manufacturing brian russell. manufacturing turning raw materials into goods which we need or want...

Manufacturing

Brian Russell

Manufacturing

Turning raw materials into goods which we need or want and are able to sell to others.

Manufacturing

Requires:• Special buildings or places of work• Organisation of people• Organisation of tools & equipment• Communication systems• Efficient working methods• Health and safety considerations

Manufacturing Terms

• Primary Processing

• Secondary Processing

Primary Processing

Turning raw materials into useful stock sizes

Materials come from:

Out of the ground

Animals

Trees & plants

Oil

Making Paper

Trees cut & shredded

Water added

Boiled up to make wood pulp

Chemicals and dyes added

Pulp poured over fine mesh and squeezed between rollers

Secondary Processing

• Casting & moulding

• Forming

• Wastage (or separation)

• Conditioning

• Assembling

• Finishing

Casting & Moulding

Injection Moulding

Die Casting

Food Moulding

Forming

Drop Forging

Pressing Line Bending

Wastage

+X

-X

-Z

+Z

Sawing

Turning

Milling

Finishing

Painting

Printing

Manufacturing Costs

Finance

Labour Costs

(or Automation)Transportation

EnergyPlant

Raw Materials

Scales of Production

• One-off or Jobbing Production

• Batch Production

• Mass or Flow Production

• Continuous Production

Just in Time

• Shared information systems

• Reduced lead times

• Less finance tied up in stock

Flexible Manufacturing

• Benefits of one-off production at mass production prices

• Only possible with ICT

Computer Integrated Manufacture

All the computer functions are integrated together in a fully automated system.

This would include moving materials/assemblies between machining operations.

Quality Issues

• Consistency

• Right first time every time

• Working to tolerances

• Materials in as well as products out

Quality Assurance

• Procedures to manage all functions which affect quality

• QA checks the systems

• Monitors processes

• Applies standards

Part of the Total Quality Management (TQM) of the company

Quality control

• One part of QA

• A series of checks – size, strength, weight, taste etc.

Tolerances

• Acceptable range of difference from standard

• Sometimes measured in plus/minus

No product manufactured in quantity can be considered to be perfect in every detail

Certification

• Manufacturers who work to recognised standards are awarded certification

BS EN ISO 9000:2000

One of the most important series of standards, these provide companies with a framework for developing a set of processes that ensure a common sense approach to the management of the organisation.