MANUFACTURING PROCESS

MANUFACTURING
PROCESSES

BY : MDM AZRINA BINTI ARSHAD

 WHY NEED TO LEARN MANUFACTURING
PROCESS?
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 1. KNOWING A BASIC PROCESS TO FABRICATE A

PRODUCT – Quality Product, Good Materials
Selection, ease of manufacturing process and reduce
reject and cost.

 2. Increase Productivity – Flow of production will be

more structured.

 3. To reduce waste and eliminate defects

 What is Manufacturing ?

 A manufacturing plant consist of a set of processes and systems

designed to transform a raw material into products.

Process &
Raw material Products
System
 There is a strong interdependence among these 3 factors.
1.1 What is manufacturing
• We use, drink, wear, and play with
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many things without giving a thought
to where they come from or how
they're made.

 Wire, Capacitor, Hand-phone,

ICs, Bottle, MPV, Car seat,
Steering, Automotive parts ,
Computer screen.

 What do these
products have
in common ?
 How they are
made ???
 1.1 What is manufacturing
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• Almost everything, has gone through some manufacturing process.
• Derived from Latin ( manus = hand, factus = made )
• Manufacturing can be defined in a few ways.

• Technologically – as application of physical and chemical processes to

alter geometry, properties, and/or appearance of starting ( raw material
) to make parts or products.
• The processes to accomplish manufacturing involve a combination of
machinery, tools, power, and division of labor.

• Economically – the transformation of materials into items of more

greater value ( value added ) by processing and/or assembly operations.

• Generally, it is a process in which raw materials are transformed into

finished goods on a large scale and division of labor.
Manufacturing includes three main stages:

1. The design of the product

2. The selection of raw materials
3. The sequence of processes through which
the product will be manufactured.
 Components
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in Products

 Single component Multi-component

(ball point pens,
automobiles, washing
 (nail, bolt, fork,
machines, etc.)
coat key, etc.)

 All components are

manufactured.
 Manufacturing means,
“Made by Hand”.
Example of Assembled Products
 Manufacture of Light Bulbs

Tungsten
2200-3000
oC

Components of a common light bulb.

 1.1.1 Historical Developments
 Early developments
 Starts with production of weapon, ceramic, textile.
 Method used were casting, hammering ( forging ), grinding.
 Source of power : water, wind and animal power.
To increase
 The 1st Industrial revolution ( circa 1760-1830 ) the
 Development of Watt’s steam engine productivity
and
 Machine tools –John Wilkinson’s boring machines ( 1775 ) organizing
 Machinery for textiles industry. large
numbers of
 Factory system production
workers
based on
 The 2nd Industrial revolution ( 1830 onwards ) division of
 Mass production labor.

 Scientific management ( motion study, time study etc )

 Assembly lines ( Henry Ford – T automobile )
 Automation factories ( 1881 -1st elect.power station in New York )

 Continuous development.
 1.1.2 Benefits on the development in manufacturing.

 Dangerous jobs
 Physically demanding jobs
 Boring jobs To be performed by
machines or robots
 Impossible job to be done by human controlled by
 Hygienic control computers.
 Dangerous job and physical demanding job

Robots are used to fix the screw .

Robots are used to do spot welding .
 Boring job

Arranging chocolate .

 It’s a task that almost anyone

could do. . .but could you do it
20,000 times ,over the course of
an eight-hour shift? .

Soldering the ICs to PCB.

 "Pick and place" robots insert

integrated circuits onto printed
circuit boards

Impossible job to be done by human.

Wire bonding in the ICs.

Hygienic Control job

 Robots are also at work making

and packaging drugs, textiles, and
foods.
 Dangerous job and physical demanding job
 90 % of robots work in factories,
and more than half are at work
making automobiles.
 Car factories are so highly
automated that most of the
human workers are there mainly
to supervise or maintain the
robots and other machines.
 Robots assemble car body panels
and weld them together, finish
and paint the car bodies, and Robots are used to fix the screw .
stack and move partially
completed cars.

 The used of robots ensures the

company meets its own stringent
requirements including
 reduced labour costs,
 energy and material
consumption
 improved health and safety
levels
 Ex : painting, welding Robots are used to do spot welding .
 Boring job

 Another example of a factory job done

by robots is arranging chocolates in
boxed assortments.
 Guided by a computer system, a robotic
arm can locate a piece of chocolate on a
moving conveyer belt,
 gently pick it up and turn it to the proper
orientation,
 then deposit it in a specific location
within a box on another moving
conveyer belt.
 It’s a task that almost anyone could do. .
.but could you do it 20,000 times ,over
the course of an eight-hour shift? .

