ENGR480 Manufacturing Systems

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Presentation transcript:

ENGR480 Manufacturing Systems Spring 2007

ENGR480 Manufacturing Systems MWF 10:00, Lab Tue 2:00 Read Syllabus for other info

What is Manufacturing? Man-u-fac-ture: To make or process a raw material into a finished product, esp. by means of a large-scale industrial operation. From Latin manu + factus: by hand, to make

Manufacturing Operations Processing Shaping (solidification, deformation, material removal, or particulate processing) Property Enhancement (heat treatment) Surface Processing (cleaning, coating) Assembly Permanent (welding, adhesive,rivets, pressfit) Reversible (threaded fasteners, friction fit)

Short History of Manufacturing 3000BC: Egyptian and Korean sand casting 1000BC: Iron age began 26BC: Egyptian lathe turning 1770AD: Steam engine, industrial revolution 1801: Interchangeable parts 1911: F.W.Taylor’s “Principles of Scientific Management”, Henry Ford’s mass production 1965: Toyota Production System, single-piece flow 2000: Virtual corporations, global manufacturing

Our Manufacturing Company You thought this was a class - it’s really a manufacturing company (we’ll call it MotorMakers Inc) Our products are small brushless outrunner electric motors.

Some Questions a Manufacturer Needs Answered Who is going to buy our product? How much will they pay for it? How much quality will we put into it? How much will it cost to make? How much money will we make? What will making this product do to the Earth?

The Next Questions Will we make 1 or 1,000,000 units? Should this product be durable or disposable? What will be our production schedule? How long can development take? How much should we invest in production efficiency for this product?

Case History: Forge Industrial Cement and sand bagging plant Manual palletizing: 120 pallets/day, 56 bags/pallet, 60 lb/bag = 400,000 lb/day Crew of 4 (work release), changed twice/day Automatic palletizer 200 pallets/day (672,000 lb/day, 68% increase)

Our Product 19 part electric motors Production Rate Goal of 5 minutes / motor Bill of materials is: (1) GoBrushless.com S-227-45-9 22.7mm 9-pole stator (1) GoBrushless.com BS-1 Stock bearing assembly (1) GoBrushless.com C-22 Rotor can (14) GoBrushless.com M5-5-1 N50 magnets (2) GoBrushless.com B-3625-10 3mm ball bearings OemWire.com 43779 26 AWG wire

Basic Steps in Motor Assembly Wind stator Insert bearing tube in stator Insert bearings and shaft in stator Place magnets in can Press can onto shaft