PRODUCTION AND

MANUFACTURING
PROCESSES
AN INTRODUCTION
By
DR. AQUEEL SHAH
Associate Professor IME
COURSE BRIEF
 course is designed to achieve following objects:

 Description of different manufacturing processes

 Effective utilization of manufacturing process in industry

 How to achieve optimization in manufacturing process

 Build up the capacity of course participants in different

manufacturing technique
STUDY CONTENTS
 CASTING

 Machining processes

 Hot and cold working (deformation process)

 Powder metallurgy

 Plastics and composites

 Surface treatments and coatings

 Joining process

 Heat treatment
STUDY MATERIAL
 PRESENTATION

 BOOKS

 INTERNET

 VIDEOS ( WILL BE SHOWN)

STUDY METHODOLOGY
 CLASS LECTURES

 ASSIGNMENTS

 DISCUSSION

 SELF INTEREST
ASSESSMENT
 Assignment

 Hourly test

 Quizzes
INTRODUCTION TO MANUFACTURING
PROCESSES & TECHNOLOGY
 Manufacturing is the use of tools and labor to make things for use or
sale. The term may refer to a vast range of human activity, from handicraft
to high tech, but is most commonly applied to industrial production, in
which raw materials are transformed into finished goods on a large scale.
MANUFACTURING PROCESS MODEL

Completed work piece

Raw material

Equipment
Manufacturing

Tooling, fixtures Process

Electrical energy
Scrap and waste
Labor
CLASSIFICATION OF MANUFACTURING PROCESSES
HOW WE PLAN FOR MANUFACTURING
 Definition Of A Need
 Conceptual Design
 Review Of Initial Design
 Design Prototype
 Production Plan
 Resource Specifications
 Manufacturing Prototype
 Manufacturing
 Inspection--quality Checks
 Packaging - Shipping
 Customer Response
MANUFACTURING A PRODUCT: GENERAL
CONSIDERATIONS
 Material Selection

 Processing Methods

 Final Shape and Appearance

 Dimensional and Surface Finish

 Economics of Tooling

 Design Requirements

 Safety and Environmental Concerns

 MANUFACTURING SUMMARY
MANUFACTURING RAW MATERIAL FINISHED PRODUCT
(means made by hand Latin word)

BASIC MANUFACTURING CYCLE OF A PRODUCT

Design process (concurrent engg.) Drawing on AutoCAD Weight criteria

Properties (physical & mechanical) Manufacturing (CAD/CAM) Inspection

QC Assembly Finishing operations Packing

SELECTION OF MATERIAL

Metallic Non metallic

Ferrous Non ferrous Organic Inorganic

 MANUFACTURING SYSTEMS-

• Job shop (including project)

• Batch production

• Mass production

VOLUME OF PRODUCTION

1) Experimental or prototype 1----------10

2) Small batch 10--------
5000
3) Batch or high volume 5000----100,000
4) Mass production 100,000 &
over
MODEL OF FACTORY SHOWING FREE FUNCTION OF MANUFACTURING

Factory operations

1) Processing Finished products

Raw material 2) Assembly
3) Material handling
4) Inspection and Test

Receiving Shipping

5) Control
INFORMATION-PROCESSING CYCLE IN A
TYPICAL MANUFACTURING FIRM

PRODUCTION DESIGN
Production development
Engineering drawings
Bills of materials
BUSINESS
FUNCTION MANUFACTURING PLANNING
Marketing Process planning
Sales Master schedule
Order Requirement planning
FACTORY
Entry Capacity planning
OPERATIONS
Costumer
Billing

MANUFACTURING CONTROL
Shop floor control
Quality control
Inventory control
TYPES OF LAYOUT- (Already Studied)

a) Fixed position layout

Work stations

Raw material

Lathe Drill
Finishing
Shipping & receiving

dept dept
dept

Grinding dept

Finished process
Office
Milling dept
Assembly

b) Process layout c) Product layout

MATERIALS INTRODUCTION
TYPES OF MATERIALS
Ferrous Metals: iron and steel.

