What is manufacture ? The vast majority of objects around us consist of numerous individual pieces that are built and assembled by a combination of processes called manufacturing (Kalpakjian, 2009) Important term Design for manufacture (DPM) is a comprehensive approach to integrating the design process with production methods, materials, process planning, assembly, testing, and quality assurance. Assembly is an important phase of manufacturing and requires a consideration of the ease, speed, and cost of putting together the numerous individual components of a product Disassembly of a product is an equally important consideration, for maintenance, servicing and recycling of individual components. Service. Products often have to be disassembled to varying degrees in order to service and, if necessary, repair them. The design should take into account the concept that, for ease of access, components that are most likely to be in need of servicing be placed, as much as possible. Environmental Issue Related with Manf. Waste Chips from machining and trimmed materials from sheet forming, casting, and molding operations. Slag from foundries and welding operations. Additives in sand used in sand-casting operations. Hazardous waste and toxic materials used in various products. Lubricants and coolants in metalworking and machining operations. Liquids from processes such as heat treating and plating. Solvents from cleaning operations. Smoke and pollutants from furnaces and gases from burning fossil fuels. Recycle Biological Industrial Green Design Manufacturing 1. Reduce waste of materials, by refining product design, reducing the amount of materials used in products, and selecting manufacturing processes that minimize Scrap (such as forming instead of machining). 2. Reduce the use of hazardous materials in products and processes. 3. Investigate manufacturing technologies that produce environmentally friendly and safe products and by- products. 4. Make improvements in methods of recycling 5. Minimize energy use. 6. Encourage recycling by using materials that are a part of either industrial or biological cycling, but not both in the same product assembly. Ensure proper handling of other waste. Selection in materials Ferrous metals: Carbon, alloy, stainless, and tool and die steels Nonferrous metals: Aluminum, magnesium, copper, nickel, titanium, superalloys, Refractory metals, beryllium, zirconium, low-melting-point alloys, and precious metals Plastics (polymers): Thermoplastics, thermosets, and elastomers Ceramics, glasses, glass ceramics, graphite, diamond, and diamond-like materials Composite materials: Reinforced plastics and metal-matrix and ceramic-matrix composites Nanomaterials Shape-memory alloys, amorphous alloys, semiconductors, and superconductors Consideration of material selection 1. Properties of materials. 2. Availability 3. Service life 4. Material substitution in products Selection of Manufacturing Processes Machining Casting Forming - Bulk Forming - Sheet Polymer Processing Joining General Trends of Manufacturing Global trends Product variety and complexity continue to increase. Product life cycles are becoming shorter. Markets have become multinational and global competition has been increasing rapidly. Market conditions fluctuate widely. Customers are consistently demanding high- quality, low-cost products and ontime delivery. Materials Material composition, purity, and defects (impurities, inclusions, and flaws) are coming under more control in order to further enhance overall properties, manufacturing characteristics, reliability, and service life. Developments have occurred in the selection of materials for improved recyclability. Developments continue in nanomaterials, nanopowders, composites, superconductors, semiconductors, amorphous alloys, shape-memory alloys (smart materials), tool and die materials, and coatings. Testing methods and equipment, including the use of advanced computers and software, particularly for ceramics, carbides, and composite materials, are continually being improved. Increasing control over the thermal treatment of materials is resulting in more predictable and reliable properties. Weight savings are being achieved with the use of materials with higher strength-to-weight and stiffness-to-weight ratios, particularly in the automotive and aerospace industries. Manufacturing Operation
Improvements are being made in predictive models of the
effects of materialprocessing parameters on product integrity, applied during a products design stage. Developments continue in ultraprecision manufacturing, micromanufacturing, and nanomanufacturing, approaching the level of atomic dimensions. Computer simulation, modeling, and control strategies are being applied to all areas of manufacturing. Rapid-prototyping technologies are increasingly being applied to the production of tooling and direct digital manufacturing. Optimization of manufacturing processes and production systems are making them more agile. Manufacturing System Advances in computer software and hardware are being applied to all aspects of production. Developments have occurred in control systems, industrial robots, automated inspection, handling and assembly, and sensor technology. Lean production and information technology are being implemented as tools to help meet major global challenges. Goals in Manufacturing View manufacturing activities not as individual, separate tasks, but as making up a large system, with all its parts interrelated. Meet all design requirements, product specifications, and relevant national and international standards for products. Build quality into the product at each stage of its production. Implement the most economical and environmentally friendly (green) manufacturing methods. Continually evaluate advances in materials, production methods, and computer integration, with a view toward realizing their appropriate, timely, and economical implementation. Adopt production methods that are sufficiently flexible in order to rapidly respond to changing global market demands and provide on-time delivery to the customer. Continue efforts aimed at achieving higher lez/els of productivity and eliminating or minimizing waste with optimum use of an organizations resources. Cooperate with customers for timely feedback for continuous improvement of a companys products.