9/12/05

Manufacturing
Group #3

Erica Velarde
David Pincus
Sean Clifton
Ruben Sosa
What is Manufacturing?

It is defined as, the process of converting

raw materials into products.

The word manufacturing is derived from the

Latin word manu factus meaning made by
hand.
 It usually involves activities in which the
manufactured product is used to
manufacture other products.

Products are seldemly made of just a single

part, such as a nail or bolt.

Most objects are constructed by assembling

a number of single parts, and these
components can be made from a variety
of materials.
Number of Single Parts in
Some Products

Rotary Lawn Mower 300 parts

Grand Piano 12,000 parts
Automobile 15,000 parts
C-5A transport plane >4,000,000 parts
Boeing 747-400 >6,000,000 parts
Duratec V-6 engine components and
materials used to manufacture them
Manufacturing is a complex activity that
involves a variety of resources and
activities:

 Product Design
 Machinery and Tooling
 Process Planning
 Materials
 Purchasing
 Manufacturing
 Production Control
 Support Services
 Marketing
 Sales
 Shipping
 Customer Service
Manufacturing Steps and
Components of a Light Bulb
Manufacturing is a vital part of a nations
economy. It is said that a nation’s level of
manufacturing activity is directly related to
its economic health; the higher the level of
manufacturing activity in a country, the
higher the standard of living of its people.
The History of Manufacturing
 It dates back to about 5000 B.C.
 It is older than recorded history
 Primitive cave and rock markings made with
tools that were manufactured for these
purposes.
 Primitive manufacturing of products for various
specific uses began with articles made of wood
and stone.
Environmentally
Conscious Design
and Manufacture
Environmentally Conscious Design and Manufacturing

Facts:
• In the United States alone, nine million passenger cars and
about 300 million tires are discarded each year; about 100
million of those tires are reused in various ways.
• More than five billion kilograms of plastic products are
discarded each year.
• Every three months, industries and consumers discard
enough aluminum to rebuild the country’s commercial air fleet.
 What Pollutes the Environment?

• Lubricants and coolants are often used in most manufacturing

operations.
• Various fluids and solvents are used in cleaning manufactured
products, some of these fluids pollute the air and water during their use.
• Many by-products from manufacturing plants have been discarded for
years (i.e., sand containing additives used in metal-casting processes;
water, oil and other fluids from heat-treating facilities and from planting
operations; slag from foundries and from welding operations.)
• A variety of metallic and non-metallic scrap, produced in operations
such as sheet forming, casting and molding.
• The effects of these activities, their damage to our environment and to
the earth’s ecosystem, and, ultimately, their effect on the quality of human
life are well recognized.
• Major concerns are water and air pollution, acid rain, ozone depletion,
the greenhouse effect, hazardous wastes, landfill seepage and global
warming.
• Many laws have been set in place in the United States and other
industrialized countries to help reduce the pollution.
 What Can We Do?

• Reduce waste of materials, by refinements in product design and

reducing the amount of materials used
• Reducing the use of hazardous materials in products and processes.
• Conducting research and development into environmentally safe
products and into manufacturing technologies.
• Ensuring proper handling and disposal of all waste.
• Making improvements in recycling, waste treatment and reuse of
materials.
 Computer-Integrated Manufacturing

What is computer-integrated Manufacturing (CIM)?

• Software and hardware are integrated from product concept
through product distribution in the marketplace.

Why is it effective?

• Responsiveness to rapid changes in market demand

and product modifications.
• Better use of materials, machinery, and personnel,
and reduction in inventory.
• Better control of production and management of the
total manufacturing operation.
• The manufacturing of high quality products at low
cost.
 Major Applications of Computers in Manufacturing

