engr 241 - introduction to manufacturing introduction and fundamentals
TRANSCRIPT
Engr 241 - Introduction to Engr 241 - Introduction to ManufacturingManufacturing
Introduction and FundamentalsIntroduction and Fundamentals
WesternIllinoisUniversity ENGINEERING TECHNOLOGY
College of Business and Technology
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What is Manufacturing?What is Manufacturing?• AKA “Production”AKA “Production”
• Process of converting raw materials into products.Process of converting raw materials into products.
• ““Manufacturing is a collection of interrelated Manufacturing is a collection of interrelated
activities that includes product design and activities that includes product design and
documentation, material selection, planning, documentation, material selection, planning,
production, quality assurance, management, and production, quality assurance, management, and
marketing of goods” (Rehg & Kraebber, 2005, p.4).marketing of goods” (Rehg & Kraebber, 2005, p.4).
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What is Manufacturing?What is Manufacturing?• “…“…manufacturing is a value-adding activity, where manufacturing is a value-adding activity, where
the conversion of materials into products adds value the conversion of materials into products adds value
to the original material” (Black & Kohser, 2008, p. to the original material” (Black & Kohser, 2008, p.
V).V).
• ““Assembly is an important phase of the overall Assembly is an important phase of the overall
manufacturing operation and requires consideration manufacturing operation and requires consideration
of the ease, speed, and cost of putting parts of the ease, speed, and cost of putting parts
together” (Kalpakjian & Schmid, 2005, p. 15).together” (Kalpakjian & Schmid, 2005, p. 15).
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Materials in ManufacturingMaterials in Manufacturing
• Metals - Ferrous (contain iron) and NonferrousMetals - Ferrous (contain iron) and Nonferrous
• Non-Metals – Plastics, Ceramics, Graphite, DiamondNon-Metals – Plastics, Ceramics, Graphite, Diamond
• Composite Materials.Composite Materials.
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Typical Manufacturing ProcessesTypical Manufacturing Processes• Casting/MoldingCasting/Molding (expendable & permanent molds) (expendable & permanent molds)
• Forming and ShapingForming and Shaping (rolling, forging, extrusion and (rolling, forging, extrusion and drawing, sheet forming, powder metallurgy)drawing, sheet forming, powder metallurgy)
• MachiningMachining (material removal – cutting, turning, (material removal – cutting, turning,
boring, drilling, milling, planing, grinding, etc.)boring, drilling, milling, planing, grinding, etc.)
• JoiningJoining (welding, brazing, soldering, diffusion (welding, brazing, soldering, diffusion
bonding, adhesive bonding, mechanical joining)bonding, adhesive bonding, mechanical joining)
• Finishing Finishing (honing, lapping, polishing, deburring, (honing, lapping, polishing, deburring,
surface treating, coating, plating)surface treating, coating, plating)
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Historical MilestonesHistorical Milestones
– 1712, Thomas Newcomen develops steam engine1712, Thomas Newcomen develops steam engine
– 1775, Boring machine developed by Wilkinson 1775, Boring machine developed by Wilkinson
(England) to produce cylinders for James Watt’s (England) to produce cylinders for James Watt’s
steam engine steam engine
– 1785, Concept of interchangeable parts in guns by 1785, Concept of interchangeable parts in guns by
LeBlanc (France), however Eli Whitney (cotton gin, LeBlanc (France), however Eli Whitney (cotton gin,
1794) credited for IP concept in 17981794) credited for IP concept in 1798
– 1800, Aessandro Volta (Italy) develops the battery1800, Aessandro Volta (Italy) develops the battery
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Historical MilestonesHistorical Milestones
– 1853, Sam Colt produced one of the largest gun 1853, Sam Colt produced one of the largest gun
mfg. co. with 1400 machine toolsmfg. co. with 1400 machine tools
– 1876, Telephone by Alexander Graham Bell1876, Telephone by Alexander Graham Bell
– 1879, Thomas Edison’s 40 hr light bulb1879, Thomas Edison’s 40 hr light bulb
– Early 1900’s, Henry Ford creates efficient assembly Early 1900’s, Henry Ford creates efficient assembly
lines – first example of lean productionlines – first example of lean production
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Historical MilestonesHistorical Milestones– In the 1920s, Ford Motor Company’s operation embodied the In the 1920s, Ford Motor Company’s operation embodied the
