INTRODUCTIONHistory of civilisation is the history of making things now known as MANUFACTURING (MFG) It is important:Technologically-Applying science to give society it reads.Economically -Creating material wealth for nations.Historically-Better weapons led to conquer the neighbours.

MANUFACTURING & PRODUCTIONThe word PRODUCTION appeared in 1483 in English derived from PROCEDURE (Latin; Lead Forward)The word MANUFACTURE appeared in 1622, stemming from MANU FACTUS (Latin; Made by hand)

MANUFACTURINGOriginally, it meant making by handsToday it means:Conversion of a design into a finished productIn 1983, International conference on production research Manufacturing as a series of inter-related activities and operations involvingDesignMaterial selectionPlanningProducingQuality assuranceManagement & marketing of products

PRODUCTIONTransformation of raw materials into products by a series of energy applications, each of which affects well defined changes in physicals/chemical characteristics of material.Making something new either tangible (products) or intangible (services)

IMPORTANCEIts history spans over several thousand years and is spread over following THREE important features:Provides for basic means of human existanceCreates wealth for nations andSteps towards human happiness and world peace

In 1991, National Academy of Engineering/Sciences in Washington DC (USA) declared following subjects necessary for US economic growth and national security:*SCIENCE*TECHNOLOGY*MANUFACTURING

FLOWS IN MANUFACTURING:FLOW OF MATERIAL: Conversion of raw material into productsFLOW OF INFORMATION: Planning & control of productionFLOW OF COST: Producing in cost-effective mannerFlow of Material involves MANUFACTURING PROCESSFlow of Information involves TECHNOLOGY MANAGEMENTFlow of Cost involves FINANCIAL MANAGEMENT

PLANNINGMANUFACTURINGPROCESSCONTROLRAW MATERIALPRODUCTSCOST FLOWCOST FLOWMFIFIFMF

MANUFACTURING SYSTEMBlack Model Model:

INPUTPROCESSOUTPUTResources:MaterialsThrough PutGoods and servicesCLASSIFICATION OF VARIOUS INDUSTRIES[A]BASED ON TYPE OF PRODUCTS:PRIMARY: Cultivating/exploiting natural resources (mining & agriculture)SECONDARY: Converts outputs of primary industry intouseful goodsTERTIARY: Represents service sector of economy (banking etc)

[B]BASED ON QUATITY OF PRODUCTION:HANDICRAFT / COTTAGE /ARTISAN TYPE : Village levelJOB-LOT /JOB SHOP TYPE: 10- 500 Units/year-Lot typeMODERATE TYPE : 2500-100,000 products/year-Batch typeMASS PRODUCTION TYPE: More than 100,000 parts/year- For descrete type e.g Car industriesOr CONTINUOS TYPE : For non-descrete products e.g Oil, Coal

TYPE OF MANUFACTURINGMASSBATCHJOB-LOTPRODUCTIONPRODUCTIONPRODUCTIONFEATURES:1) MARKET DEMAND 2) INVESTMENT3) MAN POWER4) MACHINES & EQUIPT.5) DELIVERY TIME

CHARACTERISTICS OF MASS, BATCH & JOB LOT MANUFACTURING SYSTEM

LOWHIGHHIGHLOWMASS (continuous)BATCH ModerateJOB-LOTProductivityFlexibility

CLASSIFICATION OF BASIC MANUFACTURINGMass-production: if produced continuously or intermittently at high volume for considerable period of time>100,000 parts per yearIndustry sales volume is well establishedProduction rates are independent of individual ordersMachines usually incapable of performing operation on other workCommon example: bottle caps, pencils, automobile, nuts, bolts and washers

Moderate production: produced in relatively large quantities, but the output may be variable and more dependent on sales order

Moderate production: The machines likely will be multipurpose oneThe parts produced may vary from 2500 to 100,000 per year depending on complexityExample of industry are more descriptive: printing of books, aircraft compasses and radio transmittersJob-lot production: More flexible and their production is usually limited to lots closely attuned to sales orders or expected salesProduction equipment is multipurposeEmployees may be more highly skilledPerforming various tasks depending on part or assembly being madeLot sizes customarily from 10 to 500 parts per lotQuantity depend on demand and order

Job-lot production: Example, oil field valves, special meters or antique automobile

Mass, moderate and job-lot production require different equipment and systemsThe specification of the equipment identifies what it is and what it can do

Concurrent EngineeringA philosophy that promotes interactive design and manufacturing effortTo developed product and process simultaneously, thus optimizing company resources and reducing time to market cycle