(Right) Chart showing general product

flow in concurrent engineering,
from market analysis to selling the
product
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1 Selection of Materials and Process

Factors to be consider in material selection

1. Properties of materials
2. Cost & availability
3. Appearance, service life & recycling

Factors to be consider in process selection

1. Selection of processing method
2. Dimensional accuracy
3. Operational & mfg cost
4. Net-shape mfg:
the first operation is made near to the desired product as possible

Consequences of improper selection of materials & processes

a. stop functioning
b. not function properly 11
c. unsafe for further use 11
1 Example of Process Selection (1)

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1 Example of Process Selection (2)

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1 Example of Process Selection (3)

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1 Example of Process Selection (4)

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1 Example of Process Selection (5)

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1 Example of Process Selection (6)

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 2 Role of manufacturing in nation’s
economy
Gross National Product (GNP) is the market value of all goods and
services produced in one year by labour and property supplied by the
residents of a country

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Industrial Production
Index (IPI) is a measure of
the rate of change in the
production of industrial
commodities in real terms
over time for
Manufacturing, Mining and
Electricity Sectors.

It is measured based on
volume changes in
production.

IPI give the overview of the

current trend of industrial
activities and used for 22

economic analysis.
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https://sustainabledevelopment.un.org/sdgs
Target & Indicator please refer to: https://sustainabledevelopment.un.org/sdg9

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Target & Indicator please refer to: https://sustainabledevelopment.un.org/sdg12

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 3 Sustainable manufacturing (SM)

Can be defined as a method for manufacturing that minimises waste and

reduces the environmental impact.

➢ should integrate sustainable activities at all levels of manufacturing –

product, process and system

Key Benefits from Sustainable Manufacturing

• Lower Resource and Production Costs

• Lower Regulatory Compliance Costs
• Improved Sales and Brand Recognition
• Greater Access to Financing and Capital
• Easier Employee Hiring and Retention

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 3 Sustainable manufacturing (SM)
Why companies are pursuing sustainability:

• Increase operational efficiency by reducing costs and waste

• Respond to or reach new customers and increase competitive advantage
• Protect and strengthen brand and reputation and build public trust
• Build long-term business viability and success
• Respond to regulatory constraints and opportunities

Ways that companies progress further on the path to sustainability include:

• Address sustainability in a coordinated, integrated and formal manner,

rather than in an ad hoc, unconnected and informal manner
• Focus on increased competitiveness and revenues rather than primarily
focusing on cost-cutting, risk reduction and improved efficiency
• Use innovation, scenario planning and strategic analysis to go beyond
compliance
• Integrate sustainability across business functions 27
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• Focus more on the long term
• Work collaboratively with external stakeholders
3 Tool to implement SM
Tool used: the Life Cycle Assessment (LCA)

An approach to examine fully the environmental impact of different activities

performed. Steps in LCA:

1 Define appropriate scope

2 Develop a quantitative analysis of the material and

energy inputs to the product or process at all levels

3 Relate the outputs of the system at each stage to

direct impact on the external world

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4 Make recommendations from the findings obtained in
step 1-3
3 SM Approach
Increase circularity in manufacturing to reduce utilization of resources so that
less material is extracted from earth

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3 Activities introduced to achieve SM

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https://www.industr.com/en/sustainable-manufacturing-
principles-applications-and-directions-2333598
3 Environmentally Conscious Design And
Manufacturing
Process/ manufacturing activities that cause harm to the environment

1. Lubricants & coolant for machining

2. Various fluids & solvent used in cleaning
3. By-products from mfg plant e.g. water, oil from heat-treating
facilities
4. Metallic and non-metallic scrap

MAJOR CONCERN: water and air pollution, acid rain, ozone depletion
the greenhouse effect, hazardous wastes and global warming.

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 3 Environmentally Conscious Design
And Manufacturing
Certain guidelines can be followed to reduce the risk:

1. Reducing waste of materials, by refinements in product design and

reducing the amount of materials used.
2. Reducing the use of hazardous materials in products and processes.
3. Conducting research and development into environmentally safe
products and into manufacturing technologies.
4. Ensuring proper handling and disposal of all waste.
5. Making improvements in recycling, waste treatment, and reuse of
materials.

