INTRODUCTION TO MANUFACTURING & INDUSTRIAL PROCESSES

INTRODUCTION

Manufacturing

• Making goods and services available to satisfy human wants.

• Important to a country’s economic welfare and standard of living.
• Responsible for designing processes and systems to create the product as designed.
• Manufacturing and assembly – organized activities that convert raw materials into goods
that can be sold (Manufactured goods).

CONCEPTS AND TERMINOLOGY

Goods

• Material things or products.

• Tangible items.

Services

• Nonmaterial things that we buy to satisfy our needs and/or wants.

• Service production systems include but are not limited to:
o Transportation
o Education
o Insurance

Manufactured Goods

Producer Goods

• Goods that are manufactured for other companies to utilize in manufacturing either
producer or consumer goods.
• Example: Machine tools

Consumer Goods

• Goods purchased directly by the consumer or the general public.

• Example: Books

Product Development Curve

• The goal of a manufacturer of any

product or service is to continually
improve said product or service.
• The improvement process is usually
shown on an S-shaped curve.

Sustaining Technology

• Innovations and improvements.

• Serves to continually bring more value to existing products and services.
• Note: there is a limit to the amount of materials available on Earth.
Production System

• Sometimes called the enterprise or business.

• Includes people, money, equipment, materials and supplies, markets, management, and
the manufacturing system.
• Example: Company that manufactures engines, assembly plant, glassmaking factory, etc.
Manufacturing System

• A collection of manufacturing processes and operations resulting in the desired end

product or component.
• The arrangement of the manufacturing processes in the plant or factory.
• The entire system must be controlled in order to schedule and control the plant.
• Example: manufacturing of automobiles

Manufacturing Process

• Converts unfinished materials into finished products, usually with the help of machines or
machine tools.
• Process – sequence of steps or operations for the production of goods and services.
• Example: Spot welding, milling, drilling, broaching, etc.

Job and Station

• Job – total of the work a worker performs. A group of related tasks performed at one
station.
• Station – Location or area where the production worker accomplishes his or her job.
• Example:
A Turret Lathe Operator’s job may include the following: load, start, index and stop,
unload, inspect. In addition, setting up the machine can also be part of the job.

Job and Station (For unmanned machines)

• Job – a group of related operations generally performed at one station.

• Station – location or position in a machine where specific operations are performed.
• Simple machine may have only one station while complex ones may have multiple
stations.
Job and Station

• In planning a job, a process plan is usually made by an engineer to describe how a

component is made.
• “Pinion Shaft”

Operation

• A distinct action performed to produce

a desired result.
• Categorized by Function:
o Materials Handling and
Transporting
o Processing
o Packaging
o Inspecting and Testing
o Storing

Treatment

• Continuous operation on a workpiece.

• Usually alters or modifies the product-in-process without tool contact.
• Hard to include during manufacturing due to the possible long cycle times and hazards to
the workers’ health.
• Example: heat treating, galvanizing, chemical cleaning, etc.

Tools, Tooling, and Workholders

• Tools – used to hold, cut, shape, or form the unfinished product. Also includes workholders,
jigs, and fixtures.
• Common hand tools: saw, hammer, screwdriver, file, etc.
• Cutting Tools – mechanized version of some of the hand tools such as drill bits and milling
cutters. They wear down and fail eventually after constant use so they need to be
replaced.
• Noncutting Tools for forming – extrusion dies, punches, and molds.
• Tooling – tools and cutting tools.

Workpiece and Its Configuration

• In the manufacturing of goods, the main goal is to produce a component with the required
geometry, size, and finish.
• In designing an object, the designer specifies the size, shape, and arrangement of the
surfaces.
• Part design must be analyzed to find out which materials will provide the desired properties,
including the mating to other components and best processes achieve the end product.
 HANDLING OF SOLIDS: FEEDERS AND STORAGE SILOS

FEEDERS

• Material handling equipment that are used to control and regulate the flow of bulk materials
from storage (e.g. silo) into the machinery to process them.
• Often used together with other equipment like conveyors, crushers, dryers, and mixers to
name a few.
• Different types of feeders to match different industries and operations.

