ENM208

DEFINING MANUFACTURING

ANADOLU U N I V E R S I T Y

Industrial Eng. Dep.

2006

Saleh AMAITIK

Manufacturing Processes

Spring 2005

Defining Manufacturing

The word manufacturing is defined from the Latin

manu factus

made by hand

manu = hand

factus = made

Manufacturing Processes

Spring 2005

Defining Manufacturing

Manufacturing involves making products

from raw materials by means of various

processes, machinery, and operations,

through a well-organized plan for each

activity required.

Manufacturing Processes

Spring 2005

Defining Manufacturing

Production Manufacturing

Manufacturing Engineering is the term used

widely in the United States to describe this area

of industrial activity.

Production Engineering is equivalent term to

manufacturing Engineering in other countries.

Manufacturing Processes

Spring 2005

Manufacturing Systems

The manufacturing System is a collection of manufacturing processes used to obtain a desired product(s)

The manufacturing System is the design or arrangement of the manufacturing processes.

Control of a manufacturing system applies to overall control of the whole processes or equipment.

The entire manufacturing system must be controlled in order to schedule and control production, inventory levels, product quality and so forth.

Manufacturing Processes

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Manufacturing Systems

The manufacturing System takes inputs and

produces products for the external customer

Manufacturing Processes

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Manufacturing Systems

Manufacturing System may produce

Discrete productsIndividual parts (e.g. nails, gears, engine blocks, ……etc.)

Continuous productsMay be cut into individual pieces and thus become discrete parts (e.g. a spool of wire, metal or plastic sheets, tubes , ……etc.)

Manufacturing Processes

Spring 2005

Production Systems

A production system, or the enterprise, will refer to the

total company and will include with it the

manufacturing system.

The production system includes the manufacturing

system plus all the other functional areas of the plant

for information, design, analysis, and control.

These subsystems are connected by various means to

each other to produce products(s).

Manufacturing Processes

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Production Systems

Manufacturing System)where value is added(

Manufacturing Processes

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Production Systems

Production Types

Low-quantity production (1 ~ 100 units/yr)Job shop, prototyping.

Medium-quantity production (100 ~ 10,000 units/yr)Batch production & cellular manufacturing.

High-quantity production (> 10,000 units/yr)Mass production.

Manufacturing Processes

Spring 2005

Machine

A specific piece of equipment designed to

accomplish specific processes, often called a

Machine Tool

Examples: Milling machine, punch press, ….

Machine tools linked together to make a

manufacturing system cell

Manufacturing Processes

Spring 2005

Job (Station)

A collection of operations done on machines or a

collection of tasks performed by one worker at

one location on the assembly line.

Examples: Machining, inspection, final assembly, ……

Manufacturing Processes

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Operation (Process)

A specific action or treatment, often done on a

machine, the collection of which makes up the job

of a worker.

Examples: Drilling, Forming, Welding, assembly, ……

Manufacturing Processes

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Tool

Refers to the implements used to hold, cut,

shape, or deform the work materials.

Examples: Cutting tools in machining.

Jigs and fixtures in work holding.

Punches and dies in metal forming.

Manufacturing Processes

Spring 2005

Design and Manufacturing process

Manufacturing Processes

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Concurrent Engineering

Concurrent engineering is a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support.

Manufacturing Processes

Spring 2005

Design for Manufacturing (DFM)

It is a comprehensive approach to production of products, ant it integrates the design process with materials, manufacturing methods, process planning, assembly, and quality assurance.

Implements design for manufacture requires that designers have a fundamental understanding of the characteristics, capabilities, and limitations of materials, manufacturing processes and related operations, machinery and equipment.

Manufacturing Processes

Spring 2005

Selecting materials for manufacturing

Variety of materials is now available, each having its own properties, applications, advantages, and limitations.

Manufacturing Processes

Spring 2005

Selecting materials for manufacturingWhen selecting materials for products, we consider

Mechanical properties of materials

(Strength, toughness, ductility, hardness, elasticity, fatigues, creep, ……(

Physical properties of materials

(density, specific heat, thermal expansion and conductivity, melting point, and electrical and magnetic properties, ……)

Chemical properties of materials

(corrosion, toxicity, flammability, ……)

Manufacturing Processes

Selecting materials for manufacturing

The material properties specified for a product should

be appropriate to the conditions under which the

product is expected to function.

