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OVERVIEW OF MANUFACTURING
1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
5. Manufacturing Economics
What is manufacturing?
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing -Technological
Importance
What is technology?
Technology - the application of science to provide
society and its members with those things that are
needed or desired
Technology affects our daily lives, directly and
indirectly, in many ways
Technology provides the products that help our
society and its members live better
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing - Technological
Importance
What do these products have in common?
They are all manufactured
They would not be available to our society if they
could not be manufactured
Manufacturing is the essential factor that makes
technology possible
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing - Economically
Important
U.S. Economy
Sector: %GDP
Agriculture and natural resources 5
Construction and public utilities 5
Manufacturing 12
Service industries* 78
100
* includes retail, transportation, banking,
communication, education, and government
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
What is Manufacturing?
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing - Economically
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing Example:
Artificial Heart Valve
Left: Heart valve Right: Starting titanium billet
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Manufacturing Industries
What is industry?
Industry consists of enterprises and organizations that
produce or supply goods and services.
Industries can be classified as:
1. Primary industries - cultivate and exploit natural
resources, e.g., agriculture, mining
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and capital
goods
3. Tertiary industries - service sector
Specific Industries in Each
Category
Manufacturing Industries -
continued
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Production Quantity Q
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
1. Metals/ to be modified
Venn diagram of
three basic
material types
plus composites
4. Composites
1. Product design.
2. Selection of materials.
3. Selection of production methods and
techniques
The information needed to produce a
part, most often comes in the form of a:
Working Drawing
Manufacturing Processes
Two basic types:-
1. Processing operations - transform
a work material from one state of
completion to a more advanced
state
Operations that change the geometry,
properties, or appearance of the starting
material
2. Assembly operations - join two or
more components to create a new
entity
Classification of manufacturing processes
2
Processing Operations
Alters a material‘s shape, physical
properties, or appearance in order to
add value
Three categories of processing
operations:
I.Shaping operations - alter the
geometry of the starting work material
II.Property-enhancing operations -
improve physical properties without
changing shape
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
Waste in Shaping Processes
©2012 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 5/e
ASSEMBLY OPERATIONS
The second basic type of manufacturing operation is
assembly, in which two or more separate parts are joined
to form a new entity.
Components of the new entity are connected either
permanently or semi permanently.
Permanent joining processes include welding, brazing,
soldering, and adhesive bonding.
Nonpermanent mechanical assembly methods are
available to fasten two (or more) parts together. The use of
screws, bolts, and other.
Other mechanical assembly techniques form a more
permanent connection; these include rivets, press fitting,
and expansion fits.
Production Machines and
Tooling
Overhead costs
Factory overhead
Consists of the costs of running the factory excluding materials, direct labor,
and equipment.
Corporate overhead
Consists of company expenses not related to the factory such as sales,
marketing, accounting, legal, research and development, office space,
utilities and health benefits.
Manufacturing Economics
1 A stamping press produces sheet-metal stampings in batches. The press is operated by a worker
whose labor rate = $15.00/hr and applicable labor overhead rate = 42%. Cost rate of the press =
$22.50/hr and applicable equipment overhead rate = 20%. In one job of interest, batch size = 400
stampings, and the time to set up the die in the press takes 75 min. The die cost $40,000 and is
expected to last for 200,000 stampings. Each cycle in the operation, the starting blanks of sheet metal
are manually loaded into the press, which takes 42 sec. The actual press stroke takes only 8 sec. Cost
of the starting blanks = $0.43/pc. The press operates 250 days per year, 7.5 hours per day, but the
operator is paid for 8 hours per day. Assume availability = 100% and scrap rate = 0. Determine (a)
cycle time, (b) average production rate with and without setup time included, and (c) cost per
stamping produced.
Solution: (a) Cycle time Tc = 42 + 8 = 50 sec = 0.833 min
(b) Including setup time, Tp = 75/400 + 0.833 = 1.021 min
Rp = 60/1.021 = 58.78 pc/hr
Excluding setup time, Rc = 60/0.833 = 72.03 pc/hr
(c) Equipment cost rate Ceq = 22.50(1.20)/60 = $0.45/min.
Die cost per piece Ct = 40,000/200,000 = $0.20/pc
Labor cost rate CL = 15.00(1.42)/60 = $0.355/min
This labor cost should be adjusted for the fact that although the press operates 7.5 hr/day, the
operator is paid for 8 hr. CL = 0.355(8/7.5) = $0.379
Finally, cost per stamping Cpc = 0.43 + (0.379 + 0.45)(1.021) + 0.20 = $1.48/pc
Example 3