key elements of scientific management (Frederick W. Taylor, key elements of scientific management (Frederick W. Taylor,
1856-1915):1856-1915):
•standardized product designsstandardized product designs
•mass productionmass production
• low manufacturing costslow manufacturing costs
•mechanized assembly linesmechanized assembly lines
•specialization of laborspecialization of labor
• interchangeable partsinterchangeable parts
– Fords centralized management approach led to the decline of Fords centralized management approach led to the decline of
FMC in the 1930’s – GM became the auto leaderFMC in the 1930’s – GM became the auto leader
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Historical MilestonesHistorical Milestones
– 1920’s, John Baird develops Television1920’s, John Baird develops Television
– 1927-1932, researchers in the Hawthorne Studies 1927-1932, researchers in the Hawthorne Studies
realized human factors affect productionrealized human factors affect production
– 1950’s – 1960, Lean Manufacturing revolution is born 1950’s – 1960, Lean Manufacturing revolution is born
(Taiichi Ohno, Toyota’s chief production engineer)(Taiichi Ohno, Toyota’s chief production engineer)
– 1961, Unimate, First robot in production – part of the 1961, Unimate, First robot in production – part of the
automation revolution, human replacement conceptautomation revolution, human replacement concept
– Early 1970’s, microprocessor technology developedEarly 1970’s, microprocessor technology developed
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Traditional Design/Manufacturing Traditional Design/Manufacturing (U.S.)(U.S.)
– Sequentially, rather than concurrently (simultaneously)Sequentially, rather than concurrently (simultaneously)
– Profits FIRSTProfits FIRST
– Short Term ProductionShort Term Production
– Top heavy ManagementTop heavy Management
– Machines are the solution to every problem – Automate Machines are the solution to every problem – Automate
your way to successyour way to success
– People need to be told what tasks to do, how to do People need to be told what tasks to do, how to do
tasks, and when to do taskstasks, and when to do tasks
Design Manufacturing
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Modern Design/Manufacturing (U.S.)Modern Design/Manufacturing (U.S.)
– Long-Range Planning: set goals that provide the Long-Range Planning: set goals that provide the
best ROIbest ROI
– Concurrent Engineering: Design and manufacturing Concurrent Engineering: Design and manufacturing
are encompassed togetherare encompassed together
– Lean Production: Elimination wasteful practicesLean Production: Elimination wasteful practices
– Agile/Flexible Manufacturing: Ability to rapidly Agile/Flexible Manufacturing: Ability to rapidly
change from one part/product to another, quick change from one part/product to another, quick
response to demandresponse to demand
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Modern Design/Manufacturing (U.S.)Modern Design/Manufacturing (U.S.)– Benchmarking: Set goals with respect to competitionBenchmarking: Set goals with respect to competition
– Design for Manufacturing and Assembly (DFMA): Integrates Design for Manufacturing and Assembly (DFMA): Integrates
design process with materials, manufacturing methods, design process with materials, manufacturing methods,
process planning, assembly and testing, quality assurance.process planning, assembly and testing, quality assurance.
– Rapid Prototyping: Techniques to produce and analyze part Rapid Prototyping: Techniques to produce and analyze part
models at low costs quicklymodels at low costs quickly
– Trained people can make decisions and respond to Trained people can make decisions and respond to
manufacturing problems quicker than a hierarchical manufacturing problems quicker than a hierarchical
approach. approach.
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Modern Design/ManufacturingModern Design/Manufacturing
– Design for environment (DFE)/Design for Recycling Design for environment (DFE)/Design for Recycling
(DFR): reduce waste, hazardous materials, reuse(DFR): reduce waste, hazardous materials, reuse
– Computer-Integrated Manufacturing: Supplier Computer-Integrated Manufacturing: Supplier
contact – monitoring system information as contact – monitoring system information as
occurringoccurring
– Autonomation – Mix of humans and automationAutonomation – Mix of humans and automation
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Manufacturing Goal?Manufacturing Goal?
• The goal of any manufacturing organization is to The goal of any manufacturing organization is to make moneymake money..