Spring 2005

The manufacturing properties of materials determine

whether they can be cast, formed, machined, welded,

and heated-treated with relative ease.

Manufacturing Processes

Selection of manufacturing processes

Spring 2005

Many processes are used to produce parts and shapes and there is usually more than one method of manufacturing a part from a given material

Classification of manufacturing processes

Machining (turning, drilling, milling, grinding, …….

Forming and shaping (rolling, forging, sheet forming,…..

Casting (expendable mold, permanent mold, ……)

Joining (welding, brazing, soldering, ….)

Finishing (honing, polishing, coating, heat treatment, …

Manufacturing Processes

Characterizing a manufacturing process

Spring 2005

Manufacturing Processes

Factors affecting the selection of manufacturing processes

Spring 2005

There are many factors which affect the selection of a suitable manufacturing process for a part. These factors are:

• Geometry

• Quality

• Quantity

• Material

• Machine or equipment avalibility

• Cost

Manufacturing Processes

Factors affecting the selection of manufacturing processes

Spring 2005

Geometry

Cylindrical, conical, and screw threads are mostly easily produced on a Lathe.

Plane surface, block shapes and slots are generally produced by shaping, planning or milling.

More complex parts may need to be cast, forged or shaped before machining.

The shape of a part will decide the process which

must be used to produce that part.

Manufacturing Processes

Factors affecting the selection of manufacturing processes

Spring 2005

Quality

Dimensional accuracy (tolerances).

Geometrical accuracy.

Surface finish.

An appropriate manufacturing process should provide

suitable dimensional accuracy, geometrical accuracy,

and surface finish.

Manufacturing Processes

Factors affecting the selection of manufacturing processes

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Quantity

The quantity (batch size) determines the economics of manufacturing process selection.

The cost falls as the batch size increases and more

productive techniques can be employed.

Manufacturing Processes

Factors affecting the selection of manufacturing processes

Spring 2005

Material

The material from which the part is going to be made

The material specified by the designer influences the

method of manufacturing.

Manufacturing Processes

Factors affecting the selection of manufacturing processes

Spring 2005

Machine or equipment availability

Availability of machines and equipment and of operating experience with the manufacturing facility

Cost

Operational and manufacturing cost.

Manufacturing Processes

Consequences of improper selection of materials and processes

Spring 2005

Numerous examples of product failure can be traced to

Improper selection of material.

A part is generally considered to have failed when

It stops functioning (e.g. broken shaft, gear, ….)

Improper selection of manufacturing processes.

Improper control of process variables.

It does not functioning properly or perform within required specification limits (e.g. worn bearing, …)

It becomes unreliable or unsafe for further use (e.g. crack in a shaft, ..)

Manufacturing Processes

Net-shape Manufacturing

Spring 2005

Since not all manufacturing operations produce finished parts, additional operations may be necessary.

Net-shape or near-net-shape manufacturing. The part is made, in the first operation, as close to the final desired dimensions, tolerances, surface finish, and specifications as possible.

Manufacturing Processes

Manufacturing Automation

Spring 2005

The major goals of automation in manufacturing facilities are to integrate various operations so as to improve productivity, to increase product quality, to minimize cycle times, and to reduce labor costs

Computers are now used in a very broad range of applications including:

Control and optimization of manufacturing processes.

Material handling

Automated assembly

Automated inspection and testing of products

Manufacturing Processes

Computer Integrated Manufacturing - CIM

Spring 2005

Manufacturing Processes

Computer Integrated Manufacturing - CIM

Spring 2005

Manufacturing Processes

Computer application in Manufacturing

Spring 2005

The following is an outline of the major applications of computers in manufacturing.

Computer Numerical Control - CNC

Computer Aided Process Planning - CAPP

Automated and Robotic assembly systems.

Flexible Manufacturing Systems - FMS

Automated handling of materials.

Artificial Intelligence.