1 - Introduction And Overview Of Manufacturing

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1 - Introduction and Overview ofManufacturingManufacturing Processes - 2, IE-352Ahmed M El-Sherbeeny, PhDSpring-20161Chapter 1

INTRODUCTION ANDOVERVIEW OF MANUFACTURING1.2.3.4.What is Manufacturing?Materials in ManufacturingManufacturing ProcessesProduction Systems2Chapter1- Part1

1- What is manufacturing?“act of making something (a product)from raw materials”3Chapter 1- Part 1

Manufacturing is Important Technologically Economically Historically4Chapter1- Part1

Manufacturing - Technologically ImportantWhat is technology?Technology - the application of science to provide societyand its members with those things that are needed ordesiredTechnology provides the products that help our societyand its members live betterWhat do these products have in common?They are all manufacturedManufacturing is the essential factor that makes technologypossible5Chapter1- Part1

Manufacturing - Economically ImportantU.S. economy:Sector% ofGNP*Manufacturing20%Manufacturing is one Agriculture, minerals, etc.way by which nations Construction & utilitiescreate material wealthService sector – retail,transportation, banking,communication, education, andgovernment* GNP Gross Net Product6Chapter1- Part15%5%70%

What is Manufacturing?The word manufacture is derived from two Latinwords manus (hand) and factus (make); thecombination means “made by hand” Most modern manufacturing operations areaccomplished by mechanized and automatedequipment that is supervised by humanworkers7Chapter1- Part1

Manufacturing - TechnologicallyApplication of physical and chemical processes toalter the geometry, properties, and/or appearanceof a starting material to make parts or products Manufacturing also includes assembly Almost always carried out as a sequence of operationsFigure 1.1 (a)Manufacturingas a technicalprocess8Chapter1- Part1

Manufacturing - EconomicallyManufacturing adds value to the material bychanging its shape or properties, or by combiningit with other materials (this is done by means of one ormore processing and/or assembly operations)Figure 1.1 (b)Manufacturingas an economicprocess9Chapter1- Part1

Manufacturing IndustriesIndustry consists of enterprises and organizationsthat produce or supply goods and servicesIndustries can be classified as:Primary industries - those that cultivate and exploitnatural resources, e.g., farming, miningSecondary industries - take the outputs of primaryindustries and convert them into consumer and capitalgoods - manufacturing is the principal activity, otherexamples: construction, and electric power generationTertiary industries - service sector, e.g. banking10Chapter1- Part1

Manufacturing Industries - continued Manufacturing includes several industries whose productsare not covered in this book; e.g., apparel, beverages,chemicals, and food processing For our purposes, manufacturing meansproduction of hardware Nuts and bolts, forgings, cars, airplanes,digital computers, plastic parts, andceramic products11Chapter1- Part1

Production Quantity QThe quantity of products Q made by a factory hasan important influence on the way its people,facilities, and procedures are organized Annual production quantities can be classifiedinto three ranges:Annual Quantity Q1 to 100 units100 to 10,000 units10,000 to millionsProduction rangeLow productionMedium productionHigh production12Chapter1- Part1

Product Variety PProduct variety P refers to different producttypes or models produced in the plant. Different products have different features They are intended for different markets Some have more parts than others When the number of product types made inthe factory is high, this indicates highproduct variety13Chapter1- Part1

P versus Q in Factory OperationsPQFigure 1.2 P-Q Relationship14Chapter1- Part1

More About Product VarietyAlthough P is a quantitative parameter, it is much lessexact than Q because details on how much thedesigns differ is not captured simply by thenumber of different designs Soft product variety - smalldifferences between products, e.g.,between car models made on the sameproduction line, with many common partsamong models Hard product variety - products differsubstantially, e.g., between a small carand a large truck, with few common parts (ifany)15Chapter1- Part1

Manufacturing CapabilityA manufacturing plant consists of processes andsystems (and people, of course) designed totransform a certain limited range of materialsinto products of increased value. The three building blocks - materials, processes, andsystems - are the subject of modern manufacturing.16Chapter1- Part1

Manufacturing capability includes:1. Technological processing capability2. Physical product limitations3. Production capacity17Chapter1- Part1

1. Technological Processing CapabilityThe available set of manufacturing processesin the plant (or company) Certain manufacturing processes are suitedto certain materials(By specializing in certain processes, the plant is alsospecializing in certain materials) Includes not only the physical processes,but also the expertise of the plant personnelExamples:A machine shop cannot roll steelA steel mill cannot build cars18Chapter1- Part1

2. Physical Product LimitationsGiven a plant with a certain set of processes,there are size and weight limitations on theparts or products that can be made in the plant Product size and weight affect: Production equipment Material handling equipment19Chapter1- Part1

3. Production Capacity (or plant capacity)Defined as the maximum quantity that a plantcan produce in a given time period (e.g.,month or year) under assumed operatingconditionsOperating conditions refer to number of shiftsper week, hours per shift, direct labor manninglevels in the plant, and so onCapacity is measured in terms of output units,such as tons of steel or number of carsproduced by the plant20Chapter1- Part1

