DAM 11002: Week 1 - Manufacturing Overview

Course Information

• Course title: DAM 11002: Manufacturing Process
• Week: 1
• Textbook author: MP Groover
• Textbook title: Fundamentals of Modern Manufacturing 3/e

What is Manufacturing?

• Manufacturing involves changing the shape, properties, or appearance of starting materials.
• Many objects are made from multiple parts and materials.
• Manufacturing methods have developed from hand-made to automated.
• Historically, manufacturing initially meant "made by hand."
• Modern manufacturing heavily depends on mechanized equipment and human supervision.

Manufacturing - Technologically

• Application of physical and chemical processes to alter the geometry, properties, and appearance of a starting material to create parts or products.
• Manufacturing always involves, at least, a sequence of operations.
• The process adds value to the material by changing its shape or properties.

Manufacturing - Economically Important

• Manufacturing is a crucial aspect of a nation's economy.
• The manufacturing sector contributes significantly to a nation's Gross National Product (GNP).
• Manufacturing activities encompass agriculture, minerals, construction, and various services.

Manufacturing Industries

• Industries are categorized into:
  • Primary industries (farming, mining): These cultivate and exploit natural resources.
  • Secondary industries (manufacturing): These convert primary outputs into consumer or capital goods.
  • Tertiary industries (services): These are the service sector.

Materials in Manufacturing

• Engineering materials are broadly classified into three categories:
  • Metals
  • Ceramics
  • Polymers
• Their different chemistries lead to varying mechanical and physical properties, influencing manufacturing methods.
• Composites (nonhomogeneous combinations of these three) also play a role.

Manufacturing Processes

• Two basic process types:
  • Processing operations: these operations transform a work material from one state of completion to another, altering the geometry, properties, or appearance of the starting material.
  • Assembly operations: these operations join two or more components to create a new combined entity.

Processing Operations Classification

• Solidification Processes: starting material is a heated liquid or a semifluid
• Particulate Processes: starting material is in powder form
• Deformation Processes: starting material is a ductile solid
• Material Removal Processes: starting material is a ductile or brittle solid

Solidification Processes

• Starting materials are heated to liquid or semi-liquid states.
• Examples: metal casting, plastic molding

Particulate Processing

• Involves pressing and sintering powders of metals or ceramics.
• Heat bonds the individual particles together to form solid objects.

Deformation Processes

• Shaping materials by applying forces exceeding their yield strength.
• Examples: forging, extrusion

Material Removal Processes

• Removing excess material to achieve the desired shape.
• Examples: turning, drilling, milling, grinding, nontraditional processes.

Waste in Shaping Processes

• Material removal processes typically result in waste.
• Net-shape processes minimize waste by shaping materials to the final form with minimal machining.
• Near-net-shape approaches also minimize waste by reducing the necessary machining.

Property-Enhancing Processes

• These processes modify material properties without materially altering the shape.
• Examples: heat treatment of metals and glasses; sintering of powdered metals and ceramics.

Surface Processing Operations

• Surface treatments involve processes like cleaning, mechanical working (e.g., sandblasting), and chemical or thermal treatments.
• Coating and deposition improve surface properties.

Assembly Operations

• Joining two or more parts to form a new entity.
• Joining processes: welding, brazing, soldering, adhesive bonding
• Mechanical assembly: fastening by mechanical methods (screws, bolts, nuts), press fitting, expansion fits.

Production Systems

• People, equipment, and procedures used for material combinations.
• Essential for efficient manufacturing operations.
• Includes:
  • Production facilities (factory, equipment, material handling)
  • Manufacturing support systems (departments like manufacturing engineering, production planning & control, quality control)

Production Facilities

• The factory, its equipment, and material handling systems.
• Plant layout—how equipment is arranged in the factory.
• Manufacturing systems: logical groupings of equipment.
• Examples: automated production lines, machine cells (robotic arm with other machines).

Facilities versus Product Quantities

• Company designs manufacturing systems based on product quantities.
  • Examples: low production (job shops), medium production (batch or cellular manufacturing), high production (quantity, flow line)

Low Production

• Job shops are used, making customized, specialized products in relatively small quantities.
• General-purpose equipment and highly skilled labor.

Medium Production

• Batch or cellular manufacturing is used, with setups needed between batches.
• Hard or mixed product variety.
• Equipment may be general or specialized, and workers may be skilled or semi-skilled.

High Production

• Often called mass production, designed for high-volume production of a specific product.
• Two categories: quantity or flow line production.

Quantity Production

• Mass production of single parts with single machines or groups of machines.
• Standardized machines with specialized tooling.
• Equipment dedicated to a single product type.
• Process layout or cellular layout.

Flow Line Production

• Multiple machines are arranged in a sequence, typically in production lines.
• Complex products need multiple processes.
• Units are moved through the sequence for completion.
• Workstations are often designed specifically for the product to maximize efficiency.

Manufacturing Support Systems

• Departments manage production operations, from design to quality control.
• Key departments include:
  • Manufacturing Engineering
  • Production Planning & Control
  • Quality Control

Overview of Major Topics

• A diagram illustrating the systems and their interrelation

Dimensions and Tolerances

• Factors impacting product performance.
  • Dimensions: measured sizes (linear or angular) of components on drawings.
  • Tolerances: acceptable variations from specified part dimensions.
• Important in manufacturing to ensure product function and quality.

Dimensions

• Numerical value of a part feature in appropriate units indicated on the drawing.
• Represents the nominal or basic sizes of the part and its features.

Tolerances

• Total amount a specific dimension is allowed to vary between maximum and minimum limits.
• Reflect variations in manufacturing processes.
• Define the limits of acceptable variation in the product.

Bilateral Tolerances

• Variations are allowed in both positive and negative directions from the nominal dimension.

Unilateral Tolerances

• Variation is allowed in only one direction (positive or negative), not both.

Limit Dimensions

• Maximum and minimum dimensions permissible for a part feature.

Tolerances and Manufacturing Processes

• Some processes are inherently more accurate than others.
• Example differences in accuracy between machining processes and casting processes.
• Tolerance requirements depend on the manufacturing process.

Design & Manufacturing a Product

• Two general product types:
  • Physical Goods: tangible goods that can be seen and experienced before purchase.
  • Services: actions offered for customer transactions.

Stage-Gate Product Development Process

• Steps in developing new products, with management reviews at each stage.

Characteristics of Successful Product Development

• Factors to consider when evaluating the success of a product development effort
• Product quality
• Product cost
• Development time
• Development cost
• Development capability

Who Design & Develop Products?

• Team leadership plays important role in project success.
• Various professionals work in parallel to create a successful and efficient product.

Design

• Design analysis is broken into four phases: conceptual, detailed, manufacturing, distribution and disposal.
• The design phase is very important in the product lifecycle and largely affects the product's total cost.

Products in Various Stages of Life Cycle

• Product sales, stages, and profitability typically are related.

Production Systems Diagram

• Overall structure of factory operations, showing interrelation between facilities and associated support systems.