• Computer Numerical Control (CNC): Method of controlling the

movements of machine components by direct insertion of coded
instructions in the form of numerical data.
• Adaptive Control (AC): The parameters in a manufacturing process are
adjusted automatically to optimize production rate and product quality,
and to minimize cost.
• Automated Handling of Materials: Computers have made possible
highly efficient handling of materials and components in various stages
of completion, such as when being moved from storage to machines,
from machine to machine, and at points of inspection, inventory and
shipment.
Industrial Robots: introduced
in the early 1960s, industrial
robots have been replacing
humans in operations that are
repetitive, dangerous and
boring, thus reducing the
possibility of human error and
improving productivity.
Robots with sensory-
perception capabilities have
been developed with
movements that simulate
those of humans.
• Automated and Robotic assembly systems: These systems mainly
have replaced costly assembly by human operators, although humans
still have to perform some of these operations. Products are now
designed or redesigned so that they can be assembled more easily and
faster by machines.
• Computer-Aided Process Planning (CAPP): This system is capable of
improving productivity by optimizing process plans, reducing planning
costs and improving the consistency of product quality and reliability.
• Group Technology (GT): The concept of group technology is that parts
can be grouped and produced by classifying them into families,
according to similarities in design and similarities in the manufacturing
processes employed to produce the parts.
• Just-In-Time Production (JIT): The principal of JIT is that supplies of
raw materials, parts and components are delivered to the manufacture
just in time to be used, parts and components are produced just in time to
be made into subassemblies and assemblies and products are finished
just in time to be delivered to the comsumer.
• Cellular Manufacturing (CM): This system utilizes workstations that
usually contain several production machines controlled by a central
robot, each machine performing a different operation on the part.
• Flexible Manufacturing Systems (FMS): These systems integrate
manufacturing cells into a large unit, all interfaced with a central
computer.
• Expert Systems (ES): These systems basically are complex computer
programs; they have the capability to perform various tasks and solve
difficult real life problems much as human experts would.
• Artificial Intelligence (AI): This important field involves the use of
machines and computers to replace human intelligence. Computer
controlled systems are now capable of learning from experience and of
making decisions that optimize operations and minimize costs.

All of these help keep production costs down and also speed up the
manufacturing process.
 Lean Production and Agile Manufacturing
What is it?
Lean Production: A methodology that involves a thorough
assessment of each of the activities of a company in order to
minimize waste at all levels.
• These include the efficiency and effectiveness of all its operations,
the efficiency of the machinery and equipment, the number of
personnel involved in each operation and the possible dispensing of
some of its operations and managers.
• This approach continues with a comprehensive analysis of the
costs of each activity, including those due to productive and
nonproductive labor.
 Agile Manufacturing: A term indicating the implementation of the
principles of lean production on a broad scale.
• The principal behind agile manufacturing is ensuring agility in the
manufacturing enterprise, so that it can respond rapidly to changes in
product demand and in customer needs.
• This flexibility is to be achieved through people, equipment, computer
hardware and software and advanced communication systems.
Design for Manufacture,
Assembly, Disassembly,
and Service
(DFMA)
What is DFM?
 Design for Manufacture – integrates the
design process with materials,
maufacturing methods, process planning,
assembly, testing and quality assurance.
Considerations
 Characteristics,  Machine performance
capabilities, and  Dimensional accuracy
limitations of  Surface finish
materials
 Processing time
 Manufacturing
process
 Effects of processing
method on part
 Machinery quality
 Equipment
Design for Assembly (DFA)
 Requires consideration
of ease, speed, and
cost of putting all the
parts together.
 Disassembly must also
be possible for good
design.
 Easy assembly = easy
disassembly
Benefits of DFA
 Easy disassembly makes for easy service
of parts.
 Software is available to expedite the
process and minimize cost.
 The end result is Design for Manufacture
and Assembly (DFMA)
Methods of Assembly

 Fasteners or adhesives
 Welding, soldering, brazing
Methods of Assembly (cont.)

 Hand/Machine assembly?
# of parts
 Amount of care/protection required
 Cost of labor
Selecting Materials

