Dr.

Sharifah Imihezri

Method Quizzes Assignments Project Mid-term Exam Final Examination

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Latin word manu factus meaning made by hand The process of turning raw materials into a product

Involves a sequence of operations and processes designed to create a specific product

5000-4000 BC : Manufacturing started wood work,ceramics,stone and metal work 600-800 AD Steel production 1750s Industrial Revolution : Machine tools run by invention of steam engine 1965 Computer Controlled Machines

1980s The country witnessed a transition from being a predominantly agricultural economy to one that was industrial-based. Lead agencies driving the expansion of manufacturing activities MITI Ministry of International Trade and Industry Ministry of Entrepreneur and Cooperative Development, Ministry of Science, Technology and Innovation

Product should meet design requirement Economical process Quality should be built into the system Should be flexible and responsive to new technology High productivity: Best utilization of man, material, machine, capital and available resources.

Typical product cost breakdown

Material Selection
Processing Methods Final Shape and Appearance

Dimensional and Surface Finish

Economics of Tooling Design Requirements

Safety and Environmental Concerns

Requires a clear understanding of the functions and the performance expected of the product. Depending on the complexity of the product and the type of materials used, the time span between the original concept and the marketing of the product may range from a few months to many years.

Product Design Process

1. Product needs/requirements
Stokke Chair : Comfort and safety

Eames chair :

style and functional

First molded plastic chairs to be massproduced. Initially molded in fiberglass reinforced polyester and designed in 1948.

Product Design Process

2. Product Conceptual Design

Caption from LIFE. "Natural designs embodied in Mojave desert plants fascinate Eames, who likes to mount them on the wall of his studio. From them, he says he gets ideas for his own designs."

Product Design Process

2. Product Conceptual Design

Heikki Naulap, 2004 student of the Royal College of Art, London

Product objective : To create a vehicle which offered a new kind of experience while riding. A mixture of the leaning characteristics associated with motorbikes, with a formula 1 style driving position and small sports car feeling.

Product Design Process

3. CAD/CAM
a. Design analysis using CAD software
Copyright 2009 Innovative Design Engineering, Inc.

Connector with no load

Connector stress when deformed

b. Application of CAD/CAM to make sunglasses mold

(a) Computer model of the sunglass as designed and viewed on the monitor. (b) Machine the die cavity using a computer numericalcontrol milling machine

(c) Final product. Source: Courtesy of Mastercam/CNC Software, Inc.

Product Single component (nail, bolt, fork, coat hanger, etc.) Multi-component (ball point pens, automobiles, washing machines, etc.)

Traditional Engineering

vs

Concurrent Engineering

Concurrent Engineering vs Traditional Engineering

Example of design changes as a function of time for an American and Japanese automobile. Source: Engineering Modeling and Design, Chapman, Bahill & Wymore

In traditional engineering a relatively short time is spent defining the product. A relatively long time is spent designing the product and a surprisingly long time is often spent redesigning the product. The key to shortening the overall design time is to better define the product and better document the design process.

Concurrent Engineering
1. Concurrent Engineering brings together multidisciplinary teams, Main objective : To get things right as quickly as possible, and as early as possible. To reduce the number of redesigns, especially those resulting from post-design input from support groups To find the optimum global design with respect to cost, quality and performance of the whole system.

System/fabrication produceability

Cross functional team

Systems engineering

quality, reliability and maintainability, testability, manufacturing, drafting and layout, and program management.

Mechanical engineering

Input is obtained from as many functional areas as possible before the specifications are finalized. TRADE OFFS - between design features, part manufacturability, assembly requirements, material needs, reliability issues, serviceability requirements, and cost and time constraints. This results in the product development team clearly understanding what the product requires in terms of mission performance, environmental conditions during operation, budget, and scheduling. Sometimes, only design engineers and manufacturing engineers are involved in concurrent engineering. In other cases, the cross-functional teams include representatives from purchasing marketing, production quality assurance customers and suppliers

CE

Advantages: The major iterations that do occur will occur before the design becomes final. The overall time taken to design and manufacture a new product can be substantially reduced if the design activities are carried out together rather than in series.

The reductions in design cycle time that result from concurrent engineering invariably reduce total product cost.

Design for Manufacture (DFM)

CE CE CE CE DFM DFA CE CE CE CE

The foundations of CE were built on the concepts of design for manufacturing (DFM) and design for assembly (DFA) Must be able to assess the impact of design modifications on manufacturing process selection assembly inspection tools and dies product cost

Design for Manufacture (DFM)

Questions for consideration: What material properties are required? Which manufacturing process would produce the lowest cost?

Would the material and processing strategy change if the desired quantity was 10,000 vs. 1 million per day?

Examples of the wide variety of materials and geometries for paper clips.

