intrors07by vijay ikhar.ppt

7/30/2019 IntroRs07by Vijay Ikhar.ppt

1/30

Introduction to

Manufacturing

By: Mr. Vijay L. IkharMBA(Operations Mgmt.) B.Sc.( Biotech)


2/30

GMP

Introduction to Manufacturing

Observe the objects around you:How did they become what they are?

What important role does manufacturing play in

society?

How do we define manufacturing?

Manufacturing is the ability to make goods and services

to satisfy societal needs

Manufacturing processes are strung together to create amanufacturing system (MS)


3/30

GMP

Society & Manufacturing

1930s1920s 1910s

1900s

1990s

1950s

1940s

1960s 1970s1980s


4/30

GMP

Types of Goods

Consumer Goods Items which are purchased directly by consumers Consumer electronics

Clothing

Producer Goods Items which are manufactured for other companies to

produce products from

Steel Mills - coil stock

Machine tool builders - Milling Machines Automotive suppliers - Taillight assemblies


5/30

GMP

Products

Fabricating - Manufacturing of products from

components, pieces, or sub-assemblies. Separate

discrete items such as machined parts, bolts, nuts

etc. are fabricated. Processing - Manufacturing a product in a

continuous series of operation . Examples include

wire, beverages, chemicals etc.


6/30

GMP

Manufacturing a Product

Production systems include People

Money

Equipment

Materials

Supplies

Markets

Management

Manufacturing System

All aspects of commerce


7/30

GMP


The Manufacturing System

Figure 1-4 The functions and

systems of the production

system, which includes (and

services) the manufacturing

system. The functional

departments are connected by

formal and informal informationsystems designed to service the

manufacturing system that

produces the goods.


8/30

GMP


The Manufacturing System

Collection of operations and processes to produce a

desired product or component Design or arrangement of the manufacturing processes


9/30


10/30

GMP

Roles of People in Mfg.

Manufacturing engineer responsibilities

Select and coordinate specific processes and equipment

Supervise and manage their use

Industrial (Manufacturing) engineer Manufacturing systems layout

Materials engineers

Specify ideal materials Develop new and better materials


11/30

GMP

Roles of People in Mfg.

Technicians

QC, machine set-up, machine maintenance, machine

repair, and system integration

Machinist and Tool Makers Producing close tolerance parts and tooling to

specifications

Operators

Running production parts and quality


12/30

GMP

Aspects of a Manufacturing System

Mfg. Processes The method (s) used to convert a product from one form to

another- example metal removal. A process typically

involves a sequence of steps or operations.


13/30

GMP

Characteristics of Process

Technology Mechanics

Economics or costs

Time Spans

Constraints

Uncertainties and process reliability

Skills

Flexibility

Process capability


14/30

GMP


Operations Distinct action to produce a desired result or effect

Categories of operations

Materials handling and transport

Processing

Drilling, tapping, turning, milling, injecting

Packaging

Inspecting and testing

Storing


15/30

GMP


Figure 1-6 The component called a pinion

shaft is manufactured by a sequence of

operations to produce various geometric

surfaces.


16/30

GMP


Job and station Job is a group of related operations generally done at one station

Station is the location or area where production is done

Treatments operate continuously on a workpiece Heat treating, curing, galvanizing, plating, finishing, chemical cleaning,

painting Tools, 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


17/30

GMP

Factory Layouts

Job Shop

Flow Shop

Linked-Cell Shop

Project Shop

Continuous Process


18/30

GMP

Factory Layouts

Figure 1-15 Different manufacturing

system designs produce goods at different

production rates.


19/30

GMP

Seven Basic Processes

Casting

Forming

Machining

Joining and Assembly

Surface Treatment

Heat Treatment

Other


20/30

GMP

Casting

Molten metal fills a cavity in a mold.

Quick method to transform a raw material into a

desired shape.

Two types of casting methods: Expendable mold

Sand casting

Permanent mold

Die casting

Plastic, composite manufacturing, and PM


21/30

GMP

Forming & Shearing

Changing materials into a desired shape by: Squeezing

Bending

Shearing

Drawing

Utilizes Materials that have been previously cast

or molded

Performed at cold or hot temperatures cold = room temp to .3 of the melt temperature material

hot = above .3 of the melt temperature of the material


22/30

GMP

Metal Removal - Machining

Seven basic processes Shaping

Turning

Drilling

Milling

Sawing

Broaching

Abrasive machining

Non-Traditional

Examples: EDM & Water-Jet


23/30

GMP

Joining

Mechanical Fastening

Welding

Adhesive bonding

Assembly


24/30

GMP

Surface Treatment

Aesthetic requirements

Painting

Product requirements

Safety Burrs

Surface treatment

chemical plating to resist rust


25/30

GMP

Heat Treatment

Altering the mechanical properties of a material.

Strength

Wear resistance

Resistance to penetration


26/30

GMP

Other

Inspection

Packaging

Transportation

Waste disposal

Scrap

Chemical by-products


27/30

GMP

Product Life Cycle Cost


28/30

GMP

Changing World Competition

Globalization has impacted manufacturing

Worldwide competition for global products and their

manufacture

High tech manufacturing for advanced technologyNew manufacturing systems, designs, and management


29/30

GMP

New Manufacturing Systems

Toyota Production System

Lean manufacturing system

100% good units flow without interruption

Integrated quality control Responsibility for quality is given to manufacturing

Constant quality improvement


30/30

GMP

How Do We Plan For

Manufacturing?

Definition of a need Conceptual design

Review of initial design

Design Prototype

Production plan

Resource specifications

Manufacturing Prototype

Manufacturing

Inspection--quality checks

Packaging - shipping Customer response

intrors07by vijay ikhar.ppt

Documents