Properties, Cost & Availability,

and Service Life
Types of Material
 Ferrous metals
 Nonferrous metals
 Plastics (Polymers)
 Ceramics, glass,
diamond
 Composites
 Wood
General Manufacturing Characteristics of Various
Alloys
Alloy Castability Weldability Machinability
*Aluminum E F E-G
*Copper G-F F G-F
*Gray cast E D G
iron
*White cast G VP VP
iron
*Nickel F F F
*Steel F E F
*Zinc E D E
Note: E, excellent; G, good; F, fair; D, difficult; VP, Very Poor
Types of Material (cont.)
 Nanomaterials
 Shape-memory alloys
 Amorphous alloys
 Semiconductors
 Superconductors, etc.
Properties of Materials
 Mechanical – strength, toughness, ductility hardness,
elasticity, fatigue, etc.
 Physical – density, specific heat, thermal expansion,
conductivity, melting point, and electrical/magnetic
properties
 The combination of Mech./Phys. Properties give us
strength-to-weight ratios (Important to aerospace)
 Chemical – oxidation, corrosion, general degradation,
toxicity, flammability
 Manufacturing – determines if can be cast, formed, etc.
Cost and Availability
 Depends on Reliability of Supply and
Demand for Material
 Specialized machinery
 Extensive Labor
 Personnel with special skills/training
Appearance, Service Life, and
Recyclability
 Color, feel, surface texture
 Wear, fatigue can affect performance and
service life
 Consideration for disposal after end of
service life
 Ex. Baseball bats
Selecting Manufacturing Processes
 Casting – Expendable/Permanent mold
 Forming/Shaping – Rolling, forging, etc.
 Machining – Turning, milling, grinding, etc.
 Joining – Welding, adhesive, mechanical
 Finishing – Honing, lapping, polishing
 Nanofabrication – NEMS operate on the same
level as biological molecules
Selecting Manufacturing Processes
(cont.)
 Depends on: shape to
be produced and its
properties
 Dimensional Accuracy
& Surface Finish
 Operational &
Manufacturing Costs
Consequences of Improper
Selection of Materials and
Processes
 Temperature
 Dimensional changes; surface oxidation; warping
 Design and cost for tooling – tool/die life
 Availability of equipment; experience of personnel
 Pollution
 Affects job safety and cost
Consequences

 It stops functioning
 It does not function properly or within specs
 It becomes unreliable or unsafe to use
Net Shape Manufacturing
 The first operation made on the part is
made as close to the final dimensions,
tolerances, surface finish, and
specifications as possible.
Quality Assurance and
Total Quality
Management
What is Quality Assurance?

 Most important aspect of manufacturing

 Influences the marketability of a product

 Influences customer satisfaction

Product integrity
 Is the term usually used to define a product
 Isthe product suitable for its intended purpose
 Does the product meets the market demand
 Does the product performs reliably during its life
expectancy
 Can the product be maintained with relative ease
Example of Quality Assurance. The Little
giant latter system.
Total Quality Management
 Is the responsibility of everyone involved in
design and manufacturing a product
 Management commitment to product quality
 Pride of workmanship at all levels of
production
 Use of statistical process control (SPC) and
the use of control charts for on-line monitoring
of part production
 Control chart is a device for describing in a
precise manner what is meant by
statistical control.
 It is a proven technique for improving
productivity
 It is effective in defect prevention
 It prevents unnecessary process adjustments
 It provides diagnostic information
 It provides information about process
capability
Example of control chart
Why do we care about quality
Assurance and total Quality
management?
Product Liability
 Product malfunctioning
 Laws and regulations
 Human factor

 Asengineers we have the responsibility to

design and manufacture safe products that
meet the public demand
Human Factor
 It is impossible to totally eliminate a
product safety hazard.
 Human versus machine interactions
 A chainsaw
 A table saw
 A car lift
References
 Kalpakjan and Schmid. Manufacturing Engineering and Technology.
5th ed. Pearson Education Inc. 2006
 Lindbeck. Product Design and Manufacture. Prentice-Hall, Inc.
1995
 http://en.wikipedia.org/wiki/Industrial_robot
 http://www.engineering.com
 http://www.encarta.msn.com
 http://www.hotdot-bullseye.com/Taguchi.html
 http://www.skymark.com/resources/leaders/juran.asp
 http://reliability.sandia.gov
 https://bigdealsnetwork.com/littlegiantladder/view_product.php?pr
oduct=LG-10101
Questions
1. Which of the following is not a major application of computer in manufacturing:
a. Computer Numerical Control
b. Adaptive Controls
c. Industrial Robots
d. Quality Control
2. Total quality management relates to:
a. Commitment to product quality
b. Pride of workmanship at all levels of production
c. Identifying sources of quality problems
d. All of the above
3. The history of manufacturing dates back to:
a. 1800
b. 5000BC
c. 1910
d. 1600
4. Which is not a method of assembly:
a. Mechanical fasteners
b. Welding
c. Wrapping
d. Adhesive
5. Net shape manufacturing involves:
a. Manufacturing the part as close to final tolerances as possible
b. Manufacturing the part in as many pieces as possible
c. Manufacturing the part as quickly as possible
d. Manufacturing the part as cheap as possible