1. 1 Lecture Summary Lecture Topic: Course Introduction – Introduction to Manufacturing, Part 1 Lecture Notes by: Darrell Wallace Allocated Time: 1 hr Teaching Objectives: (At the conclusion of this lecture, students should know ____) General history of manufacturing including key periods of evolution Role of manufacturing as a staple of the U.S. economy Interrelationship of manufacturing to various fields of engineering Interrelationship of ISE 311 to other manufacturing courses Required Materials / Preparation / Props Course syllabus (preceding this lecture) LCD Projector and PC or overheads

2. 2 Introduction to Manufacturing - Part 1- Darrell Wallace Youngstown State University Department of Mechanical and Industrial Engineering

3. 3 man·u·fac·ture (v) 1. To make or process (a raw material) into a finished product, especially by means of a large-scale industrial operation. 2. To make or process (a product), especially with the use of industrial machines. Latin: Manus (hand) + factus (make)

4. 4 Evolution of Manufacturing Just as today, the historical evolution of manufacturing occurred as an exchange between material technology and processing capability

5. 5 Prehistoric Periods Stone Ages (~10,000,000 – 2,000 BC) Time period varied geographically Three periods: Paleolithic (old stone age) Mesolithic (middle stone age) Neolithic (new stone age) Stone age likely led to wooden tools Bronze Age (~2500-500 BC) Iron Age (~1500 BC-1000 AD)

6. 6 Manufacturing as Craft and Art Prior to about 1800, nearly all manufacturing was “craftsmanship.” All products made as “one-offs” No standardization or mass-production

7. 7 Industrial Revolutions Major periods of Industrial growth beginning around 1800 and continuing through modern day Transfer of expertise from person to process Improvements in processes Automation Machine Tools Power Sources Materials Processing Improvements in Infrastructure

8. 8 Some Key Components of the Industrial Revolutions Consumerism Military Development and Transfer of Technology Manufacturing Tools and Processes Raw material processing (Whitney, Bessemer) Vertical integration (combined spinning / weaving) Mass Production (interchangeability, assembly lines) Machine Tools (Maudslay) Power sources Steam Engines (Newcomb / Watt) IC Engines Electric machinery Infrastructure Transportation Communication

9. 9 Source: U.S. Bureau of Economic Analysis

10. 10 U.S. Manufacturing Employment Figures Since 2001, Manufacturing employment has decreased significantly. However, contribution to the GDP has remained basically steady during that period. How is this possible? Source: U.S. Bureau of Labor Statistics

11. 11 U.S. Manufacturing Productivity 50 years to Double Output 10 years to Double Output 25 years to Double Output

12. 12 Recent Shifts in U.S. Manufacturing 2001 Marked a major shift toward increased productivity Employment in the manufacturing sector has decreased sharply, but production has not. Productivity is at an all-time high Low-value-added processes appear to be offset by improvements in higher-margin production Demand for employment will likely continue to shift from unskilled laborers to individuals who can contribute to higher productivity.

13. 13 Engineering Skills Valued in Modern Manufacturing Environment Process Expertise Improve process efficiencies Bridge gap be between design technology and production technology Design Expertise Adapt designs to make them more manufacturable Logistics and Process Flow Maximize efficiency throughout the manufacturing process

14. 14 Course Objectives Show the relationship of manufacturing to other engineering pursuits Familiarize you with the most common manufacturing processes and some fundamental analyses Encourage you to consider the many processes by which each product you encounter is manufactured Provide fundamental background for future work and education in manufacturing and related fields