Chapter 1 Introduction EIN 3390 Manufacturing Processes Summer A, 2011

Interactive Factors in Manufacturing Factors ◦Product design ◦Materials ◦Labor costs ◦Equipment ◦Manufacturing costs Strategies to reduce cost ◦Lean manufacturing ◦Systems approach

Product Development Sustaining technology: ◦Innovations bring more value to the consumer ◦Improvements in materials, processes, and design Product growth normally follows the “S” curve Figure 1-1a) A product development curve

Manufacturing and Production Systems Manufacturing is the ability to make goods and services to satisfy societal needs ◦Manufacturing processes are strung together to create a manufacturing system (MS) Production system is the total company and includes manufacturing systems

The functions and Systems of the Production System

Production System- The Enterprise Production systems include ◦People ◦Money ◦Equipment ◦Materials ◦Supplies ◦Markets ◦Management ◦Manufacturing System ◦All aspects of commerce

Manufacturing Systems Manufacturing systems ◦Collection of operations and processes to produce a desired product or component ◦Design or arrangement of the manufacturing processes Manufacturing processes ◦Convert unfinished materials to finished products  Often are a set of steps ◦Machine tool is an assembly that produces a desired result

Common Aspects of Manufacturing Job and station ◦Job is a group of related operations generally done at one station ◦Station is the location or area where production is done Operations ◦Distinct action to produce a desired result or effect ◦Categories of operations  Materials handling and transport  Processing  Packaging  Inspecting and testing  Storing

Common Aspects of Manufacturing Treatments operate continuously on a workpiece ◦Heat treating, plating, finishing, chemical cleaning, painting, curing, galvanizing Tools, tooling and workholders ◦Lowest mechanism in the production is a tool  Used to hold, shape or form the unfinished product Tooling for measurement and inspection ◦Rulers, calipers, micrometers, and gages ◦Precision devices are laser optics or vision systems that utilize electronics to interpret results

Products and Fabrications Products result from manufacture ◦Manufacturing can be from either fabricating or processing  Fabricating is the manufacture of a product from pieces such as parts, components, or assemblies  Processing is the manufacture of a product by continuous operations Workpiece and its configuration ◦Primary objective of manufacturing is to produce a component having a desired geometry, size, and finish

Roles of Engineers in Manufacturing Design engineer responsibilities ◦What the design is to accomplish ◦Assumptions that can be made ◦Service environments the product must withstand ◦Final appearance of the product ◦Product designed with the knowledge that certain manufacturing processes will be used

Roles of Engineers in Manufacturing Manufacturing engineer responsibilities ◦Select and coordinate specific processes and equipment ◦Supervise and manage their use Industrial (Manufacturing) engineer ◦Manufacturing systems layout, time study, cost Materials engineers ◦Specify ideal materials ◦Develop new and better materials

Changing World Competition Globalization has impacted manufacturing ◦Worldwide competition for global products and their manufacture ◦High tech manufacturing for advanced technology ◦New manufacturing systems, designs, and management

Manufacturing Systems Designs Five manufacturing system designs ◦Job shop ◦Flow shop ◦Linked-cell shop ◦Project shop ◦Continuous process

Job Shop Figure 1-7 This rack bar machining area is functionally designed so it operates like a job shop, with lathes, broaches, and grinders lined up.

Flow Shop Figure 1-8 The moving assembly line for cars is an example of the flow shop.

Mass Production to Lean Production Figure 1-9 The traditional subassembly lines can be redesigned into U-shaped cells as part of the conversion of mass production to lean production.

Forming Process Figure 1-11 The forming process used to make a fender for a car.

Forming Process Figure 1-11

Single-Point Metalcutting Figure 1-12 Single-point metalcutting process (turning) produces a chip while creating a new surface on the workpiece.

Characteristics of Process Technology Mechanics (static or dynamic) Economics or costs Time Spans Constraints Uncertainties and process reliability Skills Flexibility Process capability

Figure 1-14 Product life- cycle costs change with the classic manufacturing system designs.

Figure 1-16 This figure shows in a general way the relationship between manufacturing systems and production volumes. Manufacturing Systems and Production Volumes

Summary Economical and successful manufacturing requires knowledge of the relationships between labor, materials, and capital Design a manufacturing system that everyone understands Engineers must possess a knowledge of design, metallurgy, processing, economics, accounting, and human relations