2- Materials in Manufacturing21Chapter 1- Part 1

Materials in ManufacturingMost engineering materials can be classifiedinto one of three basic categories:1. Metals2. Ceramics3. PolymersTheir chemistries and also their mechanicaland physical properties are different These differences affect the manufacturingprocesses that can be used to produce productsfrom them22Chapter1- Part1

1. MetalsUsually alloys, which are composed of two or moreelements, at least one of which is metallicTwo basic groups:Ferrous metals - based on iron, comprisesabout 75% of metal tonnage in the world:Steel Fe-C alloy (0.02 to 2.11% C)Cast iron Fe-C alloy (2% to 4% C)Nonferrous metals - all other metallicelements and their alloys: aluminum, copper,magnesium, nickel, silver, tin, titanium, etc.23Chapter1- Part1

2. CeramicsCompounds containing metallic (or semi-metallic)and nonmetallic elements.Typical nonmetallic elements are oxygen,nitrogen, and carbon For processing, ceramics divide into:1. Crystalline ceramics – includes: Traditional ceramics, such as clay(hydrous aluminum silicates)Modern ceramics, such as alumina(Al2O3)2. Glasses – mostly based on silica(SiO2)24Chapter1- Part1

3. PolymersCompound formed of repeating structural units calledmers, whose atoms share electrons to form very largemolecules25Chapter1- Part1

3- PolymersThree categories:1. Thermoplastic polymers - can besubjected to multiple heating and coolingcycles without altering molecular structure2. Thermosetting polymers - moleculeschemically transform (cure) into a rigidstructure – cannot be reheated3. Elastomers - shows significant elasticbehavior26Chapter1- Part1

In addition- CompositesNonhomogeneous mixtures of the other three basictypes rather than a unique categoryFigure 1.3 Venndiagram of threebasic material typesplus composites27Chapter1- Part1

CompositesMaterial consisting of two or more phases thatare processed separately and then bondedtogether to achieve properties superior to itsconstituentsPhase - homogeneous mass ofmaterial, such as grains of identicalunit cell structure in a solid metalUsual structure consists of particlesor fibers of one phase mixed in asecond phaseProperties depend on components,physical shapes of components,and the way they are combined toform the final material28Chapter1- Part1

Composites29Chapter1- Part1

3- Manufacturing Processes30Chapter1- Part2

Manufacturing ProcessesTwo basic types:1. Processing operations transform a work material fromone state of completion to amore advanced state 2.Operations that change the geometry,properties, or appearance of thestarting materialAssembly operations - join twoor more components to create anew entity31Chapter1- Part2

Figure 1.4 Classification of manufacturing processesA1BCD232Chapter1- Part2

Processing OperationsClick to see figure 1-4 againAlters a material’s shape, physicalproperties, or appearance in order toadd value Three categories of processingoperations:1. Shaping operations - alter thegeometry of the starting work material2. Property-enhancing operations improve physical properties withoutchanging shape3. Surface processing operations - toclean, treat, coat, or deposit material onexterior surface of the work33Chapter1- Part2

AShaping Processes – Four Categories1.Solidification processes - starting materialis a heated liquid or semifluid2.Particulate processing - starting materialconsists of powders3.Deformation processes - starting materialis a ductile solid (commonly metal)4.Material removal processes - startingmaterial is a ductile or brittle solid34Chapter1- Part2

A1- Solidification ProcessesStarting material is heated sufficiently totransform it into a liquid or highly plastic state Examples: metal casting, plastic molding35Chapter1- Part2

A2- Particulate ProcessingStarting materials are powders of metals orceramics Usually involves pressing and sintering, in whichpowders are first compressed and then heated to bondthe individual particlesSteps: Pressing and sinteringSintering is a method for makingobjects from powder, by heating thematerial (below its melting point) until itsparticles adhere to each other.36Chapter1- Part2

A3- Deformation ProcessesStarting workpart is shaped by application offorces that exceed the yield strength of thematerial Examples: (a) forging, (b) extrusionA press machine performs extrusion.37Chapter1- Part2

A4- Material Removal ProcessesExcess material removed from the starting pieceso what remains is the desired geometry Examples: machining such as turning, drilling,and milling; also grinding and nontraditionalprocesses38Chapter1- Part2

AWaste in Shaping ProcessesDesirable to minimize waste in part shaping Material removal processes are wasteful in unitoperations, simply by the way they work Most casting, molding, and particulateprocessing operations waste little material Terminology for minimum waste processes: Net shape processes - when most of thestarting material is used and nosubsequent machining is required Near net shape processes - whenClick to see figure 1-4 againminimum amount of machining is required39Chapter1- Part2

BProperty-Enhancing ProcessesPerformed to improve mechanical or physicalproperties of work material Part shape is not altered, exceptunintentionally Example: unintentional warping of a heat treatedpart Examples: Heat treatment of metals and glasses Sintering of powdered metals and ceramicsClick to see figure 1-4 again40Chapter1- Part2

