Week 1 INTRODUCTION AND OVERVIEW OF MANUFACTURING in PDF

INTRODUCTION AND
OVERVIEW OF MANUFACTURING Manufacturing is Important
1. What is Manufacturing? ▪ Making things has been an essential human activity

2. Materials in Manufacturing since before recorded history
3. Manufacturing Processes ▪ Today, the term manufacturing is used for this
4. Production Systems activity
5. Trends in Manufacturing ▪ Manufacturing is important to the United States and
most other developed and developing nations
▪ Technologically
▪ Economically
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version ©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
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Technological Importance Economic Importance
Technology - the application of science to provide U.S. Economy

society and its members with those things that are Sector: %GDP
needed or desired Agriculture and natural resources 5
▪ Technology provides the products that help our Construction and public utilities 5
society and its members live better Manufacturing 15
▪ What do these products have in common? Service industries* 75
▪ They are all manufactured 100
▪ Manufacturing is the essential factor that makes * includes retail, transportation, banking,
technology possible communication, education, and government
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What is Manufacturing? Manufacturing - Technological
▪ The word manufacture is derived from two Latin ▪ Application of physical and chemical processes to
words manus (hand) and factus (make); the alter the geometry, properties, and/or appearance
combination means “made by hand” of a starting material to make parts or products
▪ “Made by hand” accurately described the fabrication
methods that were used when the English word
“manufacture” was first coined around 1567 A.D.
▪ Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers
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Manufacturing - Economic Manufacturing Industries
▪ Transformation of materials into items of greater ▪ Industry consists of enterprises and organizations that
value by one or more processing and/or assembly produce or supply goods and services
operations ▪ 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
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Specific Industries in Each Manufacturing Industries -
Category continued
▪ Secondary industries include manufacturing,

construction, and electric power generation
▪ Manufacturing includes several industries whose
products are not covered in this book; e.g., apparel,
beverages, chemicals, and food processing
▪ For our purposes, manufacturing means production
of hardware
▪ Nuts and bolts, forgings, cars, airplanes, digital
computers, plastic parts, and ceramic products
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Manufactured Products Production Quantity Q
▪ Final products divide into two major classes: The quantity of products Q made by a factory has an
1. Consumer goods - products purchased directly by important influence on the way its people, facilities, and
consumers procedures are organized
▪ Cars, clothes, TVs, tennis rackets ▪ Annual quantities can be classified into three ranges:
2. Capital goods - those purchased by companies to Production range Annual Quantity Q
produce goods and/or provide services
Low production 1 to 100 units
▪ Aircraft, computers, communication
equipment, medical apparatus, trucks, Medium production 100 to 10,000 units
machine tools, construction equipment High production 10,000 to millions of units
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Product Variety P P vs Q in Factory Operations
▪ 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
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More About Product Variety Manufacturing Capability
▪ Although P is quantitative, it is much less exact than Q ▪ A manufacturing plant consists of processes and
because details on how much the designs differ is not systems (and people) to transform a certain limited
captured simply by the number of different designs range of materials into products of increased value
▪ Soft product variety - small differences between ▪ The three building blocks - materials, processes, and
products, e.g., between car models made on the same systems - are the subject of modern manufacturing
production line, with many common parts ▪ Manufacturing capability includes:
▪ Hard product variety - products differ substantially, e.g., 1. Technological processing capability
between a small car and a large truck, with few 2. Physical product limitations
common parts (if any)
3. Production capacity
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1. Technological Processing
2. Physical Product Limitations
Capability
The set of available manufacturing processes in the plant ▪ Given a plant with a certain set of processes, there are
(or company) size and weight limitations on the parts or products
▪ Certain manufacturing processes are suited to certain that can be made in the plant
materials, so by specializing in certain processes, the ▪ Product size and weight affect:
plant is also specializing in certain materials ▪ Production equipment
▪ Includes not only the physical processes, but also the ▪ Material handling equipment
expertise of the plant personnel ▪ Production, material handling equipment, and plant
▪ A machine shop cannot roll steel size must be planned for products that lie within a
▪ A steel mill cannot build cars certain size and weight range
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3. Production Capacity Materials in Manufacturing
Defined as the maximum quantity that a plant can ▪ Most engineering materials can be classified into one
produce in a given time period (e.g., month or year) of three basic categories:
under assumed operating conditions 1. Metals
▪ Operating conditions refer to number of shifts per 2. Ceramics
week, hours per shift, direct labor manning levels
3. Polymers
in the plant, and so on
▪ Their chemistries are different, and their mechanical
▪ Usually measured in terms of output units, such as and physical properties are different
tons of steel or number of cars produced by the plant
▪ These differences affect the manufacturing processes
▪ Also called plant capacity
that can be used to produce products from them
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In Addition: Composites 1. Metals
▪ Nonhomogeneous mixtures of the other three basic ▪ Usually alloys, which are composed of two or more
types rather than a unique category elements, at least one of which is metallic. Two basic
groups:
1. Ferrous metals - based on iron, comprises
▪ Venn diagram of about 75% of metal tonnage in the world:
three basic ▪ Steel and cast iron
material types
2. Nonferrous metals - all other metallic elements
plus composites
and their alloys:
▪ Aluminum, copper, nickel, silver, tin, etc.
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2. Ceramics
Compounds containing metallic (or semi-metallic) and