Benefits of Feeders

• Automated labor
• Feeding and positioning parts with relatively less effort from the operator
• Precise counting of parts

Types of Common Feeders

• Vibratory Bowl Feeders

Utilizes an electromagnetic spring mechanism to generate vibrations, driving parts
through guides to correctly sort the parts.

o Cylindrical
o Conical/Cascade
o Stepped

Some Applications:
o Automotive Industry
o Electric Parts
o Pharmaceuticals

• Pneumatic Bowl Feeders

Similar in the vibratory bowl feeders but instead of using electromagnetic coils and
springs, a pneumatic drive unit and piston engine is used to generate vibrations.

• Centrifugal Bowl Feeders

o The parts are delivered to a rotating center
disc mounted on an angle in the center of the
feeder. The disc and bowl rotate
independently.
o Centrifugal force drives components to the
outer edge of the bowl where they are
oriented to the correct position using
mechanical or pneumatic tooling.
o Handles small or fragile components since vibrations are not utilized.
o Common parts used are those with symmetrical, simple and smooth geometry, and
have one side or end that helps in the accept-or-reject process of orientation.
o Example: Plastic Caps
 • Belt Feeders
o Similar to conveyor belts but the roller space
is smaller to able to bear more materials.
o Used for shorter distance feeding and
reloading compared to a conveyor belt.
o Used for a controlled rate of material
feeding. (e.g. woodchips for paper mills)

• Apron Feeders
o Used for heavier and larger loads compared to
belt feeders but carries shorter distance than them.
o Suited for impact.

STORAGE SILOS

• Structures designed to store different materials or substances.

• They can be built using metal, stainless steel, and reinforced concrete to name a few.

Advantage of Silos

• Needs relatively less area to store the same

amount of material than if they were to be stored
in a horizontal warehouse.
• Materials are stored following optimal conditions.
• Lower cost than other storage systems.

Disadvantage of Silos

• Risk of Suffocation from accumulated carbon dioxide.

• Fumigants and Pesticides may cause intoxication.

Types of Storage Silos

• Tower Silos
o The common ones in terms of appearance and structure.
o They can be constructed from different materials such as wood, cement, concrete,
or steel.
o Usual uses include industrial and agricultural purposes. (Bulk storage of grain, coal,
cement, woodchips, food products, and sawdust)

• Bunker Silos
o Trenches with the walls being typically made of concrete.
o Covered with plastic tarp to make it airtight.
o Tractors and loaders are usually there to load and unload the materials.
o Usually utilized for very large quantities of materials like silage (Animal feed).

• Bag Silos
o Plastic and hermetic bags (layers of polythene) or tubes commonly used for grain
and fodder storage.
o Compacted in assembly, sealed at both ends.
 HANDLING OF SOLIDS: CONVEYORS AND CONVEYING SYSTEM

CONVEYOR

• A type of material-handling equipment used to automatically transport materials, products,

and loads to different locations efficiently, usually in the same building or area.
• Handles wide-range of materials and products down the production line.
• Heavily used in different industries:
o Packaging
o Manufacturing
o Mining
o Automotive
o Food and beverage

Benefits of Conveyors

• Able to move different kinds of objects and materials from one place to another
• Relatively less strain for humans or less manual labor needed.
• Saves time during material transportation.

CONVEYOR SYSTEM

Major Parts of a Conveyor System

o Belt Support
Smooth belt movement.
Supported when placing materials.

o Pulleys
Control of the belt movement

o Drive unit
Allows the system to move.

Choice of Conveyor System

• Product Requirements – Type of material/product needed.

• Process Requirements – Operating factors and how the conveyor should move.
• Transfer Requirements – Transfer of materials to and from the conveyor.
• Flow Rate Requirements - Able to satisfy demand and the number of products needed
per unit of time.
• Operation and System Qualities:
o Cost-effective
o Energy-Efficient
o Reliable
o Safe
 TYPES OF CONVEYORS

FLAT BELT CONVEYOR

• Also called as a “conveyor belt”.

