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Introduction to Manufacturing and
Processing
MSE 319 August 25, 2014Chapter 1: Groover (See Blackboard)
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1. What is Manufacturing?2. Materials in Manufacturing3. Manufacturing Processes4. Production Systems5. Trends in Manufacturing
INTRODUCTION AND
OVERVIEW OF MANUFACTURING
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Manufacturing is Important
Making things has been an essential human activitysince before recorded history
Today, the term manufacturing is used for thisactivityManufacturing is important to the United States andmost other developed and developing nations
TechnologicallyEconomically
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Economic Importance
U.S. EconomySector: %GDP
Agriculture and natural resources 5Construction and public utilities 5Manufacturing 15Service industries* 75
100* includes retail, transportation, banking,
communication, education, and government
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0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
16.00%
18.00%
2003 2004 2005 2006 2007 2008 2009 2010
Wood products
Nonmetallic mineral products
Primary metals
Fabricated metal products
Machinery
Computer and electronic products
Electrical equipment, appliances, andcomponentsMotor vehicles, bodies and trailers, andpartsOther transportation equipment
Furniture and related products
Miscellaneous manufacturing
Food and beverage and tobaccoproductsTextile mills and textile product mills
Apparel and leather and allied products
Paper products
Printing and related support activities
Petroleum and coal products
Chemical products
Plastics and rubber products
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What is Manufacturing?
The word manufacture is derived from two Latinwords manus (hand) and factus (make); the
combination means
made by hand
Made by hand
accurately described the fabricationmethods that were used when the English word
manufacture
was first coined around 1567 A.D.
Most modern manufacturing operations areaccomplished by mechanized and automatedequipment that is supervised by human workers
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Manufacturing - Technological
Application of physical and chemical processes toalter the geometry, properties, and/or appearance of
a starting material to make parts or products
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Manufacturing - Economic
Transformation of materials into items of greater valueby one or more processing and/or assembly operations
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Manufactured Products
Final products divide into two major classes:1. Consumer goods - products purchased directly by
consumersCars, clothes, TVs, tennis rackets
2. Capital goods - those purchased by companies toproduce goods and/or provide services
Aircraft, computers, communicationequipment, medical apparatus, trucks,machine tools, construction equipment
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Production Quantity Q
The quantity of products Q made by a factory has animportant influence on the way its people, facilities, and
procedures are organized Annual quantities can be classified into three ranges:
Production range Annual Quantity Q Low production 1 to 100 unitsMedium production 100 to 10,000 unitsHigh production 10,000 to millions of units
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Product Variety P
Product variety P refers to different product types ormodels produced in the plant
Different products have different featuresThey are intended for different marketsSome have more parts than others
The number of different product types made eachyear in a factory can be countedWhen the number of product types made in thefactory is high, this indicates high product variety
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P vs Q in Factory Operations
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More About Product Variety
Although P is quantitative, it is much less exact than Qbecause details on how much the designs differ is not
captured simply by the number of different designsSoft product variety - small differences betweenproducts, e.g., between car models made on the sameproduction line, with many common parts
Hard product variety - products differ substantially, e.g.,between a small car and a large truck, with fewcommon parts (if any)
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Materials in Manufacturing
Most engineering materials can be classified into oneof three basic categories:
1. Metals2. Ceramics3. PolymersTheir chemistries are different, and their mechanicaland physical properties are differentThese differences affect the manufacturing processesthat can be used to produce products from them
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In Addition: Composites
Venn diagram ofthree basicmaterial typesplus composites
Nonhomogeneous mixtures of the other three basictypes rather than a unique category
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Shaping Processes Four Categories
1. Solidification processes - starting material is a heatedliquid or semifluid
2. Particulate processing - starting material consists ofpowders
3. Deformation processes - starting material is a ductilesolid (commonly metal)
4. Material removal processes - starting material is aductile or brittle solid
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Solidification Processes
Starting material is heated sufficiently to transform itinto a liquid or highly plastic state
Casting process at left and casting product at right
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Particulate Processing
(1) Starting materials are metal or ceramic powders,which are (2) pressed and (3) sintered
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Deformation Processes
Starting workpart is shaped by application of forcesthat exceed the yield strength of the material
Examples: (a) forging and (b) extrusion
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Material Removal Processes
Excess material removed from the starting piece so whatremains is the desired geometry
Examples: (a) turning, (b) drilling, and (c) milling
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Property-Enhancing Processes
Processes that improve mechanical or physicalproperties of work material
Examples:Heat treatment of metals and glassesSintering of powdered metals and ceramics
Part shape is not altered, except unintentionallyExample: unintentional warping of a heat treatedpart
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A batch of silicon wafers enters a furnace heated to 1000
C(1800
F) during fabrication of integrated circuits under clean room
conditions (photo courtesy of Intel Corporation).
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Surface Processing Operations
Cleaning - chemical and mechanical processes toremove dirt, oil, and other surface contaminants
Surface treatments - mechanical working such assand blasting, and physical processes like diffusionCoating and thin film deposition - coating exteriorsurface of the workpart. Examples:
ElectroplatingPhysical vapor depositionPainting
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Facilities vs Product Quantities
A company designs its manufacturing systems andorganizes its factories to serve the particular mission
of each plantCertain types of production facilities are recognized asmost appropriate for a given type of manufacturing:1. Low production 1 to 100
2. Medium production 100 to 10,0003. High production 10,000 to >1,000,000
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Manufacturing Support Systems
A company must organize itself to design theprocesses and equipment, plan and control
production, and satisfy product quality requirements Accomplished by manufacturing support systems The people and procedures by which acompany manages its production operations
Typical departments:Manufacturing engineering, Productionplanning and control, Quality control
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Trends in Manufacturing
Lean production and Six SigmaGlobalization and outsourcing
Environmentally conscious manufacturingMicrofabrication and Nanotechnology
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Lean Production and Six Sigma
Lean productionDoing more work with fewer resources, yet
achieving higher quality in the final productUnderlying objective: elimination of waste inmanufacturing
Six Sigma
Quality-focused program that utilizes workerteams to accomplish projects aimed at improvingan organization
s organizational performance
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Globalization
The recognition that we have an international economy inwhich barriers once established by national boundarieshave been reducedThis has enabled the freer flow of goods and services,capital, technology, and people among regions andcountriesOnce underdeveloped countries such as China, India,and Mexico have developed their manufacturinginfrastructures and technologies so that they are nowimportant producers in the global economy
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Outsourcing
Use of outside contractors to perform work that wastraditionally accomplished in-house
Local outsourcingJobs remain in the U.S.
Outsourcing to foreign countriesOffshore outsourcing - production in China andother overseas locationsNear-shore outsourcing - production in Canada,Mexico, and Central America
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Environmentally Conscious Manufacturing
Determining the most efficient use of materials andnatural resources in production, and minimizing thenegative consequences on the environment
Associated terms: green manufacturing, cleanerproduction, sustainable manufacturingBasic approaches:1. Design products that minimize environmental
impact2. Design processes that are environmentally
friendly
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Microfabrication and Nanotechnology
MicrofabricationProcesses that make parts and products whose
feature sizes are in the micron range (10-6
m)Examples: Ink-jet printing heads, compact disks,microsensors used in automobiles
NanotechnologyMaterials and products whose feature sizes are inthe nanometer range (10 -9 m)Examples: Coatings for catalytic converters, flatscreen TV monitors
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Overview of Major Topics