Chapter 1: introduction to manufacturing processes

CHAPTER 1: INTRODUCTION. TO MANUFACTURING. PROCESSES.

CONTENTS. ❖WHAT IS MANUFACTURING? ❖PRODUCTS AND MANUFACTURING ❖GREEN DESIGN AND MANUFACTURING ❖LEAN PRODUCTION AND AGILE MANUFACTURING ❖DESIGN FOR MANUFACTURE, ASSEMBLY, DISASSEMBLY, AND SERVICE ❖SELECTION OF MATERIALS ❖SELECTION OF MANUFACTURING PROCESSES ❖MANUFACTURING SYSTEM DESIGNS ❖QUALITY ASSURANCE AND TOTAL QUALITY MANAGEMENT ❖GENERAL TRENDS IN MANUFACTURING.

WHAT IS MANUFACTURING?. • Derived from two Latin word manus (hand) and factus (make); the combination means.

Sta rting material Manufacturing process Processed part Scrap and.

WHAT IS MANUFACTURING PROCESS?. • A sequence of operations and processes designed to create a specific product.

THE IMPORTANCE OF MANUFACTURING PROCESSES. • Increasing global competition.

• MANUFACTURING ENGINEER. • Select and coordinate specific processes and equipment..

PRODUCTS AND MANUFACTURING. • PRODUCT CREATION CYCLE.

Field warranty service Quality control Market analysis, Engineering Modeling Process design GD&T Computer Aided Manufacturing Prototyping Rapid Prototyping Production system Manufacturing 1 Statistic Process Control (SPC) Product design GD&T Computer (CAM) Aided Design (CAD).

PRODUCT DESIGN AND CONCURRENT ENGINEERING. The Design Process.

Concurrent Engineering. ◻ Also called simultaneous engineering.

Life Cycle. • Life cycle of a new product consists of:.

Role of Computers in Product Design. • Product models are simplified through computer-aided design (CAD) and computer-aided engineering (CAE) techniques.

Prototypes. • A prototype is a physical model of an individual component or product.

COMPUTER-INTEGRATED MANUFACTURING. • Computer-integrated manufacturing (CIM) integrates computer.

COMPUTER-INTEGRATED MANUFACTURING. VARIOUS ELEMENTS IN CIM INCLUDE:.

COMPUTER-INTEGRATED MANUFACTURING.

COMPUTER-INTEGRATED MANUFACTURING. Example Mold for Making Sunglasses Frames.

GREEN DESIGN AND MANUFACTURING. FACTS (PROBLEMS):.

GREEN DESIGN AND MANUFACTURING. Manufacturing operations produce waste:.

GREEN DESIGN AND MANUFACTURING. WHAT POLLUTES THE ENVIRONMENT?.

GREEN DESIGN AND MANUFACTURING. Environmentally conscious design and manufacturing considers all possible adverse environmental impacts of materials, processes, operations and products.

GREEN DESIGN AND MANUFACTURING. Guidelines for Green Design and Manufacturing :.

LEAN PRODUCTION AND AGILE MANUFACTURING. • Lean production involves a thorough assessment of each activity of a.

Agile Manufacturing : indicating the implementation of the.

DESIGN FOR MANUFACTURE, ASSEMBLY, DISASSEMBLY, AND SERVICE.

DESIGN FOR MANUFACTURE, ASSEMBLY, DISASSEMBLY, AND SERVICE.

SELECTION OF MATERIALS. • General types of materials used:.

Properties of Materials. 1. Mechanical properties.

Cost and Availability. • If materials are not available in the desired quantities, shapes, dimensions, and.

Appearance, Service Life and Recyclability. • Wear, fatigue can affect performance and service life.

Material Substitution in Products. • We would want to consider the following substitutions:.

Example Baseball Bats. • Cross sections of baseball.

SELECTION OF MANUFACTURING PROCESSES. Some examples of manufacturing methods are:.

pattern and mold other Investment casting Lost&rn casting castn•g : Melt-spin ring process proæses Expendable mold, manant Sand casing Siel-mold castmg Cerarnk:-mold casting : Permanent mold Permanent mold casting Die casting Centrifugal casting Squeeze casting.

Shearing Blanking Slitting Punching Piercing Sheet-metal-forming processes Bending and drawing Bending Hemming Roll forming Deep drawing Forming Stretch forming Hydroforming Spinning Magnetic-pulse forming.

Machining Drilling Milling Broaching Machining and finishing processes Advanced machining Wire EDM Chemical rnachining Laser machining Water-jet machining Finishing Surface grinding Centerless grinding Lapping Electrochemical polishing.

Process Selection. • Selection of process depends on geometric features of the parts and.

Net-shape and Near-net-shape Manufacturing. • Part is made in only one operation to the final desired dimensions, tolerances and.

Ultraprecision Manufacturing. • Advantages are dimensional accuracies and mirror-like surfaces.

MANUFACTURING SYSTEM DESIGNS. • Small quantities of products.

Flow Shop • Larger quantities of products • Production line • Special purpose machines.

Linked-Cell Shop • Manufacturing and subassembly cells.

Project Shop • Product being manufactured cannot be easily.

Continuous Process • Large plants • Utilized in the manufacture of liquids, oils,.

Lean Manufacturing • 100% “good” units flow from process to.

QUALITY ASSURANCE AND TOTAL QUALITY MANAGEMENT. • Product quality influences customer satisfaction.

Average Life Expectancy of Various Products Type of product U.S. dollar bill Personal computer Car battery Hair dryer Automobile Dishwasher Kitchen disposal unir Vacuum cleaner Water heater (gas) Clothes dryer (gas) Clothes washer Air-conditioning unit (central) Manufacturing cell Refrigerator Furnace (gas) Machinery Nuclear reactor Life expectancy (years) 1.5 2 4 10 10 10 12 13 13 15 15 30 40.

• At six sigma, defective parts are reduced to only 3.4 per million.

Human-factors Engineering. • Human-factors approach results in ergonomics design.