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 3 Environmentally Conscious Design
And Manufacturing
Design for the Environment (DFE) or green design.

Anticipates the possible adverse environmental impact of materials, products,

and processes, so that it can be taken into account at the earliest stages
of design and production.

Main objectives :to prevent pollution at the source and to strongly promote
recycling and reuse instead of disposal.

These goals led to the concept of design for recycling (DFR).

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4 Industrial Revolution

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4 Computer Integrated Manufacturing
(CIM)
CIM :
Extending the use of computers by integrating the hardware and software
from production concept through product distribution in market.

CIM Capability:
1. Responsive to rapid changes in market demand and product
modifications.
2. Better use of materials, machinery, personnel and reduction in
inventory
3. Better control of production and management of the total
manufacturing operation.
4. The manufacture of high-quality products at low cost

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 4 Computer Integrated Manufacturing
(CIM)
Major applications of computers in manufacturing
1. Computer numerical control (CNC)
A method of controlling the movements of machine components by
direct insertion of coded instructions in the form of numerical data
2. Adaptive control (AC)
Parameters in a manufacturing process are adjusted automatically to
optimize production rate and product quality, and to minimize cost.
3. Industrial robots
Replacing humans in operations that are repetitive, dangerous, and
boring, thus reducing the possibility of human error, decreasing
variability in product quality, and improving productivity.
4. Automated handling of materials
Handling of materials and components in various stages of completion
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(work in progress).
 4 Computer Integrated Manufacturing
(CIM)
5. Computer-aided process planning (CAPP)
Improving productivity by optimizing process plans, reducing planning
costs, consistency of product quality and reliability, cost estimating and
monitoring of work standards (time required to perform certain
operation)
6. Group technology (GT)
Parts are grouped and produced by classifying them into families,
according to similarities in design and the manufacturing processes.
7. Just-in-time production (JIT)
8. Cellular manufacturing (CM)
Utilizes workstations (manufacturing cells) that usually contain several
production machines controlled by a centre; robot, each machine
performing a different operation on the part.
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4 Computer Integrated Manufacturing
(CIM)
9. Flexible manufacturing systems (FMS)
Integrate manufacturing cells into a large unit, all interfaced with a
central computer. Efficiently producing parts in small runs and
changing manufacturing sequences on different parts quickly; this
flexibility enables them to meet rapid changes in market demand for
all types of products.
10. Expert systems (ES)
Complex computer programs and have the capability to perform
various tasks and solve difficult real-life problems much as human
experts would.
11. Artificial intelligence (AI)
Involves the use of machine and computers to replace human
intelligence. Computer-controlled system are capable of learning from
experience and of making decisions that optimize operations and
minimize costs. 38
 4 Industrial Revolution 4.0 (IR4.0)

 Industry 4.0 is related to what is called the “smart factory”

(Dutton, 2014).

 In a smart factory, a virtual copy of the physical world and

decentralized decision making can be developed (Buhr, 2015). Also,
physical systems can cooperate and communicate with each other
and with humans in real time, all enabled by the IoT and related
services.

 The concept of Industry 4.0 has its origins in Germany and has been
recognized by other leading industrial nations, although it is known
as “Connected Enterprise” in the United States and the “Fourth
Industrial Revolution” in the United Kingdom.
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4 Industrial Revolution 4.0 (IR4.0)

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4 Virtual technology

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4 Virtual technology
Virtual reality (VR) implies a complete immersion experience that shuts out the
physical world. Using VR devices such as HTC Vive, Oculus Rift or Google Cardboard,
users can be transported into a number of real-world and imagined environments
such as the middle of a squawking penguin colony or even the back of a dragon.