• The most common and simplest type of conveyor.
• Continuous flat belt (natural or synthetic material)
• Applications:
o Industrial uses
o Slow assembly lines
o Small, soft or irregular shaped materials

Curved Conveyor Belt

• Carrying materials around corners and turns.

• Makes efficient use of floor spacing.
• Able to turn 45° , 90°, 135° and 180°
• Applicable to other types of conveyors.

ROLLER CONVEYOR

• Series of rollers supported within a frame

• Objects can be moved manually, by gravity or by power.
• Applications:
o Transportation of boxes, crates, and pallets
o Packaging
o Steelmaking

Gravity Roller Conveyors

• Uses the force of gravity to move the materials along the rollers.
• No power source needed.
• Harder to control in terms of conveyor speed, which could result in damage of goods.

Powered Roller Conveyors

• Installed with motors to help run the conveyor.

• Good for longer distance travelling of materials and able to handle heavier loads
• Speed control is present.
• Possible to have different zones of conveyors.

CLEATED BELT CONVEYOR

• Have sections or dividers that keep the product secured during travel of the belt in an
inclining or declining fashion.
• Types of Cleats:
o Inverted Capital T – for fragile materials
o Forward Leaning Capital L – can be curved at the base for granular materials
o Inverted V – for large, heavy, and abrasive materials
SCREW CONVEYOR

• a.k.a. Auger Conveyors

• Handles various bulk materials (semi-fluid to free flowing)
• Closed off to prevent leaking or spilling of the material or product, as well as protection from
outside factors.
• Multiple inlet and outlet points for more effective distribution.
• Applications:
o Agricultural Production
o Chemicals and Food processing
o Mining and Minerals
o Oil Refining

PNEUMATIC CONVEYOR

• Mainly uses air to convey the materials.

• Use of fans or blowers to produce the air flow.
• Closed system to prevent contamination, effects from the surroundings, and dispersion of the
material.
• May have difficulties in transporting some materials like those with larger particle sizes, as well
as not ideal for combustible bulk solids.
• Applications:
o Transfer of powders, flakes, granules, and pellets

OVERHEAD CONVEYOR

• Continuous tracks are suspended from overhead supports or mounted from the ceiling.
• Pendants, used to hold the product, are placed on the track with various designs possible to
hold different products.
• Saves floor space and does not block the aisles in the plant or building.
• Lessens travel time of goods.
• Applications:
o Assembly Automation
o Paint Finishing
o Garments
o Warehousing
 CLASSIFICATION AND SIZE REDUCTION OF SOLIDS

CLASSIFICATION OF SOLIDS

• Solids can be classified based on their chemical composition and atomic structure.
• These can be divided into:
o Metals
o Ceramics
o Polymers
o Composites
o Advanced Materials

METALS

• Made up of one or more metallic elements and often nonmetallic elements in relatively
smaller amounts.
• Their atoms are arranged orderly and are denser compared to ceramics and polymers.
• Various uses in structural applications and other industries.
• “Metal Alloys” – metallic substances composed of two or more elements.
(e.g. Brass = Copper and Zinc)
• Typical characteristics:
o Stiff and Strong
o Ductile (able to handle large amounts of deformations without fracture).
o Resistant to fracture
o Good conductors of electricity and heat.

CERAMICS

• Compounds between metallic and nonmetallic elements

• Usually oxides, nitrides, and carbides.
• Used in various means such as cookware, cutlery, and the automotive industry.
• Common materials:
o Alumina (Aluminum Oxide)
o Silica (Silicon Dioxide)
o Silicon Carbide
o Silicon Nitride
o Traditional Ceramics (Clay minerals such as Porcelain)
o Cement and Glass
• Typical Characteristics:
o Relatively stiff and strong, comparable to metals
o Usually very brittle (their resistance to fracture are innovated to be better).
o Good heat and electric insulators.
o More resistant to harsh environments and higher temperatures than metals and
polymers.
POLYMERS

• Plastic and rubber materials.

