Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Industrial/Manufacturing Engineering More efficient and more profitable business practices Better customer service and product quality Improved efficiency Increased ability to do more with less Making work safer, faster, easier, and more rewarding Helping companies produce more products quickly Making the world safer through better designed products Reducing costs associated with new technologies

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Most things from daily life are manufactured Process of changing raw materials to make them more useful Trees have value Harvested trees have more value Baseball bats have more value At each step of process, materials have more value

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Baseball Bats Louisville Slugger Museum and Factory

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. About Manufacturing Engineering Design of machines, tools, and processes used to manufacture goods Engineers solve complex manufacturing problems Engineers design extensive manufacturing systems Engineers work in coordination with other engineers

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Typical Education Requirements Entry-level positions require bachelor’s degree in manufacturing engineering Two-year associate’s degree programs can lead into four-year programs or qualify graduates for jobs as technicians or in manufacturing field

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Professional Organizations Society of Manufacturing Engineers (SME) –Largest society for manufacturing engineers –Over 500,000 members in more than 70 countries Society of Automotive Engineers (SAE) Audio Engineering Society (AES) Society of Women Engineers (SWE) National Society of Professional Engineers Institute of Industrial Engineers

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Engineering Principles Concern materials used to manufacture products Concern processes used to change materials into useful products Materials and processes are foundations of manufacturing

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Materials Metals Ceramics Polymers Composites

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Metals Inorganic (do not come from living matter) Good conductivity to heat and electricity Can be melted and are malleable Examples are iron, lead, copper, zinc, magnesium, calcium, and mercury Two or more can form alloys

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Ceramics Very hard, inorganic, refractory (high resistance to heat), nonmetallic materials with little electrical conductivity Include clays, porcelain, abrasives, glass, plaster, gypsum, and cement Can stay sharp longer than metal Used in joint replacement, bone replacement, and dental restoration

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Polymers Organic (come from living matter) Primarily made up of carbon and hydrogen atoms Noncrystalline Synthetic polymers are plastic

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Types of Plastic Thermoplastics –Can easily be reheated and reshaped with little or no damage Thermoset plastics –Generally stronger than thermoplastics because they are cured with heat and pressure to crosslink chains –Cannot be heated and reshaped

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Locating Raw Materials First step in manufacturing process after designs are approved Natural resources found in earth, on earth, and in seas Three techniques –Harvesting –Drilling –Mining

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Drilling Used to extract water, natural gas, and oil from under earth’s surface Performed by cutting circular hole into earth to desired depth Drill head mounted on pipe turns to drill hole Directional drilling allows access to multiple reserves from one location

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Mining Used to extract materials from beneath earth’s surface Surface mining –Soil and bedrock are removed till desired resources are exposed Subsurface mining –Involves digging tunnels or shafts to reach desired resources

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Horizontal Drilling Laurie Barr/Shutterstock.com

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Harvesting Retrieving mature natural resources that grow on earth Three methods used to harvest trees –Clear-cutting –Select cutting –Seed tree cutting

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Harvesting Methods Goodheart-Willcox Publisher

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Environmentally Conscious Manufacturing (ECM) Process concerned with entire life of product from gathering of raw materials to product disposal Saving on energy costs directly affects energy consumption Waste is being reduced and recycled Going Green

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Engineering Processes Used to shape raw materials into standard stock Used to shape standard stock into finished products Two types of processing –Primary processing –Secondary processing

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Primary Processing Raw materials are processed into standard stock Standard stock describes size, shape, and characteristics of materials commonly available to consumers –Trees cut to standard size lumber –Metals formed into bars, rods, and sheets –Oil refined into gasoline, diesel fuel, or heating oil

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Secondary Processing Standard stock materials made into useful products Common secondary processing techniques –Separating –Casting and molding –Forming –Combining

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Separating Process of cutting materials to desired size or shape Mechanical separating –Involves cutting or chipping materials apart Heat separating –Cutting torches separate metals Chemical separating –Acidic material etches away unwanted materials

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Casting and Molding Involves changing materials to liquid or plastic state, then shaping them in or around mold Casting –Material changes to liquid state –Liquid is poured into mold until it solidifies Molding –Material softened to plastic state –Material forced into or around mold

