Manufacturing Types and Techniques

• Manufacturing is the use of tools, labor, machinery, and chemical processing to create finished goods

Types of Manufacturing

• Additive manufacturing, also known as 3D printing, uses layers to build shapes and patterns
• Advanced manufacturing uses new technology to improve production and bring products to market faster
• Contract manufacturing involves companies partnering with other firms to outsource manufacturing processes

Types of Manufacturing Techniques

• Make to Stock (MTS) is a production technique that manufactures a standard product based on demand forecasts
• Make to Order (MTO) involves direct work with customrs to understand their needs and product specifications
• Make to Assemble (MTA) involves starting production on component parts and assembling them when orders are placed

Types of Manufacturing Processes

• Discrete manufacturing identifies each product manufactured and uses a bill of materials to track components
• Process manufacturing has batch processing (using a recipe or formula) and continuous processing (ongoing operations)
• Mixed Mode manufacturing combines discrete and process manufacturing for customized goods
• Job shop manufacturing is a process used when a batch differs from a company's normal product
• Repetitive manufacturing breaks long processes into smaller parts, each with a dedicated assembly line.

Steps of Manufacturing

• Develop the idea
• Perform market research
• Design the product
• Finalize and prototype
• Prototype testing
• Manufacture the good
• Monitor the process

Material Handling

• Material handling is the the movement, packing, and storing of material in an appropriate and suitable location.
• Corporate objectives for material handling include finding suitable locations, determining distances, reducing damage, and tracking assets
• Other objectives include lowering manufacturing time, improving material flow , creating safe conditions, raising productivity, maximizing equipment utilization, lowering costs, and maximizing revenue

Principles of Material Handling

• Orientation: Study system relationships before planning.
• Planning: Establish a plan with alternates and contingency.
• Systems: Integrate handling and storage activities cost-effectively.
• Unit Load: Handle product in a large unit load
• Space Utilization: Encourage effective use of space.
• Standardization: Encourage standardizing handling methods and equipment.
• Ergonomic: Recognize human capabilities in equipment design.
• Energy: Consider energy consumption during handling.
• Ecology: Minimize environmental impact during handling.
• Mechanization: Encourage mechanization of handling for efficiency.
• Flexibility: Encourage methods and equipment usable in all conditions.
• Simplification: Encourage simplification by removing unnecessary movement
• Gravity: Use gravity in movement of goods.
• Safety: Ensure safe equipment according to safety rules
• Computerization: Encourage computerization of material handling and storage
• System Flow: Integrate data flow with physical material flow
• Layout: Prepare operational sequence for all systems.
• Cost: Cost-benefit analysis of all solutions.
• Maintenance: Prepare plan for maintenance and repairs.
• Obsolescence: Encourage equipment policy for economic advantage.

Types of Material Handling Equipment

• Storage and handling equipment is vertical structures and shelving to secure goods for short or long periods
• Includes pallet racks, shelves, bins, drawers, mezzanines, and stacking frames
• Bulk material handling equipment controls and transports loose materials in large quantities
• Includes conveyor belts, stackers, reclaimers, bucket elevators, and hoppers
• Industrial trucks transport goods and materials within a warehouse, and can be hand-operated or drivable
• Includes forklifts, hand trucks, pallet trucks, sideloaders, and order pickers
• Engineered systems incorporate technology, computers, and robots to store and transport goods
• Includes autonomous mobile robots, automated storage systems, and automated guided vehicles

Benefits of Material Handling

• An effective system allows companies to have needed stock in smaller spaces.
• Reduces time spent on internal operations
• Controls inventory in real-time
• Reduces operational costs
• Optimizes the overall flow of goods
• Prevents workplace accidents
• Improves employee satisfaction
• Increases productivity and efficiency.
• Saves you money due to not spending as much on equiptment

How a Materials Handling System can be Implemented Through the Supply Chain

• Manufacturing: Material handling is used to move and manage inbound shipments within storage areas or a warehouse.
• Transportation: Material handling places goods on pallets.
• Storage: It offloads goods to storage areas and shelves
• Distribution: It loads goods onto trucks

Industrial Drying Process

• Industrial dryers reduce moisture using high temperatures to preserve goods, increase shelf-life, and reduce microbial activity.
• Drying reduces weight/volume for easier transport and reduces spoilage
• Modes of heat transfer include convection, conduction, radiation, and evaporative cooling.
• Important to Use indirect drying systems for gentle heating
• Industrial drying machines apply either direct or indirect heating to transfer temperatures
• Convection is ideal for slurries and insoluble substances
• Fluidized bed dryers evaporate moisture from wet granules
• Dehumidification applies low temps to heat-sensitive materials
• Sorption dehumidifiers strip air of excess water

Lyophilization Techniques

• Lyophilization bypasses the liquid phase to keep materials intact and dry
• Vacuum chamber industrial drying equipment frees trapped moisture
• Important to note that drying cabinets are best suited for batch processing
• Radiation drying systems exploit long wavelengths to create indirect heating
• Reducing power consumption happens with energy-efficient industrial drying machines

Industrial Drying Technologies

• Hot air drying is the most common drying method
• Sun drying is the oldest and most economical but does not perserve properties.
• Contact drying involves a product touching heated walls
• Infa-red evaportates water at high temperatures
• Freeze-drying uses water sublimation
• Fluidized bed drying mixes air and solid particles
• Dielectic drying uses microwave and radio frequencies

Drying with Industrial Dryers

• Industrial dryers extract moisture from items with machinery
• Drying involves heat and mass transfer mechanisms, with heat applied to cause evaporation
• Some purposes of the process include:
• Preventing microbial growth
• Protecting materials
• Improving properties
• Preparing matierials
• Enhancing functionality

Categories of Heat Transfer in Dryers

• Conductive heat transfer heats materials through an object or surface.
• Convective heat transfer involves direct drying without surfaces
• Direct dryers use convection to heat, with hot air or gas as the medium
• Direct dryers are highly efficient and optimized with lifting flights
• Air dryers eliminate moisture from ambient air

Dryer Techniques

• Air drying involves cooling and reheating air, or using absorbent materials.
• Conveyor dryers transport products through drying stages on a conveyor belt
• Zone temps and turbine fans accelerate the drying process
• Food dryers accurately control temperature or use pure heat energy.
• Types include multi-layer mesh belt and heat pump dryers.
• Rolling bed dryers dry large volumes of biomass in a rotating drum
• They are energy-efficient and compact
• Direct dryers use conduction with a partition separating the heat medium
• They are ideal for sensitive items
• Radiant dryers transfer heat directly with electromagnetic waves
• They are contactless and reduce contamination

Types of Modes for Industrial Dryers

• Microwave dryers use electromagnetic waves in the microwave frequency range which generates heat internally
• Infrared dryers use electromagnetic radiation to transfer thermal heat
• Batch dryers is a term that several high-volume dryers are capable of and can have conveyor systems
• Continous dryers use a steady stream which involves transport chains, carts, rotary pumps, and conveyor belts

Different Types of Batch Dryers

• Tray Dryers feature trays stacked in a chamber, with air circulated by blowers.
• Vacuum Dryers work under pressure to decrease the boiling point of liquid
• Pan dryers feature an agitator to ensure even drying
• Freeze Dryers involve using a vacuum pump after materical has frozen
• Bin Dryers feature an air heater to ensure heating is sealed

Types of Continous Dryers

• Tunnel dryers use trays mounted on trolleys
• Rotary dryers are composed of drums with internal flights which lift and then send the prodcut cascading
• Fluidized bed dryers use hot air upwards tp assist in movment