lesson 1 overview of manufacturing

LESSON 1:

COURSE OVERVIEW

INTRODUCTION TO MANUFACTURING

DR HERBERT MAPFAIRA27/01/2014w

DR HERBERT MAPFAIRA

B.ENG. INDUSTRIAL ENGINEERING

MSC. MANUF. SYSTEMS ENG.

PHD. MANUF. ENG. & OPERATIONS MANAGEMENT

12 YEARS WORKING FOR PUBLIC SECTOR – UK

1 YEAR WORKING FOR TOYOTA – UK

2 YEARS MANAGEMENT CONSULTING - UKw

TODAY’S AGENDA

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Start course material Lesson 1 – Overview of Manufacturing

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COURSE INFORMATION

Course homepage: Blackboard Syllabus Handouts

This introductory presentation Some lecture material

Homework assignments Project information Announcements

Check the page for course information and announcements

TEXTBOOK

Course Textbook: M. P. Groover, Principles of Modern

Manufacturing: SI Version [Paperback]

ASSESSMENT CRITERIA

Component Percentage %

Assignments (2 x

5%)

Quizzes

Lab experiments

10 %

Mini-project

(Workshop)

10 %

Tests (2 x 10%) 20 %

Final Examination 60 %

CLASSROOM RULES

Turn off cell phones and other communication devicesNo completing homework or other assignments

Use common sense and be considerate of othersNotify instructor when absent from class as soon as possible

Before or after the factJustifiable reason

LECTURE FORMAT

The first part of class will be devoted to questions. Unreasonably long questions will be handled one on

one. If I don’t know the answer, I’ll get it for the class by

the next lecture. Lecture

Ask questions End of Class – Will try to leave time for

questions

LECTURE FORMAT

Most material will be delivered There will be periodic in-class problem

solving sessions.

Any Questions ?

LESSON OUTLINE

1. What is manufacturing?

2. Importance of manufacturing

3. Manufacturing Industries and Products

4. Materials in Manufacturing

5. Manufacturing Operations

6. Production Facilities

7. Product/Production Relationships

8. Lean Production

O

Ok, shall we start now!

©2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

What is Manufacturing?

The word manufacture is derived from two Latin words manus (hand) and factus (make); the combination means “made by hand”

“Made by hand” accurately described the fabrication methods that were used when the English word “manufacture” was first coined around 1567 A.D.

Most modern manufacturing operations are accomplished by mechanized and automated equipment that is supervised by human workers

Manufacturing can be defined in two ways, one technological, and the other economic.


Manufacturing - Technological

Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material to make parts or products– The processes to accomplish manufacturing involve a combination of

machinery, tools, and manual labor.– Manufacturing is always carried out in a sequence of operations. Each

operation bringing the material closer to the desired final stage.


Manufacturing - Economic Transformation of materials into items of greater value by

one or more processing and/or assembly operations Manufacturing adds value to the material by changing is

shape or properties or by combining it with other materials that have been similarly altered.

Materials are made more valuable through manufacturing operations performed on them:

When iron is converted to steel, value is added;

When sand is converted to glass, value is added.

When petroleum is converted to plastic, value is added; and when plastic is converted to more complex shapes, even more value is added

Why do you think manufacturing is important?


Manufacturing is Important

Making things has been an essential human activity since before recorded history

Today, the term manufacturing is used for this activity

Manufacturing is important: Technologically Economically


Technological Importance

Technology - the application of science to provide society and its members with those things that are needed or desired

Technology provides the products that help our society and its members live better

What do these products have in common? They are all manufactured

Manufacturing is the essential factor that makes technology possible


Economic Importance

U.S. EconomySector: %GDPAgriculture and natural resources 5Construction and public utilities 5Manufacturing 15Service industries* 75

100* includes retail, transportation, banking,

communication, education, and government


Manufacturing Industries

The type of manufacturing done by a company depends on the kind of product it makes.