Mixed Reality
MR brings together real world and digital elements. In mixed reality, you interact
with and manipulate both physical and virtual items and environments, using next-
generation sensing and imaging technologies. Mixed Reality allows you to see and
immerse yourself in the world around you even as you interact with a virtual
environment using your own

Augmented reality (AR) adds digital elements to a live view often by using the
camera on a smartphone. Examples of augmented reality experiences include
Snapchat lenses and the game Pokemon Go.
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4 Importance of virtual technology
4 Applications of virtual technology

•Healthcare—For training, such as for surgical simulations

•Film and TV—For movies and shows to create unique experiences

•Virtual travel—For virtual trips to an art museum—or another

planet—all from home

•Professional sports—For training programs like STRIVR to help pro

and amateur athletes

•Gaming—For over 1,000 games already available, from first-person

shooters to strategy games to role-playing adventures

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4 Virtual technology in manufacturing

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 4 Virtual technology in manufacturing

https://www.youtube.com/watch?v=wOlcUK https://www.youtube.com/watch?v=GEds6
poV7o XdHaeI

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https://www.youtube.com/watch?v=MRkqgNwkbaU
4 Impact of Virtual Manufacturing

 Services and business models

 Reliability and continuous productivity
 IT security: Companies like Symantec, Cisco, and Penta
Security have already begun to address the issue of IoT
security
 Machine safety
 Product lifecycles
 Industry value chain
 Workers' education and skills
 Socio-economic factors
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 5 Competitiveness Aspect in
Manufacturing Processes

Beginning with the 1960s, the following trends developed that have had a
major impact on manufacturing:

1.Global competition increased rapidly, and the markets became multinational

and dynamic.
2. Market conditions fluctuated widely.
3. Customers demanded high-quality, low-cost products and on-time delivery.
4. Product variety increased substantially and products became complex, and
product life cycles became shorter.

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5 General Trends in Manufacturing

Certain important trends

 Materials and processes
 Manufacturing systems
 Organizational trends

For a manufacturing enterprise to be successful, it must respond to the

following:
1. View the people in the organization as important assets, and emphasize
the importance and need for teamwork and involvement in problem
solving and in decision-making processes in all aspects of operations.
2. Encourage product innovation and improvements in productivity.
3. Relate product innovation and manufacturing to the customer and the
market, seeing the product as meeting a need.
4. Increase flexibility of operation for rapid response to product demands,
in both the domestic and the global marketplace.
5. Encourage efforts for continuous improvement in quality.
6. Ultimately and, most importantly, focus on customer satisfaction on a
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global scale.
5 Waste Reduction in Design

Design principles for economic production

1. The design should make the product as simple as possible to

manufacture, assemble, disassemble, and recycle.
2. Materials should be chosen for their appropriate manufacturing
characteristics.
3. Dimensional accuracy and surface finish should be specified as broadly as
is permissible in order to minimize manufacturing costs.
4. Net-shape manufacturing of parts should be emphasized, and secondary
and finishing operations should be avoided or minimized.

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5 Waste Reduction in Manufacturing

Lean Production
A methodology that involves a thorough assessment of each of the activities
of a company in order to minimize waste at all levels.

Requires a fundamental change in corporate culture, as well as an

understanding of the importance of cooperation and teamwork among
management and the work force.

Agile Manufacturing
Implementation of the principles of lean production on a broad scale. The
principle ensuring agility (hence flexibility) in the manufacturing
enterprise, so that it can respond rapidly to changes in product demand
and customer needs
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5 Product Improvement through
Value Engineering (VE)
 a systematic method to improve the "value" of goods or products and
services by using an examination of function.

 Value, as defined, is the ratio of function to cost. Value can therefore

be increased by either improving the function or reducing the cost.

 Value engineering a technique in which the value of a system’s outputs

is optimized by crafting a mix of performance (function) and costs.

 In most cases this practice identifies and removes unnecessary

expenditures, thereby increasing the value for the manufacturer
and/or their customers.
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 Example of Product Improvement
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through Value Engineering (VE)

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THE END

TOPIC 1
Norliana Mohd Abbas

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 EXERCISES
1. There are basically three types of production methods. Briefly explain
these three common methods and also give the advantages and
disadvantages
a. unit production
b. batch production
c. mass production

2. What is manufacturing? Describe briefly the role of the manufacturing

sector/industries in the economic development of Malaysia.

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