Charging a nonmetallic elements.
basic oxygen
furnace in ▪ Typical nonmetallic elements are oxygen, nitrogen,
steelmaking: and carbon
molten pig iron ▪ For processing, ceramics divide into:
is poured into
the BOF. 1. Crystalline ceramics – includes:
Temperatures ▪ Traditional ceramics, such as clay, and modern
are around ceramics, such as alumina (Al2O3)
1650C (3000F).
2. Glasses – mostly based on silica (SiO2)
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3. Polymers 4. Composites
Compound formed of repeating structural units called Material consisting of two or more phases that are
mers, whose atoms share electrons to form very processed separately and then bonded together to
large molecules. Three categories: achieve properties superior to its constituents
1. Thermoplastic polymers - can be subjected to ▪ Phase - homogeneous mass of material, such as
multiple heating and cooling cycles without altering grains of identical unit cell structure in a solid metal
molecular structure ▪ Usual structure consists of particles or fibers of one
2. Thermosetting polymers - molecules chemically phase mixed in a second phase
transform into a rigid structure – cannot reheat ▪ Properties depend on components, physical
3. Elastomers - shows significant elastic behavior shapes of components, and the way they are
combined to form the final material
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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
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Processing Operations Shaping Processes – Four
Categories
Alters a material’s shape, physical properties, or 1. Solidification processes - starting material is a
appearance in order to add value heated liquid or semifluid
▪ Three categories of processing operations: 2. Particulate processing - starting material consists
1. Shaping operations - alter the geometry of of powders
the starting work material 3. Deformation processes - starting material is a
2. Property-enhancing operations - improve ductile solid (commonly metal)
physical properties without changing shape 4. Material removal processes - starting material is a
3. Surface processing operations - clean, treat, ductile or brittle solid
coat, or deposit material on surface of work
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Solidification Processes Particulate Processing
▪ Starting material is heated sufficiently to transform it ▪ (1) Starting materials are metal or ceramic powders,
into a liquid or highly plastic state which are (2) pressed and (3) sintered
▪ Casting process at left and casting product at right
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Deformation Processes Material Removal Processes
▪ Starting workpart is shaped by application of forces ▪ Excess material removed from the starting piece so
that exceed the yield strength of the material what remains is the desired geometry
▪ Examples: (a) forging and (b) extrusion ▪ Examples: (a) turning, (b) drilling, and (c) milling
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Waste in Shaping Processes
▪ It is desirable to minimize waste in part shaping