CSurface Processing Operations Cleaning - chemical and mechanicalprocesses to remove dirt, oil, and othercontaminants from the surface Surface treatments - mechanical workingsuch as sand blasting, and physicalprocesses like diffusion Coating and thin film deposition - coatingexterior surface of the workpartClick to see figure 1-4 again41Chapter1- Part2

DAssembly OperationsTwo or more separate parts are joined toform a new entity Types of assembly operations:1. Joining processes – create apermanent joint Welding, brazing, soldering, andadhesive bonding2. Mechanical assembly – fastening bymechanical methods Threaded fasteners (screws, boltsand nuts); press fitting, expansionfits42Chapter1- Part2

Production Systems43Chapter1- Part2

Production SystemsPeople, equipment, and procedures used for thecombination of materials and processes thatconstitute a firm's manufacturing operations A manufacturing firm must have systems and procedures toefficiently accomplish its type of productionTwo categories of production systems:1. Production facilities2. Manufacturing support systemsBoth categories include people (people make the systems work)44Chapter1- Part2

Production systemsProduction systemsManufacturingsupport systemsProduction facilitiesLow production: Job shopMedium production: Batch productionand cellular manufacturingHigh production: quantity productionand flow line productionManufacturing engineeringProduction planning andcontrolQuality control45Chapter1- Part2

1- Production FacilitiesThe factory, production equipment, andmaterial handling systems Production facilities "touch" the product Includes the way the equipment is arrangedin the factory - the plant layoutEquipment usually organized into logicalgroupings, called manufacturing systemsExamples:Automated production lineMachine cell consisting of an industrialrobot and two machine tools46Chapter1- Part2

Facilities versus Product QuantitiesA company designs its manufacturing systemsand organizes its factories to serve theparticular mission of each plant Certain types of production facilities arerecognized as the most appropriate for agiven type of manufacturing:1. Low production – 1 to 1002. Medium production – 100 to 10,0003. High production – 10,000 to 1,000,000 Different facilities are required for each of thethree quantity ranges47Chapter1- Part2

Low ProductionJob shop is the term used for this type ofproduction facility A job shop makes low quantities ofspecialized and customized products Products are typically complex, e.g., spacecapsules, prototype aircraft, special machinery48 Equipment in a job shopis general purpose Labor force is highlyskilled Designed for maximumflexibilityChapter1- Part2

Medium ProductionTwo different types of facilities, depending onproduct variety:Batch production Suited to hard product variety Setups required between batchesCellular manufacturing Suited to soft product variety Worker cells organized to processparts without setups between differentpart styles49Chapter1- Part2

High Production Often referred to as mass production High demand for product Manufacturing system dedicated to theproduction of that product Two categories of mass production:1. Quantity production2. Flow line production50Chapter1- Part2

Quantity ProductionMass production of single parts on singlemachine or small numbers of machines Typically involves standard machines equippedwith special tooling Equipment is dedicated full-time to theproduction of one part or product type Typical layouts used in quantity production areprocess layout and cellular layout51Chapter1- Part2

Flow Line ProductionMultiple machines or workstations arranged insequence, e.g., production lines Product is complex Requires multiple processing and/orassembly operations Work units are physically moved through thesequence to complete the product Workstations and equipment are designedspecifically for the product to maximizeefficiency52Chapter1- Part2

2- Manufacturing Support SystemsA company must organize itself to design the processes and equipment, plan and control production, and satisfy product quality requirementsAccomplished by manufacturing support systems - peopleand procedures by which a company manages itsproduction operationsTypical departments:1. Manufacturingengineering2. Production planningand control3. Qualitycontrol Chapter1- Part253

Overview of Major TopicsFigure 1.10 Overview of production system and major topics inFundamentals of Modern Manufacturing.54Chapter1- Part2

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(Basic Oxygen Furnace). Temperatures are around 1650 C (3000 F).55Chapter1- Part2

A machining cell consisting of two horizontal machining centerssupplied by an in-line pallet shuttle (photo courtesy of Cincinnati Milacron).56Chapter1- Part2

A robotic arm performsunloading and loadingoperation in a turningcenter using a dual gripper(photo courtesy of CincinnatiMilacron).57Chapter1- Part2

Metal chips fly in a highspeed turning operationperformed on a computernumerical control turningcenter (photo courtesy ofCincinnati Milacron).58Chapter1- Part2

Photomicrograph of the cross section of multiple coatings oftitanium nitride and aluminum oxide on a cemented carbidesubstrate (photo courtesy of Kennametal Inc.).59Chapter1- Part2

A batch of silicon wafers enters a furnace heated to 1000 C(1800 F) during fabrication of integrated circuits under clean roomconditions (photo courtesy of Intel Corporation).60Chapter1- Part2

Two welders perform arcwelding on a large steelpipe section (photocourtesy of Lincoln ElectricCompany).61Chapter1- Part2

Automated dispensing ofadhesive onto componentparts prior to assembly(photo courtesy of EFD, Inc.).62Chapter1- Part2

Assembly workers on anengine assembly line(photo courtesy of Ford MotorCompany).63Chapter1- Part2

Assembly operationson the Boeing 777(photo courtesy of BoeingCommercial Airplane Co.).64Chapter1- Part2

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

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