 In the computer industry, robots

solder tiny wires to
semiconductor chips.
 "Pick and place" robots insert
integrated circuits onto printed
circuit boards
 these are used in all kinds of
electronics, from radios to
microwaves.
 Hygienic Control job

 Robots are also at work making and packaging drugs, textiles,

and foods.
 1.2 Classification of Manufacturing Process
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 How many class of Manufacturing Process ?

 What are they?

 Let’s do this activity :

Casting
Forming and Shaping (Bulk
deformation)

Extrusion and
Extrusion
drawing
Forming and Shaping (Sheet Metal)
Polymer Processing
Joining
Machining
 1.3 Selecting Manufacturing Process

 A company engaged in manufacturing cannot do everything.

 It must do only a certain things,
 (and it must do things well -Quality ).
 Manufacturing capability refers to the technical & physical
limitations of a manufacturing company and of its plants.

 1. Technological processing capability

 2. Physical size & weight of the product
 3. Production capacity
 1.3 Selecting Manufacturing Process

 1. Technological processing capability

 Ex : In car manufacturing.
 Certain plant perform machining operation to produce the steel billet >> Others plant
roll steel billet into sheet stock >> Others build automobiles.
 Technological processing capability is closely related to material type.
 By specializing in certain process or group of processes, the plant is simultaneously
specializing in certain material types, as well as the expertise possessed by plant
4,600 ton
personnel. transfer
press
machine
 1.3 Selecting Manufacturing Process
 2. Physical size & weight of the product
 Production machines come in different sizes.
 Larger machines must be used to process larger parts.
 The set of production equipment , material handling, storage capability, and
plant size must be planned for products that lie within a certain size and weight range.

Layout of wafer processing plant . Layout of ICs processing plant .

ShinEtsu, Japan. Infineon, German.

Layout of aero plane manufacturing plant .

Boeing, USA.
 1.3 Selecting Manufacturing
Process
 3. Production capacity
 This quantity limitation is commonly called plant
capacity or production capacity, defined as the
maximum rate of production that a plant
can achieved under assumed operating
Product Output Output /
conditions. /month year
 The operating conditions refer to number of shift / ( pcs) (pcs )
week, hours/shift, number of employee. Car 4 000 48 000

 These factors represent input to the manufacturing

ICs, 300 000 3 600 000
plant. Given these input, how much output can the Capacitor
factory produce ? TV 50 000 600 000
 Plant capacity is usually measured in terms of
output units, such as number of cars produced by a Silicon 300 000 3 600 000
wafer
final assembly plant.
Ferrari car 300 3600
 Annual production capacities can be classified into three
ranges :
 1. Low production – range : 1 ~ 100 units / year.
 2. Medium production – range : 100 ~ 10, 000 units
/ year.
 3. High production – range : 10, 000 ~ millions of
units / year.
GROUP DISCUSSION 1
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Suppose you wanted to redesign a stapler

to have fewer components. Identify the cost of
stapler. Identify the parts that it have.
You need to redesign the stapler whereby :
 list and indicate which parts would have to be
redesigned
 which part would be eliminated.
 Explain the advantages and disadvantages of
your new design stapler versus the old stapler.
 1.5 Industrial Revolution 4.0
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• Industrial revolution 1.0

1800 • Steam power

• Industrial revolution 2.0

1900 • Electrical power

• Industrial revolution 3.0

2000 • Computer and information technology

• Industrial revolution 4.0

2016
 INDUSTRY REVOLUTION
4.0

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Industry 4.0 is referred to as

production or manufacturing based
industries digitalisation
transformation, driven by connected
technologies.

Industry 4.0 introduces what is

referred to as “smart factory” in which
cyber physical systems monitor real
time physical progress of the factory
and are able to make decentralized
decisions.
The nine (9) technology drives/pillars are:
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i. Autonomous Robots
ii. Big Data Analytics
iii. Cloud Computing
iv. Internet of Things (IoT)
v. Additive Manufacturing
vi. System Integration
vii. Cybersecurity
viii. Augmented Reality
ix. Simulation.
2020 :
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