Metal chips fly in a high ▪ Material removal processes are wasteful in the unit
speed turning operation operations, but molding and particulate processing
performed on a computer
operations waste little material
numerical control turning
center (photo courtesy of ▪ Terminology for minimum waste processes:
Cincinnati Milacron).
▪ Net shape processes - little or no waste of the
starting material and no machining is required
▪ Near net shape processes - when minimum
machining is required
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A batch of silicon wafers enters a furnace heated to
1000°C (1800°F) during fabrication of integrated
Property-Enhancing Processes circuits under clean room conditions (photo courtesy
of Intel Corporation).
Processes that improve mechanical or physical

properties of work material
▪ Examples:
▪ Heat treatment of metals and glasses
▪ Sintering of powdered metals and ceramics
▪ Part shape is not altered, except unintentionally
▪ Example: unintentional warping of a heat treated
part
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Photomicrograph of the cross section of multiple

Surface Processing Operations coatings of titanium nitride and aluminum oxide on
a cemented carbide substrate (photo courtesy of
Kennametal Inc.).
▪ Cleaning - chemical and mechanical processes to

remove dirt, oil, and other surface contaminants
▪ Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
▪ Coating and thin film deposition - coating exterior
surface of the workpart. Examples:
▪ Electroplating
▪ Physical vapor deposition
▪ Painting
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Assembly Operations
Two or more separate parts are joined to form a new

entity Two welders perform
arc welding on a
▪ Types of assembly operations: large steel pipe
1. Joining processes – create a permanent joint section (photo
courtesy of Lincoln
▪ Welding, brazing, soldering, adhesive bonding Electric Company).
2. Mechanical assembly – fastening by mechanical
methods
▪ Threaded fasteners (screws, bolts and nuts);
press fitting, expansion fits
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Production Machines and

Tooling
Automated dispensing
▪ Manufacturing operations are accomplished using
of adhesive onto machinery and tooling (and people)
component parts prior ▪ Types of production machines:
to assembly (photo ▪ Machine tools - power-driven machines used to
courtesy of EFD, Inc.). operate cutting tools previously operated manually
▪ Other production equipment:
▪ Presses
▪ Forge hammers,
▪ Plastic injection molding machines
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Production Systems
People, equipment, and procedures used for the materials

A robotic arm performs and processes that constitute a firm's manufacturing
unloading and loading
operation in a turning
operations
center using a dual ▪ A manufacturing firm must have systems and
gripper (photo courtesy procedures to efficiently accomplish its production
of Cincinnati Milacron).
▪ Two categories of production systems:
▪ Production facilities
▪ Manufacturing support systems
▪ People make the systems work
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Production Facilities
The factory, production equipment, and material

handling systems
Machine cell
▪ Includes the way the equipment is arranged in the consisting of
factory - the plant layout two horizontal
▪ Equipment usually organized into logical groupings, machining
centers
called manufacturing systems. Examples: supplied by an
▪ Automated production line in-line pallet
▪ Machine cell consisting of an industrial robot and shuttle.
two machine tools
▪ Production facilities "touch" the product
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Facilities vs Product Quantities Low Production
▪ A company designs its manufacturing systems and Job shop is the term used for this type of production
organizes its factories to serve the particular mission facility
of each plant ▪ A job shop makes low quantities of specialized and
▪ Certain types of production facilities are recognized as customized products
most appropriate for a given type of manufacturing: ▪ Products are typically complex, e.g., space
1. Low production – 1 to 100 capsules, prototype aircraft, special machinery
2. Medium production – 100 to 10,000 ▪ Equipment in a job shop is general purpose
3. High production – 10,000 to >1,000,000 ▪ Labor force is highly skilled
▪ Designed for maximum flexibility
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Fixed-Position Plant Layout Medium Production
▪ Two different types of facility, depending on product

variety:
▪ Batch production
▪ Suited to medium and hard product variety
▪ Setups required between batches
▪ Cellular manufacturing
▪ Suited to soft product variety
▪ Worker cells organized to process parts without
setups between different part styles
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Process Plant Layout Cellular Plant Layout
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High Production
▪ Often referred to as mass production

