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IE 2521

Manufacturing Processes I
Ch. I
(Overview of Manufacturing)
by
Ali Abd El-Aty, ​PhD, MASME, FISME
Assistant Professor,
Mechanical Engineering Department
Faculty of Engineering-Kharj
Prince Sattam Bin Abdulaziz University
2023-2024
 Ch. I : Overview of Manufacturing 2

What is Manufacturing?
▪ The word manufacture is derived from two ▪ Most modern manufacturing operations are
Latin words manus (hand) and factus accomplished by mechanized and
(make); the combination means “made by automated equipment that is supervised by
hand” human workers.
▪ “Made by hand” described the fabrication
methods that were used when the English
word “manufacture” was first coined
around 1567 A.D.
 Ch. I : Overview of Manufacturing 3

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 to the United

States and most other developed and
developing nations
➢ Technologically
➢ Economically
 Ch. I : Overview of Manufacturing 4

Technological Definition of Manufacturing Economic Definition of Manufacturing

▪ The application of physical and chemical
processes to alter the geometry, properties,
and/or appearance of a given starting
material to make parts or products.
▪ It also includes assembly of multiple parts
to make products.
▪ The transformation of materials into items
of greater value by means of one or more
processing and/or assembly operations
▪ Manufacturing adds value
 Ch. I : Overview of Manufacturing 5

Manufacturing Industries
▪ Industry consists of enterprises and
organizations that produce or supply
goods and services.

▪ Industries can be classified as:

➢ Primary industries - cultivate and
exploit natural resources, e.g.,
agriculture, mining
➢ Secondary industries - take the
outputs of primary industries and
convert them into consumer and
capital goods .
➢ Tertiary industries - service sector
 Ch. I : Overview of Manufacturing 6

Manufacturing Industries

Primary Processing to Secondary Processing to

Mine Extracting Raw Materials
Manufacture Bar Stock Manufacture a Ladder
 Ch. I : Overview of Manufacturing 7

Manufacturing Products Production Quantity (Q)

▪ Final products divide into two major ▪ The quantity of products Q made by a
classes: factory has an important influence on
1. Consumer goods - products the way its people, facilities, and
purchased directly by procedures are organized
consumers ▪ Annual quantities can be classified into
2. Cars, clothes, TVs, tennis three ranges:
rackets
▪ Capital goods - those purchased by
companies to produce goods and/or
provide services
▪ Aircraft, computers, communication
equipment, medical apparatus, trucks,
machine tools, construction equipment
 Ch. I : Overview of Manufacturing 8

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
▪ 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)
Ch. I : Overview of Manufacturing 9

P vs Q in Factory Operations
 Ch. I : Overview of Manufacturing 10

Manufacturing Capability 1. Technological Processing Capability

▪ A manufacturing plant consists of processes ▪ A The set of available manufacturing
and systems (and people) to transform a certain processes in the plant (or company)
limited range of materials into products of ▪ Certain manufacturing processes are suited to
increased value certain materials, so by specializing in certain
▪ The three building blocks - materials, processes, the plant is also specializing in
processes, and systems - are the subject of certain materials
modern manufacturing ▪ Includes not only the physical processes, but
▪ Manufacturing capability includes: also the expertise of the plant personnel
1. Technological processing capability
➢ A machine shop cannot roll steel
2. Physical product limitations
3. Production capacity ➢ A steel mill cannot build cars
 Ch. I : Overview of Manufacturing
2. Physical product limitations
▪ Given a plant with a certain set of processes,
there are size and weight limitations on the
parts or products that can be made in the
plant
▪ Product size and weight affect:
➢ Production equipment
➢ Material handling equipment
▪ Production, material handling equipment, and
plant size must be planned for products that
lie within a certain size and weight range
11
3. Production Capacity
▪ Defined as the maximum quantity that a plant
can produce in a given time period (e.g., month
or year) under assumed operating conditions
➢ Operating conditions refer to number of
shifts per week, hours per shift, direct labor
manning levels in the plant, and so on
➢ Usually measured in terms of output units,
e.g., tons of steel or number of cars
produced
➢ Also called plant capacity
 Ch. I : Overview of Manufacturing 12

Manufacturing engineering

Process planning
▪ The scope of manufacturing engineering ▪ Process planning: the principal activity of
includes any activities and responsibilities manufacturing engineering.
that depend on the type of production ▪ Process planning includes:
operations accomplished by the
➢ deciding what processes and methods
organization. The usual activities include
should be used and in what sequence,
the following:
➢ determining tooling requirements,
➢ Process planning
➢ selecting production equipment and
➢ Problem solving and continuous systems, and
improvement
➢ estimating costs of production for the
➢ Design for manufacturability
selected processes, tooling, and
equipment.
 Ch. I : Overview of Manufacturing 13

Decisions and details required in process planning.

▪ Processes and sequence. The process
plan should briefly describe all processing
steps used on the work unit (e.g., part,
assembly) in the order in which they are
performed.
▪ Equipment selection. In general,
manufacturing engineers try to develop
process plans that utilize existing
equipment. When this is not possible, the
component in question must be purchased
or new equipment must be installed in the
plant.
▪ Tools, dies, molds, fixtures, and gages.
The process planner must decide what
tooling is needed for each process. Actual
design is usually delegated to the tool
design department, and fabrication is
accomplished by the tool room.
▪ Cutting tools and cutting conditions for
machining operations. These are
specified by the process planner, industrial
engineer, shop foreman, or machine
operator, often with reference to standard
handbook recommendations.
 Ch. I : Overview of Manufacturing 14

Decisions and details required in process planning.

