Production and Manufacturing Basics

• Production is the creation of new tangible products or intangible services.

Production vs Manufacturing

• Production transforms raw materials into products through energy applications that alter their physical or chemical properties.
• Manufacturing converts a design into a finished product.
• Manufacturing involves design, materials selection, planning, production, quality assurance, management, and marketing.

Importance of Manufacturing

• Provides fundamental means for human survival.
• Creates wealth for nations; its decline leads to national impoverishment.
• Contributes to security, welfare, and peace by reducing the need for conflict.

Three flows in manufacturing

• Materials (or material flow)
• Information (or information flow)
• Cost (or cost flow)

Marketing

• Marketing involves planning and implementing the conception, pricing, promotion, and distribution of ideas, commodities, and services to create exchange value

Productivity

• Productivity measures the effectiveness of the transformation process as a ratio of output to input.
• Physical, value, and factor productivities are measured in units, monetary values, and resources of production, respectively.
• Total Productivity measures the overall contribution of resources to efficiency.

Decision-Making

• Decision-making Procedures selects the best plan from available alternatives.
• Design specification outlines objectives, performance criteria, and design elements, providing clarity and minimizing ambiguity.
• Specification development influenced by company, product, and project factors.

Process Engineering

• Process engineering improves business processes, providing steps to produce useful products/materials for various applications.
• Process engineers design, optimizes, and oversee production processes in manufacturing or chemical plants, ensuring efficiency, safety, and quality.

Product Planning

• Product planning involves researching and developing products to meet market needs.
• Planning begins with identifying market needs through data and making production decisions based on design acceptability.

Product Design

• Product design creates drawings or graphical representations of products based on specifications.

Product Quality

• Product Quality enables product to performs the required functions and have features that customers require

Process Planning

• Process planning determines the sequence of operations for converting raw materials into finished products.
• It considers product types, quantities, available production facilities, and technology.
• Process design and operation design are the basic functions of process planning for overall process route and individual processes, respectively.

Operation Analysis

• Operation analysis can be analyzed from the viewpoints of a combination of machine elements and human elements, operative workers and work simplification.

Fixed Automation

• Fixed automation (or hard automation) is for high-volume production, dedicating equipment to specific operations and involves pre-programmed machines ensuring precision and consistency.
• Typically used for production systems with exclusively allocated equipment and high production needs.
• Applications include automated assembly machines, chemical manufacturing processes, and material handling conveyor systems.
• Advantage provide high output/efficiency and consistent product quality with low labor costs.
• Disadvantage include high initial setup cost, lack of flexibility, and difficulty in adapting to varied products.

Production Process

• Production process converts resources, particularly raw materials, into tangible goods or products through multiple stages and operations.
• Essential to any business, transforming raw materials and ideas into products and services.

Continuous/Repetitive Manufacturing Systems

• Involves operations running continuously and consistently.
• Includes process/continuous-flow production (oil and gas refineries) and mass/flow production (identical items simultaneously).

Intermittent/Non-Continuous Production Systems

• Includes batch production, job shop production (limited quantities, customer preference), and project production.

Conversion Technologies

• Conversion technologies convert unrecyclable waste into useful products like green fuels and renewable energy and contribute to a zero-waste goal.

Biochemical conversion

• Biochemical conversion uses bacteria and microorganisms to transform raw biomass into methane/ethane gas

Thermochemical conversion

• Thermochemical conversion uses heat to convert biomass into another chemical form through gasification, pyrolysis, or thermal depolymerization

Semi-Automated Handling

• Combines manual labor with some level of mechanization

Fully Automated Handling

• Relies entirely on automated machinery and systems

Process Control

• Process control monitors and adjusts process variables to maintain desired output for quality and performance.

Batch Process

• Batch Process processes materials/products in small, discrete quantities/batches.

Continuous Process

• Continuous Process involves material or work flowing more or less continuously through plant apparatus.

Artificial Intelligence (AI) in Manufacturing

• Computer system performs tasks requiring human intelligence like speech recognition and decision-making.
• Includes machine learning, deep learning, and natural language processing.
• Reactive machine, Limited Memory, Theory of Mind, and Self-Aware AI represent types of Al with varying capabilities.

Advantages of AI

• Reduces human error, automates tasks, handles big data, enables faster decision-making, mitigates risks, improves processes, and ensures 24/7 availability

Disadvantages of AI

• Increased human laziness, high implementation costs, potential job displacement, lack of creativity, inability to understand emotion

Unsymmetrical Fault Study

• Studies probabilities of faults like lightning and apparatus failure in power systems.

Types of Faults

• Open circuit, short circuit (symmetrical and unsymmetrical)

Symmetrical Faults

• Simultaneous all three phases short-circuited condition
• Symmetrical faults are Line-Line-Line Fault and L-L-L-G (Three-phase line to the ground fault)

Unsymmetrical fault

• The most common faults that occur in the power system network, include single-line-to-ground fault, line-to-line fault, and double-line-to-ground fault.

Three types of unsymmetrical faults

• Single-Line-to-Ground Fault, Line-to-Line Fault, Double-Line-to-Ground Fault

Computer-Aided-Process-Planning (CAPP)

• Technology that uses computer systems to plan and optimize the manufacturing process.

Advantages of CAPP

• Reduced process planning time/cost and improved consistency/accuracy.
• Variant, generative, and hybrid represent types of CAPP systems.

The Three types of CAPP Systems

• Variant (Retrieval) CAPP System
• Generative CAPP System
• Hybrid CAPP System

Local Area Network (LAN)

• A computer network that interconnects computers within a limited area

Types of LANs

• Client/Server LANs
• Peer-to-peer LANs
• Token ring LANs and token bus LANs
• Virtual LANs
• SD-LAN

Advantages of LAN

• Simple/inexpensive setup, accessible software, rapid communication, seamless client-server connection

Disadvantages of LAN

• Potential weak data protection, maximum damage from breaches, malware susceptibility, high installation costs, maintenance issues, space issues.

Wide Area Network (WAN)

• Telecommunications network extending over a large geographical area.

Types of WANs

• Leased Line
• Circuit-Switched WAN
• Packet-Switched WAN
• MPLS (Multiprotocol Label Switching)
• Software-Defined WAN (SD-WAN)

Advantages of WAN

• Wide geographical coverage, centralized data, updated data/files, resource sharing, global business enablement, high bandwidth

Disadvantages of WAN

• Security vulnerabilities, need for firewalls/antivirus, high setup costs, potential service/disconnection issues

Computer-Integrated Manufacturing (CIM)

• Computer systems control entire manufacturing process, from design to production.
• Integrates CAD/CAM and robotics, uses real-time adjustments, and reduces manual labor.
• CIM Three major functions and three computer aids.
• Common definition of CIM is the integration of the total manufacturing enterprise.