1. DEFINING MANUFACTURING
ENM208
DEFINING MANUFACTURING
ANADOLU U N I V E R S I T Y
Industrial Eng. Dep.
2006
Moumtaz Saleh

2. manu = hand factus = made
Manufacturing Processes
Defining Manufacturing
The word manufacturing is defined from the Latin
manu factus
made by hand
manu = hand
factus = made
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3. Manufacturing Processes
Defining Manufacturing
Manufacturing involves making products from raw materials by means of various processes, machinery, and operations, through a well-organized plan for each activity required.
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4. Production Manufacturing
Manufacturing Processes
Defining Manufacturing
Production
Manufacturing
Manufacturing Engineering is the term used widely in the United States to describe this area of industrial activity.
Production Engineering is equivalent term to manufacturing Engineering in other countries.
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5. Manufacturing Systems
Manufacturing Processes
Manufacturing Systems
The manufacturing System is a collection of manufacturing processes used to obtain a desired product(s)
The manufacturing System is the design or arrangement of the manufacturing processes.
Control of a manufacturing system applies to overall control of the whole processes or equipment.
The entire manufacturing system must be controlled in order to schedule and control production, inventory levels, product quality and so forth.
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6. Manufacturing Systems
Manufacturing Processes
Manufacturing Systems
The manufacturing System takes inputs and produces products for the external customer
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7. Discrete products Continuous products Manufacturing System may produce
Manufacturing Processes
Manufacturing Systems
Manufacturing System may produce
Discrete products
Individual parts (e.g. nails, gears, engine blocks, ……etc.)
Continuous products
May be cut into individual pieces and thus become discrete parts (e.g. a spool of wire, metal or plastic sheets, tubes , ……etc.)
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8. Manufacturing Processes
Production Systems
A production system, or the enterprise, will refer to the total company and will include with it the manufacturing system.
The production system includes the manufacturing system plus all the other functional areas of the plant for information, design, analysis, and control.
These subsystems are connected by various means to each other to produce products(s).
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9. Manufacturing Processes
Production Systems
Manufacturing System
(where value is added)
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10. Production Types Production Systems
Manufacturing Processes
Production Systems
Production Types
Low-quantity production (1 ~ 100 units/yr)
Job shop, prototyping.
Medium-quantity production (100 ~ 10,000 units/yr)
Batch production & cellular manufacturing.
High-quantity production (> 10,000 units/yr)
Mass production.
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11. Machine tools linked together to make a manufacturing system cell
Manufacturing Processes
Machine
A specific piece of equipment designed to accomplish specific processes, often called a Machine Tool
Examples: Milling machine, punch press, ….
Machine tools linked together to make a manufacturing system cell
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12. Manufacturing Processes
Job (Station)
A collection of operations done on machines or a collection of tasks performed by one worker at one location on the assembly line.
Examples: Machining, inspection, final assembly, ……
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13. Manufacturing Processes
Operation (Process)
A specific action or treatment, often done on a machine, the collection of which makes up the job of a worker.
Examples: Drilling, Forming, Welding, assembly, ……
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14. Manufacturing Processes
Tool
Refers to the implements used to hold, cut, shape, or deform the work materials.
Examples: Cutting tools in machining.
Jigs and fixtures in work holding.
Punches and dies in metal forming.
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15. Design and Manufacturing process
Manufacturing Processes
Design and Manufacturing process
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16. Concurrent Engineering
Manufacturing Processes
Concurrent Engineering
Concurrent engineering is a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support.
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17. Design for Manufacturing (DFM)
Manufacturing Processes
Design for Manufacturing (DFM)
It is a comprehensive approach to production of products, ant it integrates the design process with materials, manufacturing methods, process planning, assembly, and quality assurance.
Implements design for manufacture requires that designers have a fundamental understanding of the characteristics, capabilities, and limitations of materials, manufacturing processes and related operations, machinery and equipment.
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18. Selecting materials for manufacturing
Manufacturing Processes
Selecting materials for manufacturing
Variety of materials is now available, each having its own properties, applications, advantages, and limitations.
