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