Warm-Up Identify two different ways to change the form of a material.

Warm-Up Which type of manufacturing decreases errors and increases quality?

Manufacturing Processes The form of materials is changed by: 1.Separating 2.Forming 3.Combining 4.Conditioning

Manufacturing is… The construction of many of the same item at one time, usually using assembly lines and interchangeable parts.

Objective Identify examples of manufacturing processes Understand push and pull manufacturing

How does manufacturing affect our lives? Cheaper goods Better quality goods Jobs, jobs, jobs, Higher standard of living Food Fuel Shoes and Clothes Cars Modular Homes Integrated Circuit Chip Pencils and Pens

Manufacturing Processes The form of materials is changed by: 1.Separating 2.Forming 3.Combining 4.Conditioning

Durable Goods Do not quickly wear out. May be used over and over –Cars –Bricks –Electronics Non-durables include: –Food –Clothing –Paper products

Steps in Manufacturing Turning raw materials into finished goods on a large scale. –Obtaining and preparing raw materials –Processing the materials mechanically or chemically –Assembling –Testing –Inspecting –Packaging

Gathering Raw Materials This is done using three major methods. –Mining –Drilling –Harvesting

Mining Mining involves digging resources out of the earth. –Open-pit mining: a type of mining used when the resource is close to the surface. –Underground mining: a mining method that uses digging tunnels to reach the material.

Drilling A method used to reach underground liquid resources such as oil and water. A small round hole is drilled using a derrick and a drill bit that grinds up the rock as it drills.

Harvesting Harvesting is a method used to collect a growing resource. Trees are the major “growing” resource that produce engineering materials. Also harvested: Cotton Sugarcane and corn for ethanol production

Push Production As each person finishes his/her job, it is pushed to the next person. 9Faster production. —Increased chance of error - less quality.

Pull Production Each person does not start a new part until their last one has been pulled from them. 9Increased quality. — Fewer errors —Slower production.

Traditional Manufacturing Mass Production – –Uses interchangeable standardized parts that can quickly be assembled –Breaks complex operations down into simple steps that can be performed by unskilled workers –Output from the first process in the sequence drives –the second process and so on

New Trends in Manufacturing Lean Production – –Less of everything is required to produce the same quantity that traditional mass production generated –Less materials, equipment, manhours, time, effort, capital A ‘PULL’ Manufacturing system that is driven by customers orders and need for specific parts

New Trends in Manufacturing KANBAN Cards that carry information from one process to processes that come afterward Tell about what and how much to produce next. Identifies the type of part, how many there are, and other basic information. “Pulls” only needed parts without maintaining extra inventory

New Trends in Manufacturing Quality Circles –Employees, working in teams, set aside time to review work procedures –Come up with ways of enhancing their performance.

New Trends in Manufacturing KAIZEN –Continuous improvement –an on-going process involving a variety of activities to reduce waste and inefficiency

New Trends in Manufacturing ANDON –A system to notify management, maintenance, and other workers of a quality or process problem –Uses a signboard incorporating signal lights to indicate which workstation has the problem

Push Production As each person finishes his/her job, it is pushed to the next person. 9Faster production. —Increased chance of error - less quality.

Pull Production Each person does not start a new part until their last one has been pulled from them. 9Increased quality. —Slower production.

Push versus Pull Manufacturing PUSH – complete task as quickly as possible –Faster Production (more items made in shorter period of time) –Less quality (more likely to make mistakes) PULL – complete task only when the previously completed item is removed or ‘pulled’ –Slower production (more likely to have idle time) –Increased quality What is QC rate when 50 shirts are made and only 40 pass inspection?

Quality Control Rate of Pd 8 and 9 PushPull Total # made # passing inspection

5/4 Drill Use the data sheet provided to answer the following: - How did the amount of waste generated compare between Push and Pull production? - Use data to support your answer.

QC= QC= 125/200 X 100 = 12500/200 = 125/2 = 62.5% Number of Objects Passing Inspection Total Number of Objects Made X 100

Copy this list of manufacturing processes and give examples of each from our Thanksgiving Card Project. ProcessExamples Forming Separating Combining Conditioning Fold card Cut along line, punch Leaf Glue orange paper Stamp