• To increase net profit - simultaneously increase both To increase net profit - simultaneously increase both Return On Investment (ROI) and cash flow…to Return On Investment (ROI) and cash flow…to improve “The bottom line”.improve “The bottom line”.
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Manufacturing’s #1 Task?Manufacturing’s #1 Task?
*Customer Satisfaction**Customer Satisfaction*
• Customers must be informed about products Customers must be informed about products
• Customers must be motivated to purchase productsCustomers must be motivated to purchase products
• Customers must be satisfied with the Customers must be satisfied with the quality/performance of productsquality/performance of products
• Customers must be satisfied with the price of productsCustomers must be satisfied with the price of products
• Customers must be satisfied with product serviceCustomers must be satisfied with product service
*Companies will fail without these**Companies will fail without these*
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Manufacturing TrendsManufacturing Trends
• 1. 1. OutsourcingOutsourcing – U.S. companies typically take – U.S. companies typically take
advantage of lower labor costs found in other countriesadvantage of lower labor costs found in other countries
• 2. Manufacturing companies are restructuring to become 2. Manufacturing companies are restructuring to become
lean producerslean producers – to respond faster to customer wants, to – to respond faster to customer wants, to
make goods cheaper and faster, to reduce labor-related make goods cheaper and faster, to reduce labor-related
injuries, to increase product quality. Companies that injuries, to increase product quality. Companies that
cannot adapt are cannot adapt are out of business the next dayout of business the next day..
• 3. 3. Products are becoming more varied/specializedProducts are becoming more varied/specialized while while
lot sizes are reducing. Long-term stocking of finished lot sizes are reducing. Long-term stocking of finished
products is becoming less common.products is becoming less common.
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Manufacturing TrendsManufacturing Trends
• 4. Consumer expectations include better quality, 4. Consumer expectations include better quality,
reliability – this drives the implementation of reliability – this drives the implementation of
processes that can be controlledprocesses that can be controlled. Control = . Control =
predictable outcomes and reduction of defects.predictable outcomes and reduction of defects.
• 5. 5. Lead time reductionLead time reduction. Reducing time-to-market . Reducing time-to-market
requires products to be designed for easy requires products to be designed for easy
manufacturing and assembly. Flow approaches are manufacturing and assembly. Flow approaches are
becoming common.becoming common.
• 6. 6. Worldwide competitionWorldwide competition. Products purchased . Products purchased
today may be made anywhere in the world.today may be made anywhere in the world.
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Manufacturing TrendsManufacturing Trends
• 7. 7. Quality materialsQuality materials in = Quality out. Emphasis is being in = Quality out. Emphasis is being
placed on materials that are safe to process, safe to placed on materials that are safe to process, safe to
consumers, pure and free of defects, recyclable, easy consumers, pure and free of defects, recyclable, easy
to process, and are reliable/predictable.to process, and are reliable/predictable.
• 8. An 8. An emphasis on continuous improvementemphasis on continuous improvement of of
processes, materials, people, suppliers, quality, processes, materials, people, suppliers, quality,
product.product.
• 9. 9. Computer advancesComputer advances have significantly influenced have significantly influenced
control and inspection systems in automated control and inspection systems in automated
production, information technology production, information technology
communication/supplier relations, design platforms, communication/supplier relations, design platforms,
machine reliability, and machine flexibility. machine reliability, and machine flexibility.
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Questions to considerQuestions to consider
• 1. How important is manufacturing to the economy 1. How important is manufacturing to the economy
and your future? and your future?
• 2. What are perceptions of manufacturing? 2. What are perceptions of manufacturing?
• 3. What is continuous improvement in people?3. What is continuous improvement in people?
• 4. What are lead times? How are they reduced?4. What are lead times? How are they reduced?
• 5. What is value? 5. What is value?
• 6. What is quality? 6. What is quality?
• 7. What is waste?7. What is waste?
