manufacturing_process__overview_.doc

8/14/2019 Manufacturing_Process__Overview_.doc

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Manufacturing Process (Overview)

Manufacturing is the use of machines, tools and labor to produce goods foruse or sale. The term may refer to a range of human activity, from handicraft to hightech, but is most commonly applied to industrial production, in which rawmaterials are transformed into finished goodson a large scale.

Such finished goods may be used for manufacturing other, more complex products,such as aircraft, household appliances or automobiles, or sold to wholesalers, who inturn sell them to retailers, who then sell them to end users the "consumers".

Fig. Manufacturing Cycle

Manufacturing of products is an important activity historically, technologically, andeconomically. The products that are available to us or alternatively, the benefits ofcivilization which we enjoy today, are necessarily due to the improvement in theirquality.


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This improvement is possible withproper design, which taes into consideration thefunctional requirement as well as its manufacturing aspects. This maes abetter product available at an economical cost.

!ll this is possible with the availability and adoption of a variety of new techniquesand process replacement and improvement of prevailing processesor techni"uesthat include better and more compact design, efficient andappropriate methodsof production, mechanization, automationand numerical control andoptimaloutput.#resently there have been increasing demands on theperformance of the productby way of desirable characteristics such as resistance to elevated temperatures,higher operating speeds and ability to carry extra loads. ! variety of rawmaterials and its associated processingwould be re"uired for this purpose.

Just lie technology that can be defined as the application of science to

provide society and its members with those items! things! products that aredesired, so is the manufacturing processes.

The manufacturing processforms a vital ingredient for various products such asplant and machinery that is needed in various disciplines of engineering.

! detailed nowledge of the manufacturing processesis thus essential for everyengineer. $e will be able to appreciate the process capabilities, advantages andlimitations. This in turn would help him in the proper design of the product as perdemand in the maret.

%urther, he would be able to assess the feasibility of manufacturingthe re"uisitedesign, select the appropriate process requiring minimum manufacturing costand of the desired quality from the different! alternative techniques or

processes available.

Definition of Manufacturing

Manufacturing can be defined in two ways in the modern context i.e. technologicaland economic. Technologically, manufacturing is the application of physicaland chemical processes for changing the geometry, characteristics and! orappearance of a given input material to produce parts or products, theassembly involving many parts to mae products is also included in manufacturing.


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The processes to accomplish manufacturing involve a combination of machines!tools, man power, power! energy and methodsas represented in %ig.

#conomically, manufacturing means the transformation of materials into

items! goods of greater value by way of one or more processing and! orassembly operations as shown in %ig. The meaning of greater value is thatmanufacturing adds value to the material by altering its shape or characteristics.$hematerial has been made more valuable by virtue of the manufacturingoperations performed on it.


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Manufacturing Industries and Products

Manufacturingis an important activity, but it is performed by various enterprises&

organizations as a commercial activity for the purpose of financial gains andcustomer satisfaction.%ndustry means enterprises and organizations that are able to produce or supplygoods& products and services.The final products made by manufacturing industries are termed as manufactured

products. These can be divided into &onsumer 'roductsand&apital goods.

Manufacturing Processes

%or every engineer a through nowledge of the manufacturing processes isessential. This would help him to appreciate the advantages, limitations andcapabilitiesof the process.


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'ith such nowledge, he would be able to assess the feasibility of manufacturinga particular product from the designs. %urther, he would be able to select properprocesses, which would re"uire the lowest manufacturing cost and wouldmanufacture the product of re"uisite "uality.

Classification of Manufacturing Processes

Manufacturing processes can be classified in six groups. They are(). 'rimary (haping or )orming 'rocesses #rimary shaping or forming ismanufacturing of a solid body from a molten or gaseous state or from an amorphousmaterial. Some of the important primary shaping processes is(* &asting* 'owder Metallurgy* 'lastic technology.

+. +eforming 'rocesses eforming processes mae use of suitable stresses lie

compression, tension, shear or combined stresses to cause plastic deformation ofthe materials to produce re"uired shapes without changing its mass or materialcomposition. Some of the forming processes are(* )orging* #xtrusion* olling* (heet metal woring* etc.

-. Machining/Removing Processes The principle used in all machiningprocesses is to generate the surface re"uired by providing suitable relative motionsbetween the wor piece and the tool. Some of the machining processes are(* $urning* +rilling Milling* -rinding* (haping* etc.

. Joining processes /n this process one or more pieces of metal parts are unitedtogether to mae sub*assembly or final product. Some of the important joiningprocesses are(* 'ressure welding* +iffusion welding* brazing* esistance welding* soldering*etc.

0. Surface Finishing Processes These processes are utilized to provide intendedsurface finish on the metal surface of a job. Some of the important surface finishingprocesses are(

* 'lastic coating* Metallic coating* #lectroplating* etc.

1. Material Properties Modification Processes /n this type of process, materialproperties of a wor piece is changed in order to achieve desired characteristics

without changing the shape. Some of the processes are(* eat and surface treatment* /nnealing* (tress relieving.


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!pes of Production S!stems

Types of production and choice of production type dictates the machinere"uirements, organizational system and to a large extent, layout, planning andinventory sub*systems. There are three main types of production, namely, job, batchand flow or process production.

Plant "a!out

#lant layout is the arrangement of the physical element of facilities 2or machines&e"uipment3 which mae the product or service. Thus facilities layout is the overallarrangement of machines, men, material handling, service facilities, and passagere"uired to facilitate efficient operation of production system. The primary goal ofplant layout is to maximize profit by the arrangement of all plant facilities to the best

advantage of the 4manufacturing equation5 men, material, machines, and moneyin fulfilling this goal.

The pattern by which departments and facilities within departments are arrangedmay be viewed either in terms of wor flow or the function of the productive system.!ccording to wor flow pattern, four basic types are used in manufacturingoperations. These are(* %ixed position layout* #roduct or line layout* #rocess or functional layout* 6roup layout.

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