Industry consists of enterprises and organizations that produce or supply goods and services

Let us explore this relationship by first examining the types of industries in manufacturing and then identifying the products they make

Industries can be classified as:1. Primary industries - cultivate and exploit natural resources, e.g.,

agriculture, mining

2. Secondary industries - take the outputs of primary industries and convert them into consumer and capital goods

3. Tertiary industries - service sector

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 22/37

More Industry Classifications

Process industries, e.g., chemicals, petroleum, basic metals, foods and beverages, power generation Continuous production Batch production

Discrete product (and part) industries, e.g., cars, aircraft, appliances, machinery, and their component parts Continuous production Batch production



Process Industries and Discrete Manufacturing Industries


Specific Industries in Each Category


Manufactured Products

Final products divide into two major classes:1. Consumer goods - products purchased directly by

consumers Cars, clothes, TVs, tennis rackets

2. Capital goods - those purchased by companies to produce goods and/or provide services Aircraft, computers, communication

equipment, medical apparatus, trucks, machine tools, construction equipment


Manufacturing Capability

A manufacturing plant consists of processes and systems (and people, of course) designed to transform a certain limited range of materials into products of increased value

The three building blocks ‑ materials, processes, and systems ‑ are the subject of modern manufacturing

Manufacturing capability includes:

1. Technological processing capability

2. Physical product limitations

3. Production capacity


1. Technological Processing Capability

The available set of manufacturing processes in the plant (or company)

Certain manufacturing processes are suited to certain materials By specializing in certain processes, the plant is also

specializing in certain materials Includes not only the physical processes, but also the

expertise of the plant personnel Examples:

A machine shop cannot roll steel A steel mill cannot build cars


2. Physical Product Limitations

Given a plant with a certain set of processes, there are size and weight limitations on the parts or products that can be made in the plant

Product size and weight affect: Production equipment Material handling equipment

Production, material handling equipment, and plant size must be planned for products that lie within a certain size and weight range


3. Production Capacity

Defined as the maximum quantity that a plant can produce in a given time period (e.g., month or year) under assumed operating conditions

Operating conditions refer to number of shifts per week, hours per shift, direct labor manning levels in the plant, and so on

Usually measured in terms of output units, such as tons of steel or number of cars produced by the plant

Also called plant capacity


Materials in Manufacturing

Most engineering materials can be classified into one of three basic categories:

1. Metals

2. Ceramics

3. Polymers Their chemistries are different Their mechanical and physical properties are

dissimilar These differences affect the manufacturing

processes that can be used to produce products from them

What typical operations are you likely to find in manufacturing?



Manufacturing Operations

There are certain basic activities that must be carried out in a factory to convert raw materials into finished products

For discrete products:

1. Processing

2. Assembly operations

3. Material handling

4. Inspection and testing

5. Coordination and controlA processing operation transforms a work material from one state of

completion to a more advanced state using energy to alter its shape,

properties or appearance to add value to the material.



Fig. 2.3

Classification of manufacturing processes


Processing Operations

Alters a material’s shape, physical properties, or appearance in order to add value

Three categories of processing operations:

1. Shaping operations - alter the geometry of the starting work material

2. Property‑enhancing operations - improve physical properties without changing shape

3. Surface processing operations - to clean, treat, coat, or deposit material on exterior surface of the work


Shaping Processes – Four Categories

1. Solidification processes - starting material is a heated liquid or semifluid

2. Particulate processing - starting material consists of powders

3. Deformation processes - starting material is a ductile solid (commonly metal)

4. Material removal processes - starting material is a ductile or brittle solid


Waste in Shaping Processes

Desirable to minimize waste in part shaping Material removal processes are wasteful in unit

operations, simply by the way they work Most casting, molding, and particulate processing

operations waste little material Terminology for minimum waste processes:

Net shape processes - when most of the starting material is used and no subsequent machining is required

Near net shape processes - when minimum amount of machining is required


Property‑Enhancing Processes

Performed to improve mechanical or physical properties of work material

Part shape is not altered, except unintentionally Example: unintentional warping of a heat treated

part Examples:

Heat treatment of metals and glasses Sintering of powdered metals and ceramics


Surface Processing Operations

Cleaning - chemical and mechanical processes to remove dirt, oil, and other contaminants from the surface

Surface treatments - mechanical working such as sand blasting, and physical processes like diffusion

Coating and thin film deposition - coating exterior surface of the workpart



Assembly Operations

Joining processes Welding Brazing and soldering Adhesive bonding

Mechanical assembly Threaded fasteners (e.g., bolts and nuts, screws) Rivets Interference fits (e.g., press fitting, shrink fits) Other

An assembly operation joins two or more components to create

a new entity which is called an assembly, subassembly, etc.