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Countries Lacking Manufacturing Countries Lacking Manufacturing Suffer Economically Impacting SOLSuffer Economically Impacting SOL• ““Converting materials from one form to another Converting materials from one form to another
adds value to them. The more efficiently materials adds value to them. The more efficiently materials
can be produced and converted into the desired can be produced and converted into the desired
products that function with the prescribed quality, products that function with the prescribed quality,
the greater will be the companies’ productivity and the greater will be the companies’ productivity and
the better will be the standard of living of the the better will be the standard of living of the
employees.” (Black & Kohser, 2008, p. 1).employees.” (Black & Kohser, 2008, p. 1).
• ““A nation’s level of manufacturing activity is related A nation’s level of manufacturing activity is related
directly to its economic health; generally, the higher directly to its economic health; generally, the higher
the level of manufacturing activity in a country, the the level of manufacturing activity in a country, the
higher the standard of living of its people.” higher the standard of living of its people.”
(Kalpakjian & Schmid, 2006, p. 1).(Kalpakjian & Schmid, 2006, p. 1).
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ManufacturingManufacturing• Mfg companies contribute roughly 20% of GNP Mfg companies contribute roughly 20% of GNP
(value of goods & services produced) (Black & (value of goods & services produced) (Black & Kohser, 2008).Kohser, 2008).
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Manufacturing Requires & Manufacturing Requires & Therefore Creates Service Jobs:Therefore Creates Service Jobs:
– Advertising/Marketing/SalesAdvertising/Marketing/Sales
– Education/TrainingEducation/Training
– Health Care & InsuranceHealth Care & Insurance
– Communication & Communication &
– Distribution/TransportationDistribution/Transportation
– UtilitiesUtilities
– Banking/FinanceBanking/Finance
• This is evident in most metropolitan areas and select This is evident in most metropolitan areas and select
countries (goods and services are available – SOL is countries (goods and services are available – SOL is
impacted)impacted)
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Manufacturing CostManufacturing Cost
(Black & Kohser, 2008, p. 2).(Black & Kohser, 2008, p. 2).
•“…“…manufacturing costs represent about 40% of a manufacturing costs represent about 40% of a product’s selling price” (Kalpakjian & Schmid, 2006, product’s selling price” (Kalpakjian & Schmid, 2006, p. 40).p. 40).
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Manufacturing – Relative People Manufacturing – Relative People CostsCosts• While cutting labor is often viewed as a cost-While cutting labor is often viewed as a cost-
reduction practice, “Reductions in direct labor will reduction practice, “Reductions in direct labor will have only marginal effects on the total people have only marginal effects on the total people costs” (Black & Kohser, 2008, p. 3). costs” (Black & Kohser, 2008, p. 3).
Engineers
Mkg-Sales-Mgt
Indirect Labor
Direct Labor
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Manufacturing Product LifecycleManufacturing Product Lifecycle
• Every product has a lifecycle – the stage of the Every product has a lifecycle – the stage of the lifecycle (maturity of the product) determines the lifecycle (maturity of the product) determines the form of manufacturing system in place (Job Shop –> form of manufacturing system in place (Job Shop –> Mass Production)Mass Production)
• The demand for a product changes during the The demand for a product changes during the lifecycle –Demand is commonly known as Order lifecycle –Demand is commonly known as Order WinningWinning
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Manufacturing Product LifecycleManufacturing Product Lifecycle
(Rehg & Kraebber, 2005, p. 13).(Rehg & Kraebber, 2005, p. 13).
