1. Definition of "Manufacturing"
"Manufacturing" is a process for converting ideas and market or customer needs into artifacts; Includes design, procurement, test, finance, human resources, marketing, etc.
manufacturing is the conversion of raw materials into useful products
Main Focus of This Course

2. Little "m" manufacturing is all about
Creating shapes by various means and assembling these shapes into a useful product
The processes used to transform raw material into finished products
A physical product always has a shape
Function
Aesthetics
These shapes are created by a wide variety of processes
Students must remember that these processes exist only in the context of the larger Manufacturing process

3. People, money, machines and automation
Manufacturing
Customer needs
People, money, machines and automation
Societal pressures, Government regulations, company plans and policies, etc
manufacturing
Raw
material
Products

4. The manufacturing Process
Materials Science, Statics, Dynamics, Thermodynamics, Fluid dynamics
Products
Material
Transformation
Processes
Assembly
Raw Material
Machines and Automation

5. Shapes and Production Method
TABLE 1.2 Shapes and Some Common Methods of Production

6. Engineering Materials
FIGURE 1.4 An outline of engineering materials

7. Production Methods for a Simple Part
FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

8. Fundamentals of manufacturing - Manufacturing Concepts
The method chosen depends on the material and the shape and properties required
Formability
Machinability
Hardenability
Castability
Compactability
Sinterability
Weldability

9. Why is Manufacturing Important?
Impact on economy
Major wealth creation engines
Gross Domestic Product
jobs
Most decisions made during design are impacted by production/manufacturing processes
Critical Decisions/Trade-offs
function vs cost vs schedule
Choose materials
Choose process(es)
Cost determined by the material and the processes used to create the shape

10. Some functional parameters affected by production processes
Mechanical properties (Strength, Hardness, Fatique, Ductility, Resistance to environment)
Tolerances
Surface finish
Resistance to corrosion and abrasion
Electrical properties
Thermal Properties
Appearance/surface finish

11. Commercially Available Materials

12. Manufacturing Process Capabilities
Figure Manufacturing process capabilities for minimum part dimensions. Source: J. A. Schey, Introduction to Manufacturing Processes (2d ed.). McGraw-Hill, 1987.

13. Dimensional Tolerance
Figure Dimensional tolerance capabilities of various manufacturing processes.

14. Dimensional Tolerance and Surface Finish
Figure 40.5 Relationship between relative manufacturing cost and dimensional tolerance.
Figure Relative production time, as a function of surface finish produced by various manufacturing processes. Source: American Machinist. See also Fig

15. Examples of General Function/Process Relationships
Cast metals tend to be brittle
Forging adds strength along flow lines
Machining is cost effective for small lot sizes
Casting, forging and extrusion have high setup costs but low production costs
Heat treatments affect hardness, strength, corrosion resistance and fatigue properties
Machining results in lots of scrap (the buy to fly ratio)

16. Buy to Fly Ratio
The weight of the purchased raw material divided by the weight of the final part
Process Buy to fly ratio
Machining
Hot closed die forging
Sheet metal forming
Extrusion
Permanent mold casting
Powder metallurgy

17. Critical Fact
You cannot design any hardware without taking into account the production process used to make that product
Manufacturing considerations must be included in the design as early as possible

18. What is Manufacturing - Dimensions
Product Creative Characteristics (How new products differ from previous ones)
Product Size (physical dimension)
Product Complexity/Sophistication
Scale
Material Flow
Degree of Automation
Organization

19. Product Creative Characteristics
How new products differ from previous ones
Selection design (Lego houses)
Configuration design (automobiles)
Parametric design (portable generators)
Redesign (New VCR)
Original design (the original VCR, the Space Shuttle)

20. Product Size (physical dimension)
A individual device on a computer chip
A computer chip
A television
An automobile
A Navy cruiser

21. Number of parts/amount of electronics/intelligence
A nail
A TV
A car or truck
A 777 aircraft
A satellite
Mars sojourner
A CPU chip (5 million components)

22. Scale Number of people and disciplines involved Artisan
Garage machine shop
General Motors, Arlington Plant
Boeing Commercial Aircraft
Engineering firms who make bridges, chemical plants or dams

23. Material Flow How the work is organized on the shop floor
Discrete parts (traditional job shop)
Cellular (New machine shops)
Semicontinuous
Continuous flow (bottle making)
Process (chemical industry and oil refineries)

24. Degree of Automation How much automation exists on the shop floor
Manual
Machine assisted
Computer controlled - islands of automation
Computer integrated manufacturing

25. Company Organization How the enterprises organize to produce
Traditional
Lean
Agile
Next Generation