Nonferrous Metals and Alloys: aluminum, magnesium,

copper, nickel, titanium, super alloys, beryllium, zirconium,
low-melting alloys, precious metals.

Plastics: thermoplastics, thermosets, elastomers.

Ceramics: glass, graphite, diamond.

Composite materials: reinforced plastics, metal-matrix and

ceramic-matrix composites, honeycomb structures.
 PROPERTIES OF MATERIALS
 Mechanical Properties: strength, toughness, ductility, hardness,
elasticity, fatigue, creep.

Behavior Under Loading: tension, compression, bending, torsion,

shear.

 Physical Properties: density, specific heat, thermal expansion,

thermal conductivity, melting point, electrical and magnetic properties.

 Chemical Properties: oxidation, corrosion, degradation, toxicity,

flammability.
FERROUS METALS: APPLICATIONS
 Structural: building structures, concrete reinforcement

 Automotive: chassis, engine parts, drive train, body parts

 Marine: ship hulls, structure, engines

 Defense: tanks, weapons

 Consumer Products: appliances, recreational vehicles, toys, utensils

and tools
NON FERROUS METALS: APPLICATIONS
 Architectural: aluminum windows and doors

 Automotive: aluminum engine blocks, copper wiring

 Marine: brass/bronze fittings, bearings, propellers

 Defense: brass shell casings

 Consumer Products: electrical wiring, utensils, jewelry,

electronics
PLASTICS: APPLICATIONS
 Architectural: electrical and thermal insulation, weather seals, carpets,
wall coverings, paint

 Aerospace: electrical and thermal insulation, instrument

panels,upholstery, seals

 Automotive: body panels, instrument panels, upholstery, electrical and

thermal insulation, seals, hoses, tires

 Consumer Products: toys, sporting goods, appliances, tools, utensils,

clothing, shoes, packaging
MANUFACTURING PROCESSES FOR METALS

 Casting: expendable mold and permanent mold.

 Forming and Shaping/HT and CW: rolling, forging, extrusion,
drawing, sheet forming, powder metallurgy, molding
 Machining: turning, boring, drilling, milling, planing, shaping,
broaching, grinding, ultrasonic machining, chemical machining,
electrical discharge machining (EDM), electrochemical machining,
high-energy beam machining
 Joining: welding, brazing, soldering, diffusion bonding, adhesive
bonding, mechanical joining
 Finishing/Surface coating: honing, lapping, polishing, burnishing, de-
burring, surface treating, coating, plating
 CASTING PROCESSES
Introduction of molten metal into a mold cavity; upon solidification, metal
conforms to the shape of the cavity.

Die Casting Sand Casting

FORMING AND SHAPING PROCESSES/HW
AND CW
Bulk deformation processes that induce shape changes by plastic deformation
under forces applied by tools and dies.

Forging Extrusion
 MACHINING PROCESSES
Material removal from a work piece: cutting, grinding, nontraditional machining processes .

Milling Lathe Machine

MANUFACTURING PROCESSES FOR PLASTICS

 Plastics are shipped to manufacturing plants as

pellets or powders and are melted just before the
shaping process. Polymers melt at relatively low
temperatures and are easy to handle.

 Plastics can be molded and formed, as well as

machined and joined, into many shapes with relative
ease.
CONCLUSION
 Role of manufacturing engineering is indispensable in
country’s GDP.
 In order to produce more competitive and affordable
goods it is necessary that we master the techniques
involved in manufacturing and apply them appropriately.
 In order to achieve optimization in manufacturing and
production we must know the production processes and
theory which is the sole purpose of this course
 The contents of this course will equip course members
with much needed manufacturing techniques needed to
achieve right and appropriate decisions at strategic and
tactical level in manufacturing organization