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Order Winning Criteria Order Winning Criteria
• “… “… are the minimal operational capabilities required are the minimal operational capabilities required to get an order” (Rehg & Kraebber, 2005, p. 13)to get an order” (Rehg & Kraebber, 2005, p. 13)
• Typical OWC include Price, quality/reliability, Typical OWC include Price, quality/reliability, delivery speed, innovation, after-sale service, delivery speed, innovation, after-sale service, flexible financing flexible financing
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Order Winning Criteria & Product Order Winning Criteria & Product LifecycleLifecycle
• Order-winning criteria change during the product Order-winning criteria change during the product lifecyclelifecycle
• 1) In 1) In Startup/IntroductionStartup/Introduction, product is new – low , product is new – low volume, customers enticed to become acquainted volume, customers enticed to become acquainted with productswith products
• 2) In 2) In GrowthGrowth, innovation is typically the OWC, D>C, , innovation is typically the OWC, D>C, demand stresses company capacity, new buyers, demand stresses company capacity, new buyers, corporate entrycorporate entry
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Order Winning Criteria & Product Order Winning Criteria & Product LifecycleLifecycle• 3) In 3) In MaturityMaturity (maximum profits), D=C, price is (maximum profits), D=C, price is
often the OWC – standard designs of products. often the OWC – standard designs of products. Companies try to lengthen the Maturity phase to Companies try to lengthen the Maturity phase to increase ROI, Repeat buyers, corporate rivalry, increase ROI, Repeat buyers, corporate rivalry, intense marketing strategiesintense marketing strategies
• 4) In 4) In Commodity/DeclineCommodity/Decline, demand for the standard , demand for the standard product begins to drop and are replaced by newer product begins to drop and are replaced by newer improved products, company dropout, sales improved products, company dropout, sales stabilize or fallstabilize or fall
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Manufacturing Product LifecycleManufacturing Product Lifecycle
(Black & Kohser, 2008, p. 22).(Black & Kohser, 2008, p. 22).
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Manufacturing Product LifecycleManufacturing Product Lifecycle
(Black & Kohser, 2008, p. 22).(Black & Kohser, 2008, p. 22).
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Manufacturing Product Lifecycle Manufacturing Product Lifecycle ExamplesExamplesTreated Lumber = CommodityTreated Lumber = Commodity
Camera Film = Decline Camera Film = Decline
Diamond Ring = CommodityDiamond Ring = Commodity
Computer Mouse = CommodityComputer Mouse = Commodity
PEX Pipe = Maturation PEX Pipe = Maturation CD Player = DeclineCD Player = Decline
HDV Camcorders = GrowthHDV Camcorders = Growth
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Manufacturing Product Lifecycle Manufacturing Product Lifecycle ExamplesExamplesCereal = CommodityCereal = Commodity
LCD HD Televisions = Growth/Maturation LCD HD Televisions = Growth/Maturation
Styrofoam Cups = Commodity/DeclineStyrofoam Cups = Commodity/Decline
Steel-Framed Bicycle = Decline/ObsolescenceSteel-Framed Bicycle = Decline/Obsolescence
Auto-Nav Systems = Growth Auto-Nav Systems = Growth
New Software, Food, Video Game = Introduction/Growth New Software, Food, Video Game = Introduction/Growth
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Product Volume vs Production Product Volume vs Production MethodMethod
(Black & Kohser, 2008, p. 25).(Black & Kohser, 2008, p. 25).
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Manufacturing Product LifecycleManufacturing Product Lifecycle
““It is crucial to achieve this integration [of It is crucial to achieve this integration [of manufacturing and assembly] during the design manufacturing and assembly] during the design phase because about 70% of the life-cycle cost of a phase because about 70% of the life-cycle cost of a product is determined when it is designed” (Black & product is determined when it is designed” (Black & Kohser, 2008, p. 22).Kohser, 2008, p. 22).
• Design choices include materials, fabrication Design choices include materials, fabrication methods, material handling, assembly and methods, material handling, assembly and inspection methodsinspection methods
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Questions to considerQuestions to consider
• 1. Can the product life cycle be changed/altered? If 1. Can the product life cycle be changed/altered? If
so, how do manufacturers alter the product life so, how do manufacturers alter the product life
cycle? cycle?
• 2. What are a manufacturer’s reasons for dropping a 2. What are a manufacturer’s reasons for dropping a
product/operations? What does a manufacturer do product/operations? What does a manufacturer do
(in terms of product development) to stay in (in terms of product development) to stay in
business?business?
• 3. What is the role of the manufacturing engineer in 3. What is the role of the manufacturing engineer in
the product life cycle?the product life cycle?
