Manufacturing Technology - BDA 31403

Manufacturing Technology - BDA 31403

• Course Instructor: Prof. Ir. Dr. Yusri Bin Hj Yusof
• Course Code: BDA 31403
• University: Universiti Tun Hussein Onn Malaysia (UTHM)

Introduction and Overview of Manufacturing

• Manufacturing is an essential human activity, predating recorded history.
• Manufacturing is crucial to developed and developing nations for technological and economic reasons.
• Manufacturing is the process that makes technology possible.
• Manufacturing involves transforming materials into usable products through processes and assembly operations.

Economic Importance

• Manufacturing sector accounts for a significant portion of the US economy (12% of GDP).
• Agriculture, natural resources, construction, and service industries are other key sectors.
• Data is collected on the Productivity of different economic sectors in the US economy

Technological Importance

• Technology is the application of science to provide society with necessities and desires.
• Technology impacts daily life directly and indirectly.
• Manufactured products are essential for society and its members' well-being.

Manufacturing Example: Artificial Heart Valve

• Transforming a titanium billet (raw material) into a heart valve embodies the manufacturing concept.

Manufacturing Industries

• Industries categorized into primary, secondary, and tertiary sectors.
• Primary: Agriculture, forestry, fishing, livestock, mining, and petroleum
• Secondary: Aerospace, apparel, automotive, basic metals, beverages, building materials, chemicals, computers, construction, consumer appliances, electronics, equipment, fabricated metals, food processing, glass, ceramics, heavy machinery, paper, petroleum refining, pharmaceuticals, plastics, power utilities, publishing, textiles, tire and rubber, wood and furniture.
• Tertiary: Banking, communications, education, entertainment, financial services, government, health, hotel, information, insurance, legal, real estate, repair, maintenance, restaurant, retail trade, tourism, transportation, wholesale trade.
• Manufacturing includes construction, and electric power generation and other sectors.
• Manufacturing produces hardware, nuts, bolts, forgings, cars, airplanes, digital computers, plastic parts, and ceramic products.

Manufactured Products

• Consumer goods are purchased by individuals (e.g., cars, clothes, TVs, tennis rackets).
• Capital goods are purchased by companies to produce other goods or services (e.g., aircraft, computers, communication equipment, medical apparatus, trucks, machine tools, construction equipment).

Production Quantity Q

• The quantity of goods produced (Q) significantly influences factory organization.
• Production ranges include: Low (1-100 units), Medium (100-10,000 units), and High (10,000+ units).

Product Variety P

• Product variety (P) refers to the different types or models produced in a plant.
• Products are often intended for different markets and have varying component counts.
• High variety suggests a factory makes diverse products.
• A graph depicted the relationship between Production quantity and Product variety to show the trade off between production quality and variety.

Manufacturing Capability

• Manufacturing plants have inherent limitations in the varieties of products, quantities, and types of processes they employ.
• Technological processing competence is important
• Physical product constraints, the sizes and weights, are taken into consideration
• Production capacity (i.e., plant capacity) is a measure of maximum production in a specific time period.

Materials in Manufacturing

• Most engineering materials categorized into Metals, Ceramics, Polymers, and Composites.

Processing Operations

• Processing operations transform work materials into advanced states.
• Types of processing operations include shaping, property-enhancing, and surface processing operations.
• These categories are based on whether the geometry of the starting work material is altered, its mechanical and physical properties are improved, or a surface coating is added to the workpart.
• Four categories of shaping processes: Solidification, Particulate, Deformation, and Material removal

Assembly Operations

• Assembly joins two or more components into a new entity.
• Types include permanent and mechanical assembly.

Production Machines and Tooling

• Manufacturing relies on machinery and tooling.
• Examples: Forging hammers, presses, plastic injection molding machines, machine tools.

Production Systems

• Production systems combine people, equipment, and procedures to efficiently produce goods.
• Two main categories of systems: Production facilities and Manufacturing support systems.

Production Facilities

• Production facilities include the factory, production equipment, and material-handling systems.

• Examples include production lines and machine cells.

Facilities vs Product Quantities

• Production facilities are tailored to product quantities (low, medium, high).
• Low production: Job shops, for customized products.
• Medium production: Batch production and cellular manufacturing, for medium variety and quantity.
• High production: Quantity production and flow lines, for high volume, standard products.

Recent Developments in Manufacturing

• Technologies like Microelectronics, Computerization of Manufacturing, Flexible Manufacturing, Microfabrication, Nanotechnology, Lean Production, Six Sigma, Globalization/Outsouring, and Environmentally conscious manufacturing are driving innovations and advancements in the field.

Typical Cost Breakdown for a Manufactured Product

• Costs of manufacturing components are summarized in a pie chart;
• Research, Engineering. and Administration/Marketing components constitute about 25% of the final product cost.
• Materials/parts constitute another 50% of the final product cost.
• Manufacturing cost represents approximately 40% of the final product cost