1. INTRODUCTION AND OVERVIEW OF MANUFACTURING
Materials in Manufacturing
Design
Manufacturing Processes
Production Systems
What is Manufacturing?
Technologically
Economically
Historically
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

2. Materials in Manufacturing
Metals
Ceramics
Polymers
Venn diagram
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

3. Composites Material consisting of two or more phases
phases processed separately
bonded together
properties superior to its constituents
Phases
homogeneous mass of material
particles or fibers
Properties
depend on components
direction of fibres
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

4. Metals, Ceramics, Polymers & Composites
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

5. Manufacturing - Technologically
Physical and chemical processes
Alter geometry
Alter properties
Alter appearance
Machining and assembly operations
Manufacturing as a technical process
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

6. Manufacturing - Economically
Transformation of materials
Create items of greater value
Manufacturing adds value
changing its shape or properties
combining it with other materials
Manufacturing as an economic process
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

7. Metal chips fly in a high speed turning operation performed on a computer numerical control turning center (photo courtesy of Cincinnati Milacron).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

8. Life Cycle Assessment
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

9. Two welders perform arc welding on a large steel pipe section (photo courtesy of Lincoln Electric Company).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

10. Manufacturing Industries
Primary industries
cultivate and exploit natural resources
farming
mining
Secondary industries
use outputs of primary industries
convert them into consumer and capital goods
manufacturing is the principal activity
Tertiary industries
service sector
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

11. Steelmaking involves charging of a basic oxygen furnace, in which molten pig iron produced in a blast furnace is poured into the BOF. Temperatures are around 1650°C (3000 ° F).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

12. A robotic arm performs unloading and loading operation in a turning center using a dual gripper (photo courtesy of Cincinnati Milacron).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

13. A batch of silicon wafers enters a furnace heated to 1000°C (1800°F) during fabrication of integrated circuits under clean room conditions (photo courtesy of Intel Corporation).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

14. Assembly workers on an engine assembly line (photo courtesy of Ford Motor Company).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

15. Production Quantity Q & Variety P
Production range Annual Quantity Q
Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of
Production Variety P
Soft product variety
Hard product variety
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

16. P versus Q in Factory Operations
P-Q Relationship
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

17. A machining cell consisting of two horizontal machining centers supplied by an in-line pallet shuttle (photo courtesy of Cincinnati Milacron).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

18. Manufacturing Capability
Manufacturing plant
processes and systems
people
transform materials into products
materials, processes and systems
Manufacturing capability
Technological processing capability
Physical product limitations
Production capacity
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

19. Video
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

20. Manufacturing Processes
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

21. Solidification Processes
Starting material is heated
Transform it into a liquid or plastic state
metal casting
plastic molding
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

22. Particulate Processing
Starting materials are powders
metal powder
ceramic powder
sintering
powder
pressing
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

23. Deformation Processes
Starting workpart is shaped
application of forces
exceed the yield strength
forging
extrusion
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

24. Material Removal Processes
Excess material removed
transform to desired geometry
Example includes machining
grinding and nontraditional processes
turning
drilling
milling
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

25. Photomicrograph of the cross section of multiple coatings of titanium nitride and aluminum oxide on a cemented carbide substrate (photo courtesy of Kennametal Inc.).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

26. Assembly operations on the Boeing 777 (photo courtesy of Boeing Commercial Airplane Co.).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

27. Automated dispensing of adhesive onto component parts prior to assembly (photo courtesy of EFD, Inc.).
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

28. Production Facilities
fixed position layout
fixed position layout
cellular layout
product layout
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

29. Overview of Production Systems
John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing