Criteria for manufacturing

process selection

By Eng.\Adel Osama
Criteria for manufacturing
process selection
contents
1. Introduction to manufacturing
2. Classification of manufacturing processes
3. Materials used in manufacturing processes
4. Selection criteria
5. Identify processes
6. Evaluate processes
7. Selection of manufacturing processes
8. Case study
Criteria for manufacturing process selection

Manufacturing is economic term for producing goods

or products for human beings for desired services.
Product = f( functionality , size,shape,properties
[thermal, physical, mechanical],surface finish and
tolerance).
Criteria for manufacturing process selection
For some mechanical design engineers ,manufacturing process selection
is the last thing they think about during the design process ,that is not
effective way to work . The best approach is to keep manufacturing
concerns in mind throughout the entire design process which result in
good product that is easy to design and less costly to produce and
environment friendly .
Criteria for manufacturing process selection

Classification of manufacturing processes

Processes to get Processes to get

Processes to get
desired size and desired degree of
desired properties
shape surface finish
• casting • Heat treatment • Polishing
• Welding • Coating on surfaces • Honing
• Forming • lapping
• machining
Criteria for manufacturing process selection

Materials used in manufacturing processes

Metals
polymers
ceramic
Composite materials
Criteria for manufacturing process selection

For any material

Physical Mechanical Chemical

properties properties properties
• Melting point • Yield strength • Chemical
• Thermal • Ductility affinity
conductivity • Ultimate
• Thermal strength
expansion
Criteria for manufacturing process selection

For any given product ,there will be multible manufacturing processes

that you will need to select from.
The process you will choose will depend o many factors called the
process selection drivers including the following :

1-Selection 2-Identify 3-Evaulate 4-Selection

criteria processes processes processes
Criteria for manufacturing process selection

Selection criteria as first step

The first step in manufacturing process selection is etaplish selection criteria based on key
processes selection drivers which are :

Required material

Expected manufacturing volume

The geometery and tolerance required for product

Criteria for manufacturing process selection

Identify major processes as second step

A smaller range of processes will be available to satisfy required material ,required

quantity ,part geometery
For ex:
I want to manufacture a plastic chair ,I will choose injection moulding not die casting
As the last process is only for metals
Criteria for manufacturing process selection

Evaluate processes as third step

After identifying the major processes for manufacturing a product ,it is the time to
evaluate them based on less broad parameters then weighted create decision matrix
with a score for each of theses important elements:

Tooling and
Process Processing
equipment
capability time
cost

Degree of
Skill required Post procesing
automation
for operation required
available
Criteria for manufacturing process selection

Select processes as fourth step

After evaluating each element on decision matrix and give extra weight to those elements
which are most important, Then the result will be the effective and efficient processes
that will produce the standard required part for acceptable cost of production:
 Criteria for manufacturing process selection

Process Processing Tooling and Automotive Skilled Post processing score

capability(5) time(4) equipment available(3) required for required(4)
cost(4) operation(2)
Injection 5 4 4 3 2 4
moulding
Vaccum 1 4 1 3 2 4
casting(mold
degrade after
20 copies)
Thermo 3 3 3 2 2 2
forming
 Criteria for manufacturing process selection

Process Processing Tooling and Automotive Skilled Post processing score

capability(5) time(4) equipment available(3) required for required(4)
cost(4) operation(2)
Injection 25 16 16 9 4 16 86
moulding
Vaccum 5 16 4 9 4 16 54
casting(mold
degrade after
20 copies)
Thermo 15 16 12 6 4 8 61
forming

Then the best and economical process for manufacturing a plastic chair is injection
moulding
Criteria for manufacturing process selection

Case study
Required
material is
polymers

Production
volume is 20
parts per hour

Given
geometry
 Criteria for manufacturing process selection

Identify major processes

Injection
moulding

Vaccum casting

Thermoforming
 Criteria for manufacturing process selection

Evaluate major processes by weighted decision matrix

Process Processing Tooling and Automotive Skilled Post processing score

capability(5) time(4) equipment available(3) required for required(4)
cost(4) operation(2)
Injection 5 4 4 3 2 4
moulding
Vaccum 1 4 1 3 2 4
casting(mold
degrade after
20 copies)

Thermo 3 3 3 2 2 2
forming
 Criteria for manufacturing process selection

Evaluate major processes by weighted decision matrix

Process Processing Tooling and Automotive Skilled Post processing score

capability(5) time(4) equipment available(3) required for required(4)
cost(4) operation(2)
Injection 25 16 16 9 4 16 86
moulding
Vaccum 5 16 4 9 4 16 54
casting(mold
degrade after
20 copies)

Thermo 15 16 12 6 4 8 61
forming
Criteria for manufacturing process selection

The best and economical process for manufacturing a plastic chair is

injection moulding
Thanks for listening