• A number of them are organic compounds chemically based on hydrogen, carbon, and
other nonmetallic elements (e.g., O, N, and Si)
• Very large molecular structures (Chainlike)
• Common materials:
o Polyethylene (PE)
o Nylon
o Polyvinyl Chloride (PVC)
o Polycarbonate (PC)
o Polystyrene (PS)
o Silicone rubber
• Typical characteristics:
o Low densities
o Not as stiff and strong as the other material types.
o Ductile and pliable.
o Chemically Inert and unreactive.
o Tendency to soften or decompose at modest temperatures.
o Low electrical conductivities and nonmagnetic.

COMPOSITES

• Made up of two or more materials (metal, ceramic, or polymer)

• Combine the properties of the individual materials into one.
• Various uses such as in aircraft, aerospace, and high-tech sporting equipment.
• Either Natural-occurring (e.g. bones) or Synthetic (Man-made)
• Common materials:
o Fiberglass
o Carbon-fiber Reinforced Polymer
o Wood

ADVANCED MATERIALS

• Utilized in high-tech applications or products/equipment that do more complex operations

and functions.
• Included are the traditional materials with enhanced properties and the newly developed,
high-performance materials.

SEMICONDUCTORS

• Have electrical properties in between electrical conductors and insulators.

• Heavily used in integrated circuitry, electronics, and computers.

BIOMATERIALS

• Used in components implanted in the human body to replace damaged body parts.
• Must not be toxic and should be compatible with body tissues.
SMART MATERIALS

• Materials that are able to sense changes in their environment and act accordingly in a
predetermine manner.
• Components usually include a sensor (detects a signal) and actuator (response from the
signal).

NANOMATERIALS

• Can be under the previous types of materials (metal, ceramic, etc.)

• Distinguished based on their size. Dimensions of these structures are on the order of
nanometers (10-9)
• Nanotechnology – the study of the properties of nanomaterials.
• Some physical and chemical characteristics may experience some form of change when
the particle size approaches atomic dimensions.
• Properties may depend on size in the nanoscale domain.

SIZE REDUCTION & SEPARATION OF SOLIDS

• In different processes, such as in the food industry, it is important for materials to be

reduced during operation.
• Communition – produce smaller particles from larger ones.
• Size reduction refers to the mechanical process of breaking down solids into smaller
particle sizes.
• Reasons for Size Reduction:
o To meet size requirements.
o To separate materials.
o To make the solids mix with each other properly.
o To improve properties of products.

COMPRESSION

• Also called “Crushing”

• Rupturing of a material when external force is applied on it, exceeding its strength.
• Particles are irregular in size and shape after crushing.
• Coarse reduction of Solids
• Equipment:
o Roll Crusher
o Gyratory Crusher
o Jaw Crusher
• Applications of Crushing:
o Extraction of juice from sugarcane
o Raw Ores (Mining)
IMPACT

• A material experiencing a sudden blow of force.

• Imagine how a hammer works.
• Produces Coarse, Medium, or Fine products.
• Equipment:
o Hammer Mill
o Impact Testing Equipment
• Applications of Impact:
o Food (Grinding of legumes, nuts, and beans)
o Pharmaceutical (Powder making)
o Cosmetics (Powder making)

ATTRITION

• Rubbing or wearing down a material using friction.

• Imagine how a file works.
• Results in fine products.
• Equipment:
o Attrition Mill
o Ball Mill
o Sand Mill
• Applications of Attrition:
o Spices, Seeds, and Fibers
o Materials that cannot be reduced by impact

CUTTING

• Forcing a sharp and thin knife (cutting tool) through the material.
• Separation of the material.
• Results in products with definite particle size and at times, a definite shape.
• Equipment:
o Rotary Knife Cutter
o Milling Cutters
• Applications of Cutting:
o Cutting fruits and vegetables (food)
o Woodworking
o Fabrics