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Forming Mechanical process used to change material shape Compression –Materials are hammered through forging Bending –Materials are bent till desired shape is reached Stretching –Stock is drawn through holes smaller than stock

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Combining Multiple parts are joined together through mechanical assembly and bonding Adhesion –Bonding of two materials using glue or cement Cohesion –Heat or pressure joins two materials

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Engineering Tools Drafting and design software Computer simulation Jigs and fixtures Stopwatches and timers Measuring tools Production charts and schedules Tools

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Engineering Applications Manufacturing engineers design and control manufacturing processes Engineers decide on effective type of manufacturing Engineers design system to be cost effective and meet quality specifications

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Production Management Manufacturing engineers design all aspects of production from start to finish Engineers must understand all characteristics of products to be made Engineers must understand all specific requirements of products to be made

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Types Continuous manufacturing –Produces highest number of products at highest quality and lowest cost Intermittent manufacturing –Produces smaller batches of one part Custom manufacturing –Produces single product or small number of products to meet customer needs

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Facility Engineering Carried out by engineers with expertise in tools, materials, processes, and products to be manufactured Production facilities are designed for efficient production of products Facilities are designed for smooth, efficient flow through production

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Selecting and Sequencing Manufacturing Operations Engineers are responsible for deciding what operations will be used to create products Engineers are responsible for deciding order of operations to create products Operations must be designed in efficient and economical way

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Operation Sheets Used to record operation name, machines, and tooling outlined by engineer Goodheart-Willcox Publisher

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Flow Process Chart Used to record and communicated order of processes to make each part Goodheart-Willcox Publisher

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Operations Process Chart Used to study all operations in manufacture of product Show processes involved in making each part Show assembly operations Goodheart-Willcox Publisher

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Plant Layout Location of materials and how they are moved through plant Most plans are designed using one of two methods –Process layout –Product layout

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Process Layout Commonly used in intermittent and custom manufacturing Equipment is located based on process it performs Goodheart-Willcox Publisher

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Product Layout Commonly used for continuous manufacturing Entire facility is designed around manufacture of one product Goodheart-Willcox Publisher

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Plant Layout Communications Plant layouts are communicated through drawings and 3-D models Design must be communicated accurately Equipment and utilities must be placed correctly

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Design for Manufacturing Products are designed to meet specifications Products are designed so they can be manufactured efficiently Products may be designed to reduce amount of materials required Designing for manufacturing can reduce costs Design

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Production Control Lean manufacturing Material supply Materials handling Quality control Cost control Safety

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Lean Manufacturing Looks to eliminate seven sources of waste –Overproduction –Overprocessing –Excess motion –Excess inventory –Defects –Transportation –Waiting

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Material Supply Must have enough material to keep operations running Too much material on hand is costly Just-in-time (JIT) delivery systems –Provide material delivery exactly when needed –Complex system to manage

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Materials Handling Movement of materials and products through plant Materials must be moved from storage to workstation Materials moved by conveyor, vehicle, or by hand Systems must be efficient and cannot damage products

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Quality Control System that ensures products meet or exceed specifications People want and deserve quality Inspection throughout manufacturing process Centers on training and motivating workers Workers give feedback on ideas for quality control

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Cost Control Products must be produced for specified price Material purchasing Machine scheduling Labor costs –Efficiency –Time and motion studies

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Safety Safety programs are critical Manufacturers value and ensure health and safety of employees OSHA regulations must be followed Process must be designed to ensure worker safety and health Process must be compliant with safety regulations

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Manufacturing Engineering in Action Decisions about manufacturing types Decisions on manufacturing operations Plant layout based on efficient sequence Design, implementation, and overseeing quality control program Constant monitoring of all aspects of production

Permission granted to reproduce for educational use only.© Goodheart-Willcox Co., Inc. Videos See the role industrial engineering plays at Disney.Disney Look at how industrial engineering benefits a variety of industries.variety of industries Watch a segment from "Today in America" that focuses on IIE and industrial engineering.Today in America Take a look at some more videos about industrial engineering from the 2014 Industry Advisory Board's YouTube student video contest: –First place: Oregon State UniversityOregon State University –Second place: Texas A&M UniversityTexas A&M University –Third place: University of WashingtonUniversity of Washington