Design for Assembly (DFA)

Products are designed with ease of assembly in mind. Why???? Product contains fewer parts it will take less time to assemble, Parts are provided with features which make it easier to grasp, move, orient and insert them. In addition products must be design for ease of disassembly. Why???? Maintenance, servicing, recycling of components reduce assembly time assembly costs.

Factory tour in Maranello, Italy

The 'new assembly line' makes use of pincer machines designed by Italian robot manufacturers Comau that permit easy access to all sides of the vehicle. The cars are placed at the best height for each worker, and can be rotated to permit work to be done on its underside.

The machines permit technicians to control the height and rotation of the vehicle, permitting even the undersides to be worked on with ease.

My dream car

 What is DFM?
The objective of DFM is to identify product concepts that are easy to manufacture DFM is the first step in which a team approach is taken to develop the product DFM is an umbrella which covers a variety of tools and techniques to accomplish a manufacturable product

Why DFM?

Lower development cost Shorter development time Faster manufacturing start of build Lower assembly and test costs Higher quality

 How do all the pieces fit together?

DFM in industry is typically divided into 2 main activities:

A team which will be responsible for the product development and delivery. (cross functional team: ME, EE, MFG., CE, PE, Quality) The tools and methods to enable DFM that ensure the design meets the objectives.

DFM Method

Estimate the manufacturing costs. Reduce the costs of components. Reduce the costs of assembly. Reduce the costs of supporting production. Consider the impact of DFM decisions on other factors.

DFM Method
Proposed Design Estimate the Manufacutring Costs

Reduce the Costs of Components

Reduce the Costs of Assembly

Reduce the Costs of Supporting Production

Consider the Impact of DFM Decisions on Other Factors

Recompute the Manufacturing Costs

Good enough ? Y

Acceptable Design

DFM Tools: DFA Guidelines

- One assembly direction tops down -No adjustments required -No hidden features - Easy to fabricate parts - Standard parts (one screw type)

- Test direction access from top

- Parts are self-guiding

- Sub-assemblies reduce handling of small hard to grip parts

- Avoid tangle with use of fixtures - Symmetry in two axis

- Holes large enough (straightness issues if too deep) - Common datums for all fixtures -One common plane for assembly - Tabs for robotic lift

-Die cast with minimal amount of holes (debris chip) -Standard cutters -Guide features - bottom rails for conveyor

Ease of Assembly

Part Part Part Part Part Part Part

is inserted from the top of the assembly is self-aligning does not need to be oriented requires only one hand for assembly requires no tools is assembled in a single, linear motion is secured immediately upon insertion

Consider Customer Assembly

Customers will tolerate some assembly Design product so that customers can easily and assemble correctly Customers will likely ignore directions

DFM Tools: DFA Guidelines

Summary of DFA Guidelines Minimize the number of parts Standardize and use as many common parts as possible Design parts for ease of fabrication (use castings without machining and stampings without bend) Use standard cutters, drills, tools Minimize assembly directions Maximize compliance; design for assembly Minimize handling Eliminate adjustments Use repeatable, well understood processes Design parts for efficient testing Use Guide features Incorporate symmetry in both axis Avoid designs that will tangle. Design parts that orient themselves

Design for Production General Principles

1.

2.
3. 4. 5. 6. 7.

Use Common Sense Plan and Define Consider Available Facilities Consider Available Tools Consider Available Worker Skills Employ Simplicity Standardize

Design for Production Guidelines (Cont.)

8. 9. 10. 11. 12. 13. 14.

Minimize assembly direction (Top down direction preferred) Maximize compliance in assembly Minimize handling in assembly Minimize complexity of design Maximize common jigs and fixtures Optimize work position Ease access

Manufacturing Costs Defined

Sum of all the expenditures for the inputs of the system (i.e. purchased components, energy, raw materials, etc.) and for disposal of the wastes produced by the system

Elements of the Manufacturing Cost of a Product

Manufacturing Cost

Components

Assembly

Overhead

Standard

Custom

Labor

Equipment and Tooling

Support

Indirect Allocation

Raw Material

Processing

Tooling

Manufacturing Cost of a Product

Component Costs (parts of the product)

Parts purchased from supplier Custom parts made in the manufacturers own plant or by suppliers according to the manufacturers design specifications

Assembly Costs (labor, equipment, & tooling) Overhead Costs (all other costs)
Support Costs (material handling, quality assurance, purchasing, shipping, receiving, facilities, etc.)

Environmentally Conscious Design and Sustainable Manufacturing

Design for recycling Design for the environment Green design - environmentally safe and friendly - considers the possible negative environmental impact of materials, products and processes

Sustainable manufacturing
Capable of being continued with minimal long-term effect on the environment reducing waste materials reducing the use of hazardous materials proper handling and disposal of all waste improvements in waste treatment and in recycling/ruse of materials

Whats in my PC? Material Plastic Ferrous metals Non-ferrous metals Electronic boards Glass
http://www.recycling-guide.org.uk

Proportion 23% 32% 18% 12% 15%

The complex mixture of materials make PCs very difficult to recycle!