▪ High demand for product
▪ Manufacturing system dedicated to the
production of that product
▪ Two categories of mass production:
1. Quantity production
2. Flow line production
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Quantity Production Flow Line Production
Mass production of single parts on single machine or Multiple machines or workstations arranged in
small numbers of machines sequence, e.g., production lines
▪ Typically involves standard machines equipped with ▪ Product is complex
special tooling ▪ Requires multiple processing and/or assembly
▪ Equipment is dedicated full-time to the production of operations
one part or product type ▪ Work units are physically moved through the
▪ Typical layouts used in quantity production are sequence to complete the product
process layout and cellular layout ▪ Workstations and equipment are designed
specifically for the product to maximize efficiency
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Product Plant Layout
Assembly workers on
an engine assembly
line (photo courtesy of
Ford Motor Company).
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Manufacturing Support Systems Trends in Manufacturing
▪ A company must organize itself to design the ▪ Lean production and Six Sigma
processes and equipment, plan and control ▪ Globalization and outsourcing
production, and satisfy product quality requirements
▪ Environmentally conscious manufacturing
▪ Accomplished by manufacturing support systems
▪ Microfabrication and Nanotechnology
▪ The people and procedures by which a
company manages its production operations
▪ Typical departments:
▪ Manufacturing engineering, Production
planning and control, Quality control
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Lean Production and Six Sigma Globalization
▪ Lean production The recognition that we have an international economy in

▪ Doing more work with fewer resources, yet which barriers once established by national boundaries
have been reduced
achieving higher quality in the final product
▪ This has enabled the freer flow of goods and services,
▪ Underlying objective: elimination of waste in capital, technology, and people among regions and
manufacturing countries
▪ Six Sigma ▪ Once underdeveloped countries such as China, India,
▪ Quality-focused program that utilizes worker and Mexico have developed their manufacturing
teams to accomplish projects aimed at improving infrastructures and technologies so that they are now
an organization’s organizational performance important producers in the global economy
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Environmentally Conscious
Outsourcing
Manufacturing
Use of outside contractors to perform work that was Determining the most efficient use of materials and
traditionally accomplished in-house natural resources in production, and minimizing the
negative consequences on the environment
▪ Local outsourcing
▪ Associated terms: green manufacturing, cleaner
▪ Jobs remain in the U.S. production, sustainable manufacturing
▪ Outsourcing to foreign countries ▪ Basic approaches:
▪ Offshore outsourcing - production in China and 1. Design products that minimize environmental
other overseas locations impact
▪ Near-shore outsourcing - production in Canada, 2. Design processes that are environmentally
Mexico, and Central America friendly
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Microfabrication and
Overview of Major Topics
Nanotechnology
▪ Microfabrication
▪ Processes that make parts and products whose
feature sizes are in the micron range (10-6 m)
▪ Examples: Ink-jet printing heads, compact disks,
microsensors used in automobiles
▪ Nanotechnology
▪ Materials and products whose feature sizes are in
the nanometer range (10-9 m)
▪ Examples: Coatings for catalytic converters, flat
screen TV monitors
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Week 1 INTRODUCTION AND OVERVIEW OF MANUFACTURING in PDF

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INTRODUCTION AND

OVERVIEW OF MANUFACTURING Manufacturing is Important

1. What is Manufacturing? ▪ Making things has been an essential human activity

Technological Importance Economic Importance

Technology - the application of science to provide U.S. Economy

Manufacturing - Economic Manufacturing Industries

▪ Secondary industries include manufacturing,

Manufactured Products Production Quantity Q

▪ Product variety P refers to different product types or

More About Product Variety Manufacturing Capability

3. Production Capacity Materials in Manufacturing

Compounds containing metallic (or semi-metallic) and

Two basic types:

Solidification Processes Particulate Processing

Waste in Shaping Processes

▪ It is desirable to minimize waste in part shaping

Processes that improve mechanical or physical

Photomicrograph of the cross section of multiple

▪ Cleaning - chemical and mechanical processes to

Two or more separate parts are joined to form a new

Production Machines and

People, equipment, and procedures used for the materials

The factory, production equipment, and material

Fixed-Position Plant Layout Medium Production

▪ Two different types of facility, depending on product

▪ Often referred to as mass production

Product Plant Layout

Lean Production and Six Sigma Globalization

▪ Lean production The recognition that we have an international economy in

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