1. Advanced Manufacturing Laboratory Department of Industrial Engineering Sharif University of Technology Session #20

2.  Instructor  Omid Fatahi Valilai, Ph.D. Industrial Engineering Department, Sharif University of Technology  Email: FValilai@sharif.edu, Tel: 6616-5706  Website: Sharif.edu/~fvalilai  Recommended prerequisite  Manufacturing process I (21-418)  Class time  Sunday-Tuesday 18:00-19:30  Course evaluation  Mid-term(25%)  Final exam(40%)  Quiz(5%)  Exercise (Manufacturing Lab.)(30%) Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 2

3.  Reference:  Edward B., “Integrated product and process design and development : the product realization process”, CRC Press, 2010  John Priest, Jose Sanchez;“Product Development and Design for Manufacturing: A Collaborative Approach to Producibility and Reliability, Second Edition”, CRC Press, 2001  Mital et al.,“Product Development A Structured Approach to Consumer Product Development, Design, and Manufacture”, Butterworth- Heinemann, 2008 Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 3

4.  Contents:  Product development in the changing Global world  Stages of Product Development  The Structure of the Product Design Process  Early design: Requirement definition and conceptual Design  Trade-off analyses: Optimization using cost and utility Metrics  Detailed design: Analysis and Modeling  Design Review: Designing to Ensure Quality  Production System; Strategies, planning, and methodologies  Production System Development  Planning and Preparation for Efficient Development  Supply chain: Logistics, packaging, supply chain, and the environment Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 4

5.  Selection of Manufacturing Processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 5

6.  Selection of Manufacturing Processes  The manufacturing process is the science and technology by which a material is converted into its final shape with the necessary structure and properties for its intended use.  Formation of the desired shape is a major portion of processing.  The product processing could be a simple, one-step operation or a combination of various processes, depending on the processability of the material used and the specifications for the finished part, which includes surface finish, dimensional tolerances, and so forth. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 6

7.  Selection of Manufacturing Processes  What leads to a successful manufacturing process? The performance of any manufacturing process depends on  Rate: material flow through the system.  Cost: material, labor, tooling, equipment.  Time: lead time to procure materials, processing time, setup time.  Quality: deviation from the targe Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 7

8.  Selection of Manufacturing Processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 8

9.  Selection of Manufacturing Processes  Primary processes  The primary process generates the main shape of the final product  Casting: Casting is the fastest way to attain simple or complex shapes for the part from its raw material.  Forging: Forging is a deformation process in which the work is compressed between two dies using either impact or gradual pressure to form the part.  Extrusion: Extrusion is a compression forming process in which the worked metal is forced to flow through a die opening to produce the desired cross-sectional shape. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 9

10.  Selection of Manufacturing Processes  Primary processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 10

11.  Selection of Manufacturing Processes  Primary processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 11

12.  Selection of Manufacturing Processes  Primary processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 12

13.  Selection of Manufacturing Processes  Primary processes  The primary process generates the main shape of the final product  Casting: Casting is the fastest way to attain simple or complex shapes for the part from its raw material. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 13

14.  Selection of Manufacturing Processes  Primary processes  The primary process generates the main shape of the final product  Casting: Casting is the fastest way to attain simple or complex shapes for the part from its raw material. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 14

15.  Selection of Manufacturing Processes  Primary processes  The primary process generates the main shape of the final product  Casting: Casting is the fastest way to attain simple or complex shapes for the part from its raw material. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 15

16.  Selection of Manufacturing Processes  Secondary processes  The secondary processes, in addition to generating the primary shape, form and refine features of the part.  These processes may appear at the start or later in a sequence of processes.  These include all the material removal processes and processes such as machining, grinding, and broaching. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 16

17.  Selection of Manufacturing Processes  Primary processes  The primary process generates the main shape of the final product  Casting: Casting is the fastest way to attain simple or complex shapes for the part from its raw material. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 17

18.  Selection of Manufacturing Processes  Tertiary processes  The tertiary processes do not affect the geometry or shape of the component and always appear after one or more primary and secondary processes.  This category consists of finishing processes, such as surface treatments and heat treatments.  Selection of a tertiary process is simplified because many tertiary processes affect only a single attribute of the part. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 18

19.  Selection of Manufacturing Processes  Tertiary processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 19

20.  Selection of Manufacturing Processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 20

21.  Selection of Manufacturing Processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 21

22.  Selection of Manufacturing Processes Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #20 22

23. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Product Planning & Development (21423), Session #5  Phase 11  Product Manufacturing Processes Selection Analysis 23