Ultracompact PC is Dell's smallest and most environmentally conscious computer to date. It's one-fifth the size of standard desktops and uses about 70% less energy.
http://www.time.com

Environmentally Conscious Design and Sustainable Manufacturing

Classified as a bicycle in all 50 states, 'ELF', the three-wheeled solar and pedal powered electric assist velomobile by American organic transit hybridizes the advantages of bicycle and automotive transportation into a waterproof body

Made with 45% recycled aluminum and a vacuum formed trylon (composite of 85% recycled ABS and solarcote) frame.

Selecting manufacturing process

General classification of shapes *

*M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.

Selecting manufacturing process

ProcessMaterial matrix with the dot indicating a compatibility between the material and the corresponding manufacturing process. *

*M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.

Selecting manufacturing process

ProcessShape matrix with the dot indicating a compatibility between the shape and the corresponding manufacturing process. *

*M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.

Dr. Sharifah Imihezri

Introduction: Global Manufacturing

Mfg: China, Ireland

Mfg: China Mfg: China, Ireland Mfg: Mexico, China, Taiwan, Philippines

Mfg: Japan, Thailand, Germany, Philippines

Mfg: Malaysia

Mfg: Singapore, Thailand

Mfg: Thailand, Singapore, Hungary, Philippines

COMPUTER INTEGRATED MANUFACTURING

Described as the computerised integration of product design, planning, production, distribution and management

Computer Aided Design

Prototype Manufacture

Costs and production methods calculated

Materials automatically ordered

Manufacturing begins using CAM

Quality control is applied at every stage

Products is assembled by robots

Quality control is applied at every stage

Products distribution

Financial accounts are updated

Stage One - Computer Aided Design. A product is designed totally on computer. When complete it is tested or its functions simulated on screen before even a prototype is made. If a circuit is involved it is designed by using software and tested on screen. Improvements / alterations are made to the design using the same CAD software. Stage Two - Prototype Manufacture. Prototypes are manufactured on machines such as 3D printers which produce an accurate 3D model. CNC routers and laser cutters may also be used to produce a realistic model. Sometimes working models are manufactured. Stage Three - The computer system controlling the plant works out the most efficient method of manufacture. It calculates costs, production methods, numbers to be manufactured, storage and distribution.

Stage Four - The computer system orders the necessary materials to manufacture the product. Keeping costs to a minimum. The just in time philosophy is applied. This means that materials / components are ordered as needed. Very little is stored at the factory. Usually only enough materials are stored to keep the factory going for a small number of days. Materials are automatically reordered when required, to keep the factory working smoothly and continuously. Stage Five - Manufacturing begins with the product being made using CAM (Computer Aided Manufacture). Computers control CNC machines such as laser cutters, CNC routers and CNC lathes. Stage Six - Quality control is applied at every stage. The product is tested using computer control inspections. For instance, the accuracy of manufacture is tested automatically. This ensures that the product is manufactured to the correct sizes.

Stage Seven - The product is assembled by robots. This is automated (controlled) by the computer system. Stage Eight. The product is quality checked before being stored for distribution to the customer. All storage is automated. This means that computer controlled vehicles move the finished product from the manufacturing area to storage. The computer systems keep track of every individual product. Products are bar coded which are constantly scanned and recorded by the computer system. Stage Nine - The product is automatically moved from store to awaiting lorries / trucks for distribution to the customer.

Stage Ten - Financial accounts are updated, bills chased up and paid by the computer system.

Greek word : automatos self acting

Goals of automation 1. Integrate various aspects of manufacturing operationsimprove product quality minimise cycle times reduce labor cost 2. Improve productivity 3. Reduce human involvement : boredom human error 4. Reduce workpiece damage manual handling of parts 5. Economise on floor space 5. Increase the level of safety for personnel hazardous working conditions

Milling Assembly & Test Grinding

T T

T T

T T D D

CG SG D D

CG SG D D

M M

M M

Drilling

Plating

Job shop Layout - work travels to dedicated process centers

Similar resources placed together

Machines are grouped according to function into machine centers. Orders for individual products are routed through the various machine centers to obtain the required processing. This layout may be appropriate when there are many different products, each with a low volume of production. Skilled labour

Also known as fixed-position automation Produce standardized products e.g engine block, valve, gear Specialized machines and lack flexibility Machines cant be modified to a significant extent to accommodate a variety of products This automation approach is best suited for mass production of the same product with few alterations or change-overs. Note the various machining operations

straight

circular

Also known as flexible automation or programmable automation Has greater flexibility through computer control This method is ideal for handling small batches of product and product changes.