process engineering introduction

7/28/2019 Process Engineering Introduction

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Process Engineering and ProductProcess Engineering and Product

EngineeringEngineeringDr. P. M.Dr. P. M. PandeyPandey


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The Process Engineering FunctionThe Process Engineering FunctionProcess: It is simply a method which products canProcess: It is simply a method which products can

be manufactured from raw materials.be manufactured from raw materials.

It could also be described as a method for shapingIt could also be described as a method for shapingraw materials into usable product forms.raw materials into usable product forms.

In this course, the term process, applies to theIn this course, the term process, applies to the

shaping of metal, plastic or rubber in the raw materialshaping of metal, plastic or rubber in the raw materialstates.states.

The course does not concern about those industriesThe course does not concern about those industrieswhich produce food stuffs, textiles, chemicals orwhich produce food stuffs, textiles, chemicals or

medicines. This course is also not intended for use inmedicines. This course is also not intended for use inrelation to the industry which makes raw materials.relation to the industry which makes raw materials.


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General Manufacturing ProcessesGeneral Manufacturing Processes Casting and MouldingCasting and Moulding

Machining or CuttingMachining or Cutting

Forming or DeformingForming or Deforming AssemblyAssembly

In addition to the process for shaping rawIn addition to the process for shaping raw

materials, finishing operations are used to obtain thematerials, finishing operations are used to obtain thefinal quality desired. These processes include:final quality desired. These processes include:

Cleaning, Painting, Buffing, Plating, Polishing,Cleaning, Painting, Buffing, Plating, Polishing,DeburringDeburring, Heat treatment etc., Heat treatment etc.

Nearly all products manufactured require at leastNearly all products manufactured require at leasttwo or more of the five general processes. Thereforetwo or more of the five general processes. Therefore

process engineering deals with all five general processesprocess engineering deals with all five general processes


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Product EngineeringProduct EngineeringThe product to be manufactured is first conceivedThe product to be manufactured is first conceived

by the engineer. This engineer determines the need forby the engineer. This engineer determines the need for

a product. It may be an entirely new product or newa product. It may be an entirely new product or newmodel of the old product. Experimental designs aremodel of the old product. Experimental designs aremade ,and scale models are made and tested. Finally amade ,and scale models are made and tested. Finally a

production design is created after all faults have beenproduction design is created after all faults have been

corrected. Part prints are drawn to illustrate the productcorrected. Part prints are drawn to illustrate the productgraphically. All dimensions and specifications requiredgraphically. All dimensions and specifications requiredare included on the print. The material to be used in theare included on the print. The material to be used in the

product is specified, and product name and number isproduct is specified, and product name and number is

included. Functions of a product engineeringincluded. Functions of a product engineeringdepartment can be itemized as followsdepartment can be itemized as follows


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Product Engineering (contd)Product Engineering (contd)A.A. Design Product for FunctionDesign Product for Function

1.1. Build model for testingBuild model for testing

2.2. Provide part printsProvide part printsa.a. Physical dimensionsPhysical dimensions

b.b. MaterialMaterial

c.c. Special process required such as painting plating, heatSpecial process required such as painting plating, heattreatment, testing etc.treatment, testing etc.

3.3. Provide tool design and construction aidsProvide tool design and construction aidsa.a. Master layoutsMaster layouts

b.b. TemplatesTemplatesc.c. Master models.Master models.


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Product Engineering (contd)Product Engineering (contd)

4.4. Provide specifications or standards manualProvide specifications or standards manual

a.a. Material specificationMaterial specification

b.b. Specification for testing and inspectionSpecification for testing and inspection

c.c. Procedures for testing and inspectionProcedures for testing and inspectiond.d. Specification for threads, gears, keys,Specification for threads, gears, keys, splinessplines etc.etc.

e.e. Procedures and specifications for joining processProcedures and specifications for joining process


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B.B. Design the Product for CustomerDesign the Product for Customer

SatisfactionSatisfaction

1.1. Sales appealSales appeal

a.a. AppearanceAppearance

b.b. ImprovementsImprovements

c.c. Design to meet the needs of the customerDesign to meet the needs of the customer

2.2. Durability and life expectancyDurability and life expectancy


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Product Engineering (contd)Product Engineering (contd)C.C. Design the Product for CostDesign the Product for Cost

1.1. Cost should be low enough to compete in marketCost should be low enough to compete in market2.2. Cost should be high enough to provide profitCost should be high enough to provide profit