▪ Methods. Methods include hand and body ▪ Estimating production costs. This is
motions, workplace layout, small tools, often accomplished by cost estimators
hoists for lifting heavy parts, and so forth. with help from the process planner.
Methods must be specified for manual
operations (e.g., assembly) and manual
portions of machine cycles (e.g., loading
and unloading a production machine).
Methods planning is traditionally done by
industrial engineers.
▪ Work standards. Work measurement
techniques are used to establish time
standards for each operation.
 Ch. I : Overview of Manufacturing 15

TRADITIONAL PROCESS PLANNING

▪ A typical processing sequence to fabricate a discrete part consists

of:
➢ a basic process,
➢ one or more secondary processes,
➢ operations to enhance physical properties,
➢ Finishing operations
▪ A typical processing sequence to fabricate a discrete part consists
of:
Ch. I : Overview of Manufacturing 16

TRADITIONAL PROCESS PLANNING

 Ch. I : Overview of Manufacturing 17

TRADITIONAL PROCESS PLANNING

▪ Guidelines and considerations in deciding processes and their sequence in process planning.
➢ Design and Quality requirements.
➢ Production volume and rate.
➢ Available processes.
➢ Material utilization.
➢ Precedence constraints.
➢ Reference surfaces.
➢ Minimize setups.
➢ Eliminate unnecessary steps.
➢ Flexibility.
➢ Safety.
➢ Minimum cost.
Ch. I : Overview of Manufacturing 18

TRADITIONAL PROCESS PLANNING

 Ch. I : Overview of Manufacturing 19

Production Machines and Tooling Recent Developments in Manufacturing

▪ Manufacturing operations are ➢ Microelectronics
accomplished using machinery and ➢ Microfabrication and
tooling (and people) Nanotechnology
▪ Types of production machines: ➢ Lean production and Six Sigma
➢ Machine tools - power-driven ➢ Globalization and outsourcing
machines used to operate cutting ➢ Environmentally conscious
tools previously operated manufacturing
manually ➢ Computerization in manufacturing
➢ Other production equipment such ➢ Flexible manufacturing
as Presses, Forge hammers, ➢ Virtual Manufacturing
Plastic injection molding
machines.
What is Virtual Manufacturing (VM)?
 Ch. I : Overview of Manufacturing 20

What is Virtual Manufacturing (VM)?

▪ There are several different definitions of virtual
manufacturing (VM).
➢ VM is a simulation-based method that supports
engineers to define, simulate, and visualize the
manufacturing process in a computer environment.
➢ Virtual manufacturing is a concept of executing
manufacturing processes in computers as well as in
the real world, where virtual models allow for
prediction of potential problems for product
functionality and manufacturability before real
manufacturing occurs.
➢ Virtual manufacturing is the integrated application of
simulation, modelling and analysis technologies and
tools to enhance manufacturing design and
production decisions and control at all process levels
 Ch. I : Overview of Manufacturing 21

What is Virtual Manufacturing (VM)?

▪ By using virtual manufacturing, the
manufacturing process can be defined and
verified early in the design process. In
addition, the manufacturing time can be
estimated. Material cost and manufacturing
time constitute a significant portion of the
product cost.
▪ The concept of Virtual Manufacturing (VM)
represents a technological aspect of CIM, and
is defined as the concept of “executing
manufacturing processes in computers as well
as in the real world”.
▪ The purpose of VM is to achieve a total
manufacturing integration by integrating
various kinds of manufacturing in virtual as
well as real domain.
 Ch. I : Overview of Manufacturing 22

What is Virtual Manufacturing (VM)?

▪ By using virtual manufacturing, the
manufacturing process can be defined and
verified early in the design process. In
addition, the manufacturing time can be
estimated. Material cost and manufacturing
time constitute a significant portion of the
product cost.
▪ The concept of Virtual Manufacturing (VM)
represents a technological aspect of CIM, and
is defined as the concept of “executing
manufacturing processes in computers as well
as in the real world”.
▪ The purpose of VM is to achieve a total
manufacturing integration by integrating
various kinds of manufacturing in virtual as
well as real domain.
 Ch. I : Overview of Manufacturing 23

The importance of using CAD/CAE/CAM in VM

 Ch. I : Overview of Manufacturing 24

The importance of using CAD/CAE/CAM in VM

CAD

• CAD is an automated
technology for electronic
capture of geometry (form
and fit) of parts and how
the parts are arranged to
form subassemblies and
assemblies.
 Ch. I : Overview of Manufacturing 25

The importance of using CAD/CAE/CAM in VM

CAM

• Originally CAM referred

to numerical control of
machine tools.
• Now CAM includes all
automated processes in
MFG.
 Ch. I : Overview of Manufacturing 26

The importance of using CAD/CAE/CAM in VM

CAE CIM
(computer aided engineering) (computer integrated manufacturin
 Important Definitions 27

Example for CADCAM

Part Creating
 Important Definitions 28

Example for CADCAM

Plastic injection simulation
 Important Definitions 29

Example for CADCAM

Product molding
 Important Definitions 30

Example for CADCAM

Production simulation
 Important Definitions 31

Example for CADCAM

Mold machining
 Ch. I : Overview of Manufacturing 32

CAE

CATIA (CAD/CAM/CAE) Pro-E (CAD/CAM/CAE)

 Ch. I : Overview of Manufacturing 33

CAE

NX (CAD/CAM/CAE) Inventor (CAD/CAE)

 Ch. I : Overview of Manufacturing 34

CAE

Solid Edge (CAD/CAE) Solid Works (CAD/CAE)

 Ch. I : Overview of Manufacturing 35

CAE

Solid Edge (CAD/CAE) Solid Works (CAD/CAE)

 Ch. I : Overview of Manufacturing 36

CAE

ANSYS (CAE/FEA) NX Nastran (CAE/FEA) ABAQUS (CAE/FEA)

 Ch. I : Overview of Manufacturing 37

Questions…