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Product Life Cycle ConsiderationsProduct Life Cycle Considerations• Manufacturers desire a long life cycle (growth is good)Manufacturers desire a long life cycle (growth is good)
• Manufacturers must be concerned with price is OWCManufacturers must be concerned with price is OWC
• Manufacturers may outsource operations if price is Manufacturers may outsource operations if price is dominant OWC to stay in business dominant OWC to stay in business
• Manufacturers must be concerned when product life is at Manufacturers must be concerned when product life is at the end of maturation or in declinethe end of maturation or in decline
• If the lifecycle is near the end, companies must diversify If the lifecycle is near the end, companies must diversify in what they produce or potentially go out of businessin what they produce or potentially go out of business
• Manufacturers work with customers, develop R&D Manufacturers work with customers, develop R&D programs, pilot test new products to experience re-programs, pilot test new products to experience re-growthgrowth
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Product Life Cycle ConsiderationsProduct Life Cycle Considerations• Manufacturers drop products/operations where Manufacturers drop products/operations where
liability/safety is an issue (production, environment, liability/safety is an issue (production, environment, personnel, customer, government regulations) personnel, customer, government regulations)
• Manufacturers drop products/operations when product Manufacturers drop products/operations when product demand is lacking (decline/obsolescence/commodity) – demand is lacking (decline/obsolescence/commodity) – raises costs to make those productsraises costs to make those products
• Manufacturers drop products/ops. when producing Manufacturers drop products/ops. when producing those products increases more than the actual returnthose products increases more than the actual return
• Manufacturers may drop products/outsource Manufacturers may drop products/outsource operations if they do not have capabilityoperations if they do not have capability
• Manufacturers may drop products if other products are Manufacturers may drop products if other products are in the growth phase or entering another market is in the growth phase or entering another market is possiblepossible
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Manufacturing Engineers: CRAManufacturing Engineers: CRA• May coordinate and supervise processes/equipment May coordinate and supervise processes/equipment
to be utilized, choose machines/equipment for tasks to be utilized, choose machines/equipment for tasks (as part of design)(as part of design)
• ““Industrial or manufacturing engineers are Industrial or manufacturing engineers are responsible for manufacturing systems design (or responsible for manufacturing systems design (or layout) of factories. They must take into account the layout) of factories. They must take into account the interrelationships of the design and the properties of interrelationships of the design and the properties of the materials that the machines are going to process the materials that the machines are going to process as well as the interaction of the materials and as well as the interaction of the materials and processes.” (Black & Kohser, 2008, p. 10).processes.” (Black & Kohser, 2008, p. 10).
• May design specialized tooling, work-holding devicesMay design specialized tooling, work-holding devices
• May work with design engineers to facilitate May work with design engineers to facilitate economical production of goodseconomical production of goods
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Manufacturing Engineers: CRAManufacturing Engineers: CRA• Determine how a product is to be made (specific Determine how a product is to be made (specific
mfg processes)mfg processes)
• May design or select instruments/tools to perform May design or select instruments/tools to perform quality inspectionsquality inspections
• May select tools and tool materials to carry out May select tools and tool materials to carry out machining/forming processes of materials machining/forming processes of materials
• May make modifications to the manufacturing May make modifications to the manufacturing system to decrease the cost-per-unit without system to decrease the cost-per-unit without sacrificing 3F’ssacrificing 3F’s
• May serve as a liaison to foreign suppliersMay serve as a liaison to foreign suppliers
• May serve as the primary contact for cost reduction May serve as the primary contact for cost reduction strategies in the production of productsstrategies in the production of products
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Supporting InformationSupporting Information
• http://www.industryweek.com/ReadArticle.aspx?Artihttp://www.industryweek.com/ReadArticle.aspx?ArticleID=13312cleID=13312
• http://www.industryweek.com/ReadArticle.aspx?Artihttp://www.industryweek.com/ReadArticle.aspx?ArticleID=10867&SectionID=10cleID=10867&SectionID=10
• http://www.bls.gov/iag/manufacturing.htmhttp://www.bls.gov/iag/manufacturing.htm
• http://www.bls.gov/news.release/ecopro.t01.htmhttp://www.bls.gov/news.release/ecopro.t01.htm
• See See Standard of LivingStandard of Living report report
• http://www.sme.org/gmn/data/docs/018834http://www.sme.org/gmn/data/docs/018834
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Future Topics for DiscussionFuture Topics for Discussion
• Materials and their propertiesMaterials and their properties
• Processing materialsProcessing materials
• 3F’s of Product Design3F’s of Product Design
• Over-engineering/Overdesign and Value EngineeringOver-engineering/Overdesign and Value Engineering
• Lean-related topicsLean-related topics