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19. Selecting materials for manufacturing
Manufacturing Processes
Selecting materials for manufacturing
When selecting materials for products, we consider
Mechanical properties of materials
(Strength, toughness, ductility, hardness, elasticity, fatigues, creep, ……(
Physical properties of materials
(density, specific heat, thermal expansion and conductivity, melting point, and electrical and magnetic properties, ……)
Chemical properties of materials
(corrosion, toxicity, flammability, ……)
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20. Selecting materials for manufacturing
Manufacturing Processes
Selecting materials for manufacturing
The material properties specified for a product should be appropriate to the conditions under which the product is expected to function.
The manufacturing properties of materials determine whether they can be cast, formed, machined, welded, and heated-treated with relative ease.
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21. Selection of manufacturing processes
Many processes are used to produce parts and shapes and there is usually more than one method of manufacturing a part from a given material
Classification of manufacturing processes
Machining (turning, drilling, milling, grinding, …….
Forming and shaping (rolling, forging, sheet forming,…..
Casting (expendable mold, permanent mold, ……)
Joining (welding, brazing, soldering, ….)
Finishing (honing, polishing, coating, heat treatment, …
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22. Characterizing a manufacturing process
Manufacturing Processes
Characterizing a manufacturing process
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23. Machine or equipment avalibility Cost
Manufacturing Processes
Factors affecting the selection of manufacturing processes
There are many factors which affect the selection of a suitable manufacturing process for a part. These factors are:
Geometry
Quality
Quantity
Material
Machine or equipment avalibility
Cost
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24. Manufacturing Processes
Factors affecting the selection of manufacturing processes
Geometry
Cylindrical, conical, and screw threads are mostly easily produced on a Lathe.
Plane surface, block shapes and slots are generally produced by shaping, planning or milling.
More complex parts may need to be cast, forged or shaped before machining.
The shape of a part will decide the process which must be used to produce that part.
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25. Dimensional accuracy (tolerances).
Manufacturing Processes
Factors affecting the selection of manufacturing processes
Quality
Dimensional accuracy (tolerances).
Geometrical accuracy.
Surface finish.
An appropriate manufacturing process should provide suitable dimensional accuracy, geometrical accuracy, and surface finish.
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26. Manufacturing Processes
Factors affecting the selection of manufacturing processes
Quantity
The quantity (batch size) determines the economics of manufacturing process selection.
The cost falls as the batch size increases and more productive techniques can be employed.
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27. The material from which the part is going to be made
Manufacturing Processes
Factors affecting the selection of manufacturing processes
Material
The material from which the part is going to be made
The material specified by the designer influences the method of manufacturing.
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28. Machine or equipment availability
Manufacturing Processes
Factors affecting the selection of manufacturing processes
Machine or equipment availability
Availability of machines and equipment and of operating experience with the manufacturing facility
Cost
Operational and manufacturing cost.
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29. Improper selection of material.
Manufacturing Processes
Consequences of improper selection of materials and processes
Numerous examples of product failure can be traced to
Improper selection of material.
Improper selection of manufacturing processes.
Improper control of process variables.
A part is generally considered to have failed when
It stops functioning (e.g. broken shaft, gear, ….)
It does not functioning properly or perform within required specification limits (e.g. worn bearing, …)
It becomes unreliable or unsafe for further use (e.g. crack in a shaft, ..)
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30. Manufacturing Processes
Net-shape Manufacturing
Since not all manufacturing operations produce finished parts, additional operations may be necessary.
Net-shape or near-net-shape manufacturing. The part is made, in the first operation, as close to the final desired dimensions, tolerances, surface finish, and specifications as possible.
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31. Manufacturing Processes
Manufacturing Automation
The major goals of automation in manufacturing facilities are to integrate various operations so as to improve productivity, to increase product quality, to minimize cycle times, and to reduce labor costs
Computers are now used in a very broad range of applications including:
Control and optimization of manufacturing processes.
Material handling
Automated assembly
Automated inspection and testing of products
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32. Manufacturing Processes
Computer Integrated Manufacturing - CIM
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33. Manufacturing Processes
Computer Integrated Manufacturing - CIM
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34. Manufacturing Processes
Computer application in Manufacturing
The following is an outline of the major applications of computers in manufacturing.
Computer Numerical Control - CNC
Computer Aided Process Planning - CAPP
Automated and Robotic assembly systems.
Flexible Manufacturing Systems - FMS
Automated handling of materials.
Artificial Intelligence.
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