Other Factory Operations

Material handling and storage Inspection and testing Coordination and control



Material Handling

““A means of moving and storing materials between processing A means of moving and storing materials between processing and/or assembly operations”and/or assembly operations”

Material transport Vehicles, e.g., forklift trucks, AGVs, monorails Conveyors Hoists and cranes

Storage systems Unitizing equipment Automatic identification and data capture (AIDC)

Bar codes RFID Other AIDC equipment

In manufacturing a product, how much time in percentage do you think is spend in actual processing of the product?



Time Spent in Material Handling

Fig. 2.4



Inspection and Testing

Inspection – examination of the product and its components to determine whether they conform to design specifications Inspection for variables - measuring Inspection of attributes – gaging

Testing – observing the product (or part, material, subassembly) during actual operation or under conditions that might occur during operation



Coordination and Control

Regulation of the individual processing and assembly operations Process control Quality control

Management of plant level activities Production planning and control Quality control


Production Systems

People, equipment, and procedures used for the combination of materials and processes that constitute a firm's manufacturing operations

A manufacturing firm must have systems and procedures to efficiently accomplish its type of production

Two categories of production systems: Production facilities Manufacturing support systems

Both categories include people (people make the systems work)



Production Facilities

A manufacturing company attempts to organize its facilities in the most efficient way to serve the particular mission of the plant

Certain types of plants are recognized as the most appropriate way to organize for a given type of manufacturing

The most appropriate type depends on: Types of products made Production quantity Product variety



Production Quantity

Number of units of a given part or product produced annually by the plant

Three quantity ranges:

1. Low production – 1 to 100 units

2. Medium production – 100 to 10,000 units

3. High production – 10,000 to millions of units



Product Variety

““Refers to the number of different product or part Refers to the number of different product or part designs or types produced in the plantdesigns or types produced in the plant””

Inverse relationship between production quantity and product variety in factory operations

Product variety is more complicated than a number Hard product variety – products differ greatly

Few common components in an assembly Soft product variety – small differences between

products Many common components in an assembly



Product Variety vs. Production Quantity

Fig. 2.5



Low Production Quantity

Job shopJob shop – makes low quantities of specialized and customized products

Also includes production of components for these products

Products are typically complex (e.g., specialized machinery, prototypes, space capsules)

Equipment is general purpose Plant layouts:

Fixed position Process layout



Fixed-Position Layout

Fig. 2.6 (a)



Process Layout

Fig. 2.6 (b)



Medium Production Quantities

1.1. Batch productionBatch production – A batch of a given product is produced, and then the facility is changed over to produce another product Changeover takes time – setup time Typical layout – process layout Hard product variety

2.2. Cellular manufacturingCellular manufacturing – A mixture of products is made without significant changeover time between products Typical layout – cellular layout Soft product variety



Cellular Layout

Fig. 2.6 (c)



High Production (mass production)

1.1. Quantity productionQuantity production – Equipment is dedicated to the manufacture of one product Standard machines tooled for high production (e.g.,

stamping presses, molding machines) Typical layout – process layout

2.2. Flow line productionFlow line production – Multiple workstations arranged in sequence Product requires multiple processing or assembly

steps Product layout is most common



Product Layout

Fig. 2.6 (d)



Relationships between Plant Layout and Type of Production Facility

Fig. 2.7


Example of Processes

A spectacular scene in steelmaking is charging of a basic oxygen furnace, in which molten pig iron produced in a blast furnace is poured into the BOF. Temperatures are around 1650°C (3000 ° F).


A machining cell consisting of two horizontal machining centers supplied by an in-line pallet shuttle (photo courtesy of Cincinnati Milacron).


A robotic arm performs unloading and loading operation in a turning center using a dual gripper (photo courtesy of Cincinnati Milacron).


Metal chips fly in a high speed turning operation performed on a computer numerical control turning center (photo courtesy of Cincinnati Milacron).


Photomicrograph of the cross section of multiple coatings of titanium nitride and aluminum oxide on a cemented carbide substrate (photo courtesy of Kennametal Inc.).


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).


Two welders perform arc welding on a large steel pipe section (photo courtesy of Lincoln Electric Company).


Automated dispensing of adhesive onto component parts prior to assembly (photo courtesy of EFD, Inc.).


Assembly workers on an engine assembly line (photo courtesy of Ford Motor Company).


Assembly operations on the Boeing 777 (photo courtesy of Boeing Commercial Airplane Co.).

lesson 1 overview of manufacturing

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