Manufacturing Technology

Learning Standards 4. Manufacturing Technology Manufacturing is the process of converting raw materials into physical goods, involving multiple industrial processes (e.g., assembly, multiple stages of production, quality control). 4.1 Describe and explain the manufacturing systems of custom and mass production. 4.2 Explain and give examples of the impacts of interchangeable parts, components of mass-produced products, and the use of automation, e.g., robotics. 4.3 Describe a manufacturing organization, e.g., corporate structure, research and development, production, marketing, quality control, distribution. 4.4 Explain basic processes in manufacturing systems, e.g., cutting, shaping, assembling, joining, finishing, quality control, and safety.

Learning Objectives Students will be able to: 1) Define Production Process 2) Define & Explain 3 Separating Processes - Sawing / Drilling / Turning 3) Define & Explain 4 Forming Processes - Bending / Casting / Forging / Extruding 4) Define & Explain 4 Combining Processes - Mechanical Fastening / Heat Fastening / Snap Joint Fastening / Gluing 5) Define & Explain 3 Finishing Processes - Smoothing / Coating / Polishing 6) Define Manufacturing 7) Explain the difference between Custom Manufacturing & Mass Production

Learning Objectives 8) Explain the importance of interchangeable parts to the Mass Production process 9) Explain the importance of robots to the Mass Production process 10) Describe & explain the organization of a manufacturing organization

Production Processes Steps taken to change raw materials so that they can be made into products Process Raw MaterialProduct

Separating A process that removes pieces of material to make it the size & shape you want Cutting the object to make it the size you wantSawing:

Separating Makes a hole in the materialDrilling:

Separating Spinning a piece of metal or wood on a machine and using a sharpened tool to shape it Turning:

Forming A process that changes the shape of the material - No material is added or taken away Material is shaped by forcing part of it into a different position Bending:

Forming Liquid material is poured into a mold, it takes on the shape of the mold as it hardens Casting:

Forming Shaping metal by heating it and then hammering it into the shape you want Forging:

Forming Softened material is squeezed through a small opening. The material hardens and retains the shape of the opening Extruding:

Combining A process that joins materials together to make finished product Using small piece of metal or plastic to hold parts together (Nails, screws, staples, nuts & bolts, rivets, velcro, etc.) Mechanical Fastening:

Combining Heating materials so that they soften & flow into each other (Welding & Soldering) Heat Fastening:

Combining Holds things together without a separate fastener (CD Case) Snap Joint Fastening:

Combining Using an adhesive to stick one part to another Gluing:

Finishing A process that improves a product’s appearance and/or its performance To make flatSmoothing:

Finishing Using paints, clear finishes or plastic to cover & protect the material Coatings:

Finishing Makes the material glossy (or shiny)Polishing:

Manufacturing of converting raw materialsThe process into physical products Raw Material Product Process

Comparison of Custom Manufacturing & Mass Production Custom ManufacturingMass Production Usually made in limited numbersSame item produced many times Made exactly as the person it is being made for wants it Not made exactly how a person wants it Made from start to finish by same worker (or small group of workers) Workers only work on one part of the product Worker(s) is/are usually a skilled craftsmen Product is often machine made Products can be produced using Custom Manufacturing or Mass Production Manufacturing

Custom Manufacturing: Advantages & Disadvantages Custom Manufacturing Advantages Custom Manufacturing Disadvantages You can get the product exactly how you want it Usually has a higher cost Product is unique – no one has exactly the same one Product takes longer to make Product is not easily replaceable Mass Production: Advantages & Disadvantages Mass Production Advantages Mass Production Disadvantages Product can be made quicklyWill not be made exactly how you want it Product can be made at a lower cost Product will not be unique

Mass Production One of the first products to be mass produced was… the Automobile Ford Model T (1908)

Henry Ford’s 4 Main Principles of Mass Production 1) Reduction of Wasted Effort: Henry Ford’s goal was to have his cars produced by workers without wasting time & effort 2) Interchangeable Parts: Ford’s idea was to reduce cost by making the individual pieces of the car the same every time 3) Continuous Flow: Car was constantly moving through assembly stations while the workers stayed in one place 4) Division of Labor: Workers were specialized & focused on one task when building car

Henry Ford’s 4 Main Principles of Mass Production Interchangeable Parts Continuous Flow Division of Labor Reduction of Wasted Effort More cars were produced

Assembly Line

Manufacturing Organizations In many companies the overall process is led by the CEO (Chief Executive Officer) Groups of people (departments) are responsible for different parts of the manufacturing process The CEO works with other leaders in the company to make sure that quality products are made and sold

Manufacturing Organization Departments Marketing: Helps determine what types of products should be made & sold Makes sure company understands wants & needs of customer Research & Development: Researches & develops plan to make product after consulting with Marketing Meets with other organization leaders to get plan approved

Production: Makes product after idea has been approved Quality Control: Makes sure the product meets appropriate standards when being made Makes sure workers are safe when making product Safety: Manufacturing Organization Departments

Sales: Sells the product Distribution: Transports the product to where it can be bought Manufacturing Organization Departments

Robots Take their instructions from a computer that has been programmed by a human Can be programmed to do different tasks Do jobs that are dangerous, boring or unpleasant for people

Robots Even though they are expensive manufacturing companies have found robots to be very useful