Introduction to Manufacturing

• Manufacturing is the making of every part by various processes.
• Converting raw materials into products requires manufacturing.
• A higher level of manufacturing leads to a higher standard of living.
• A healthy economy has manufacturing as its backbone.
• Engineers are needed for manufacturing.
• Manufacturing involves activities where manufactured products are used to create other products.
• Manufacturing requires making products from raw materials through machinery, various processes, and operations, with a well-organized plan for each activity.
• Production Engineering is a term used for manufacturing in Europe and Japan.
• Manufacturing is a complex activity which includes product design, marketing, support services, shipping, and process planning.
• Resources are the materials, capital, energy, and people.
• Computer-integrated manufacturing systems are used in this process.

Manufacturing Adherence

• The product must meet design parameters and specifications.
• Production must be achieved in the most economical manner.
• Quality should be built in through the entire production.
• Production methods should be flexible to respond to market changes.
• New material developments, production methods, and computer integration should be followed to ensure efficient production.
• Striving for higher productivity and optimum resource utilization is essential for manufacturing organizations.
• Manufacturing activities must be considered in the broader scheme of things.

Class Example 1, Paper Clip Design

• Material choice is a key consideration, whether to use metal or plastic.
• The thickness of the material must be determined.
• Mechanical properties such as stiffness and strength are essential.
• The shape of the material is crucial as it needs to be round.
• Surface finishing has to be determined.
• Cost, appearance, style, texture, and corrosion resistance are important factors.

Production Questions

• Will the material bend without cracking or breaking?
• Is cutting smooth or will it leave a burr?
• The most cost-effective manufacturing method should be used at the desired rate to stay competitive.

Class Example 2, Transistors

• Transistors have small dimensions, typically 3-30µm.

Design for Manufacturing

• Design and manufacturing must be intimately interrelated.
• Design and manufacturing should not be separate disciplines or activities.
• Design requirements and specifications must be met.
• Manufacturing must be economical and relatively easy.
• Designers require a fundamental understanding of material characteristics, capabilities, manufacturing processes, and related machinery.
• Designers must assess the impact of design modifications on manufacturing process selection, product cost, and assembly.
• Manufacturing, process planning, computer-aided design techniques should use computer programs for analysis.
• Rapid prototyping and expert systems are important.

Manufacturing Layout

• The design process
• Selecting materials
• Selecting manufacturing processes
• Assembly
• Product quality
• Automation
• Economics
• Organization

The Product Design Process

• Definition of product need
• Original concept
• Conceptual design
• Design analysis
• Physical and analytical models
• Prototype testing
• Evaluation
• Revised design
• Final evaluation
• Production drawings
• Material specification
• Process and equipment selection
• Tool and die design and construction
• Production
• Inspection, and Quality control

Properties of Materials

• Mechanical properties such as strength, toughness, ductility, hardness, elasticity, fatigue, and creep.
• Strength-to-weight ratio and stiffness-to-weight ratio are important.
• Material attributes affect castability, formability, machinability, weldability, and heat treatability.

Material Selection

• The availability and cost of processed materials and manufactured components are major considerations.
• Desired quantities, shapes, and dimensions are important.
• Additional processes can increase costs.
• Supply and support reliability affect manufacturing.
• Appearance, service life, and disposal are factors to consider..
• Standard components should be used where possible.

Manufacturing Processes

• Casting (expendable mold and permanent mold)
• Forming and shaping (rolling, forging, extrusion, drawing, sheet forming, powder metallurgy, and molding)
• Machining (turning, boring, drilling, milling, planing, shaping, broaching, grinding, ultrasonic machining, and chemical machining)
• Joining (welding, brazing, soldering, diffusion bonding, adhesive bonding, and metal joining)
• Finishing operations (honing, lapping, polishing, burnishing, de-burring, coating, and plating)
• Hard materials do not cast or machine easily
• The manufacturing process alters material properties.
• Size, thickness, and shape determine the process selection.
• Flat parts cannot be cast properly, and complex parts cannot be formed easily.
• Tolerances and surface finish are better formed when cold.
• Tool and die costs can be very expensive.
• Lower scrap rates are important for expensive materials.
• Machining versus Forming should be determined.
• Machines may require outside firms and environmental considerations.

Design for Assembly

• Permit assembly with relative ease
• Use parts that are multipurpose
• Address the capabilities and limitations of each manufacturing process
• Assess accuracy and consistency is essential.
• Maintenance and disposal are important.

Product Quality

• Quality products are reliable and function as expected over time.
• Quality is built into the product.

Automation Impact

• Integrate operations to improve productivity
• Increase product quality and uniformity
• Minimizes cycle time and effort
• Reduce labor costs
• Reduce human factored errors.

Computer Usage

• Covers a broad range of applications.
• Controls and optimizes manufacturing processes.
• Automation is used for material handling and inventory management.
• Automated inspection and testing are used.
• Reliable record-keeping systems are used.