3.3. Cost should be in correct relationship withCost should be in correct relationship with

durability and life expectancydurability and life expectancyD.D. Design the Product for ease of MaintenanceDesign the Product for ease of Maintenance

and Assemblyand Assembly

1.1. Ease of repairEase of repair

2.2. Ease of assembly and disassemblyEase of assembly and disassembly

3.3. Provide drawing for maintenance and assemblyProvide drawing for maintenance and assembly


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The product engineer must transmit theThe product engineer must transmit the

Information to the process engineer so that workInformation to the process engineer so that work

May continue. Paper work passing from product toMay continue. Paper work passing from product toProcess engineer includesProcess engineer includes

A.A. Paper printsPaper prints

B.B. Engineering releasesEngineering releasesi.i. Production rate per yearProduction rate per year

ii.ii. SubSub--assembly and assembly numbersassembly and assembly numbers

iii.iii. Release dateRelease date--date on which processing, tooling and alldate on which processing, tooling and all

planning may start.planning may start.iv.iv. Part name, number and material.Part name, number and material.

C.C. Change in part prints when revision are madeChange in part prints when revision are made

D.D. Change in engineering releasesChange in engineering releases


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Process EngineeringProcess Engineering

Process engineering takes place directly afterProcess engineering takes place directly after

product engineering has completed the design ofproduct engineering has completed the design ofproduct.product.

It takes the information from product engineerIt takes the information from product engineer

and they create the plan for manufactureand they create the plan for manufacture

Processing is then the function ofProcessing is then the function ofdetermingdeterming

exactly how a product will be modeexactly how a product will be mode


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Process Engineering (contd)Process Engineering (contd)A.A. To determine the manufacturing process to be usedTo determine the manufacturing process to be used

B.B. To determine the order of sequence of operationTo determine the order of sequence of operationnecessary to manufacture the partnecessary to manufacture the part

1.1. Operation routing or line upOperation routing or line up

2.2. Process picturesProcess pictures

C.C. To determine and order the tooling and gaugesTo determine and order the tooling and gauges

needed to manufacture the partneeded to manufacture the part

1.1.

Orders to designOrders to design

2.2. Orders to buildOrders to build

3.3. Orders to buyOrders to buy


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Process Engineering (contd)Process Engineering (contd)

D.D. To determine, select and order theTo determine, select and order the

equipment needed to manufacture the partequipment needed to manufacture the partE.E. To determine need for and originate ordersTo determine need for and originate orders

for all process revisions necessary whenfor all process revisions necessary when

part print changes occurpart print changes occur

F.F. To follow up the tooling and equipment toTo follow up the tooling and equipment todetermine if all if all is functioning asdetermine if all if all is functioning as

planned and if not, make the necessaryplanned and if not, make the necessaryrevisionsrevisions


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G.G. To provide estimates of cost of tooling andTo provide estimates of cost of tooling and

equipment needed to manufacture new productsequipment needed to manufacture new products

H.H. To determine part changes necessary to easeTo determine part changes necessary to ease

manufacture or reduce cost and request part printmanufacture or reduce cost and request part print

changeschanges

I.I. To take part in product study groups to assist theTo take part in product study groups to assist the

product engineer in the design of a product thatproduct engineer in the design of a product that

will be feasible and economical to makewill be feasible and economical to make


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Process engineering is definitely a field requiringProcess engineering is definitely a field requiring

incentive and creativity as well as experience. Creatingincentive and creativity as well as experience. Creatinga new process may be as interesting as new product.a new process may be as interesting as new product.

So many new processes are developed and processSo many new processes are developed and process

engineering has to be up to dateengineering has to be up to dateFailure to use a better, low cost or safer processFailure to use a better, low cost or safer process

due to ignorance may result into drastic losses. Thedue to ignorance may result into drastic losses. The

best process plan of this year may be obsolete nextbest process plan of this year may be obsolete nextyear.year.


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Product Engineering

Tool design Process Engineering Purchasing

Tool making Tryout Manufacturing

Methods &workstandards

Product specification

Equipmentspecification

Production MachinesProduction Tooling

Tooling

Design

Tooling Specification

Mfg. Specifications1. Open routing.


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Selection of ManufacturingSelection of Manufacturing

ProcessProcess

Manufacturing costManufacturing cost

Production volume and production rateProduction volume and production rate

Characteristics and properties ofCharacteristics and properties ofworkpieceworkpiece

materialmaterial Limitation on shape and sizeLimitation on shape and size

Surface finish and tolerance requirementsSurface finish and tolerance requirements

Functional requirements of the productFunctional requirements of the product

process engineering introduction

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