chapter 1 introduction ein 3390 manufacturing processes summer a, 2011

Chapter 1Chapter 1IntroductionIntroduction

EIN 3390 Manufacturing ProcessesEIN 3390 Manufacturing ProcessesSummer A, 2011 Summer A, 2011

Interactive Factors in ManufacturingInteractive Factors in ManufacturingFactors

◦Product design◦Materials◦Labor costs◦Equipment ◦Manufacturing costs

Strategies to reduce cost◦Lean manufacturing◦Systems approach

Product DevelopmentProduct Development

Sustaining technology:◦ Innovations bring

more value to the consumer

◦ Improvements in materials, processes, and design

Product growth normally follows the “S” curve

Figure 1-1a) A product development curve

Manufacturing and Production Manufacturing and Production SystemsSystemsManufacturing is the ability to make goods and

services to satisfy societal needs◦ Manufacturing processes are strung together to

create a manufacturing system (MS)Production system is the total company and

includes manufacturing systems

The functions and Systems of the Production System

Production System- The Production System- The EnterpriseEnterprise

Production systems include◦People◦Money◦Equipment◦Materials◦Supplies◦Markets◦Management◦Manufacturing System◦All aspects of commerce

Manufacturing SystemsManufacturing SystemsManufacturing systems

◦Collection of operations and processes to produce a desired product or component

◦Design or arrangement of the manufacturing processes

Manufacturing processes◦Convert unfinished materials to finished

products Often are a set of steps

◦Machine tool is an assembly that produces a desired result

Common Aspects of Common Aspects of ManufacturingManufacturing

Job and station◦Job is a group of related operations generally done

at one station◦Station is the location or area where production is

doneOperations

◦Distinct action to produce a desired result or effect◦Categories of operations

Materials handling and transport Processing Packaging Inspecting and testing Storing

Common Aspects of Common Aspects of ManufacturingManufacturingTreatments operate continuously on a

workpiece◦Heat treating, plating, finishing, chemical cleaning,

painting, curing, galvanizingTools, tooling and workholders

◦Lowest mechanism in the production is a tool Used to hold, shape or form the unfinished product

Tooling for measurement and inspection◦Rulers, calipers, micrometers, and gages◦Precision devices are laser optics or vision systems

that utilize electronics to interpret results

Products and FabricationsProducts and FabricationsProducts result from manufacture

◦Manufacturing can be from either fabricating or processing Fabricating is the manufacture of a product from

pieces such as parts, components, or assemblies Processing is the manufacture of a product by

continuous operationsWorkpiece and its configuration

◦Primary objective of manufacturing is to produce a component having a desired geometry, size, and finish

Roles of Engineers in Roles of Engineers in ManufacturingManufacturing

Design engineer responsibilities◦What the design is to accomplish◦Assumptions that can be made◦Service environments the product must

withstand◦Final appearance of the product◦Product designed with the knowledge that

certain manufacturing processes will be used

Roles of Engineers in Roles of Engineers in ManufacturingManufacturing

Manufacturing engineer responsibilities◦Select and coordinate specific processes and

equipment◦Supervise and manage their use

Industrial (Manufacturing) engineer◦Manufacturing systems layout, time study, cost

Materials engineers◦Specify ideal materials◦Develop new and better materials

Changing World CompetitionChanging World Competition

Globalization has impacted manufacturing◦Worldwide competition for global products and

their manufacture◦High tech manufacturing for advanced

technology◦New manufacturing systems, designs, and

management

Manufacturing Systems DesignsManufacturing Systems Designs

Five manufacturing system designs◦Job shop◦Flow shop◦Linked-cell shop◦Project shop◦Continuous process

Job ShopJob Shop

Figure 1-7 This rack bar machining area is functionally designed so it operates like a job shop, with lathes, broaches, and grinders lined up.

Flow ShopFlow Shop

Figure 1-8 The moving assembly line for cars is an example of the flow shop.

Mass Production to Lean Mass Production to Lean ProductionProduction

Figure 1-9 The traditional subassembly lines can be redesigned into U-shaped cells as part of the conversion of mass production to lean production.

Forming ProcessForming Process

Figure 1-11 The forming process used to make a fender for a car.

Forming Process Forming Process

Figure 1-11

Single-Point MetalcuttingSingle-Point Metalcutting

Figure 1-12 Single-point metalcutting process (turning) produces a chip while creating a new surface on the workpiece.

Characteristics of Process Characteristics of Process TechnologyTechnology

Mechanics (static or dynamic)Economics or costs Time SpansConstraintsUncertainties and process reliabilitySkillsFlexibilityProcess capability

Figure 1-14 Product life-cycle costs change with the classic manufacturing system designs.

Figure 1-16 This figure shows in a general way the relationship between manufacturing systems and production volumes.

Manufacturing Systems and Manufacturing Systems and Production VolumesProduction Volumes

SummarySummaryEconomical and successful manufacturing

requires knowledge of the relationships between labor, materials, and capital

Design a manufacturing system that everyone understands

Engineers must possess a knowledge of design, metallurgy, processing, economics, accounting, and human relations