Introduction to Manufacturing Systems PDF

08.10.2024. ENS 208-6 Introduction to Manufacturing Systems Contents 1. What is Manufacturing? 2. Product...

08.10.2024. ENS 208-6 Introduction to Manufacturing Systems Contents 1. What is Manufacturing? 2. Product Design and Concurrent Engineering Introduction to Production Systems 3. Design for Manufacture, Assembly, Disassembly, and Service 4. Green Design and Manufacturing General Introduction 5. Selection of Materials 6. Selection of Manufacturing Processes 7. Computer-integrated Manufacturing 8. Quality Assurance and Total Quality Management 9. Lean Production and Agile Manufacturing 10. Manufacturing Costs and Global Competition 11. General Trends in Manufacturing What Is Manufacturing? Industrial revolutions Manufacturing is the process of turning raw materials or parts into finished goods through the use of tools, human labor, machinery, and chemical processing. Before the Industrial Revolution, most products were handmade using human labor and basic tools. Industry 4.0 Industry 4.0 related technologies ❑ Industry 4.0 refers to the fourth phase in the Industrial Revolution that focuses on interconnectivity, automation, machine learning, and real-time data. ❑ Intelligent networking of machines and processes for the industry with the help of information and communication technology is changing how manufacturers do business. ❑ It is the digital transformation of manufacturing. It gives the access to the real-time data and insights you need to make smarter, faster decisions, which can ultimately boost the efficiency and profitability of entire operation. 1  08.10.2024. What is Technology? General Technology classification Technology refers to methods, systems, and devices which are the result of scientific knowledge being used for practical purposes. Technology uses scientific principles, and applies them to change the environment in which humans live. Technology can also use scientific principles to advance industry or other human constructions. What is product? A part, subassembly and assembly Anything that can be offered to a market for attention, subassembly acquisition, use or consumption that might satisfy a want or need. assembly part A part, subassembly and assembly Manufacturing process ❑ An assembly is a final product that is made up of two or more sub-assemblies to perform a certain function ❑ When an assembly is a component of another assembly, it is referred to as a subassembly. ❑ Assembly and subassembly involve putting pieces together to form functional products 2  08.10.2024. Manufacturing process What Is Manufacturing? Example: Incandescent Light Bulbs Components of a common incandescent light bulb What Is Manufacturing? What Is Manufacturing? Incandescent Light Bulbs Manufacturing steps in making an incandescent light bulb The Design Process Design and manufacturing Product Design and Concurrent activities take place sequentially Engineering 3  08.10.2024. Product Design and Concurrent Engineering Product Design and Concurrent Engineering The Design Process  It would be more desirable to: Concurrent Engineering 1. Use a different material  Any iterations will require a smaller effort and less wasted 2. Use the same material but in a different condition time would occur 3. Modify the design of a component Concurrent Engineering  Also called simultaneous engineering  From the earliest stages of product design and engineering, all are simultaneous Product Design and Concurrent Engineering Product Life Cycles (PLC) Life Cycle  Product Life Cycle (PLC) – the course of a product’s sale  Life cycle of a new product consists of: and profit over it lifetime 1. Product start-up  PLC – shows the stages that products go through from 2. Rapid growth of the product in the marketplace development to withdrawal from the market 3. Product maturity  Typical Product Lifecycle help many companies make 4. Decline planning decisions  Facility can be designed for Product Families and the  Life-cycle engineering requires that the entire life of a organization tries to match lifecycle demands to keep product be considered capacity utilized Product Life Cycles (PLC) Product Life Cycles (PLC)  Product life cycles describe the changes in Companies want their consumer demand over time products to enjoy a  No product can be in demand forever long life cycle.  Trends, technology and lifestyles change affects consumer demand Hershey’s actively promotes the fact that it has been “unchanged since 1899” 4  08.10.2024. Product Life Cycles (PLC) The Stages of the Product Life Cycle  Each product may have a different life cycle 1) Development  PLC determines revenue earned 2) Introduction/Launch  Contributes to strategic marketing planning 3) Growth  May help the firm to identify when a product needs 4) Maturity support, redesign, withdrawal, etc. 5) Saturation  May help in new product development planning 6) Decline  May help in forecasting and managing cash flow 7) Withdrawal Product Life Cycles (PLC) Sales & Profit Life Cycles Product Design and Concurrent Engineering Role of Computers in Product design Role of Computers in Product Design  Product models are simplified through computer- aided design (CAD) and computer-aided engineering (CAE) techniques  CAD systems are capable of rapid and complete analysis of designs  This is the process known as paperless design  Performance of structures can be analysed 5  08.10.2024. Product Design and Concurrent Engineering Product Design and Concurrent Engineering Role of Computers in Product Design (Con’t) Prototypes  Computer-aided manufacturing involves all phases  A prototype is a physical model of an individual of manufacturing component or product  Performing tasks such as:  Rapid prototyping use CAD/CAM and various 1. Programming for numerical control machines specialized technologies 2. Designing tools, dies, moulds, fixtures, and work-  Prototypes developed can review for possible holding devices modifications to the original design, materials, or 3. Maintaining quality control production methods Rapid prototyping Rapid prototyping Design for Manufacture, Assembly, Disassembly, and Product Design and Concurrent Engineering Service Virtual Prototyping  Design for manufacture (DFM) integrate the design  It is a software-based method that uses advanced process with production methods, materials, process graphics and virtual-reality environments planning, assembly, testing, and quality assurance  To allow designers to view and examine a part in  Design for assembly (DFA), Design for manufacture and detail assembly (DFMA), and Design for disassembly (DFD) are  Also known as simulation-based design all important for manufacturing  Assembly requires a consideration of the ease, speed, and cost of individual components of a product 6  08.10.2024. Design for Manufacture, Assembly, Disassembly, and Design for Manufacture, Assembly, Disassembly, and Service Service  Examples  Examples Green Design and Manufacturing Manufacturing operations produce waste like: Green Design and Manufacturing 1. Chips from machining and trimmed materials 2. Slag from foundries and welding 3. Additives in sand used in sand-casting 4. Hazardous waste and toxic materials 5. Lubricants and coolants 6. Liquids from heat treating 7. Solvents from cleaning operations 8. Smoke and pollutants from furnaces Green Design and Manufacturing Green Design and Manufacturing  Environmentally conscious design and manufacturing considers Eco Production emphasizes: all possible adverse environmental impacts of materials, 1. Sustainable and efficient manufacturing activities processes, operations and products 2. Waste-free production  Design for recycling (DFR) - two basic activities 3. Using recyclable and nonhazardous materials 1) Biological cycle 4. Reducing energy consumption - Organic materials degrade and lead to new soil that sustain life 5. Using renewable energy 6. Maintaining ecosystems 2) Industrial cycle 7. Using available materials and energy sources - Product that can be recycled and reused continuously 8. Exploring the reuse and recycling of materials 7  08.10.2024. Green Design and Manufacturing Guidelines for Green Design and Manufacturing 1. Reduce waste of materials Selection of Materials 2. Reduce hazardous materials products and processes 3. Investigate environmental-friendly manufacturing technologies 4. Improvements in methods of recycling and reusing 5. Minimize energy use 6. Encourage recycling Selection of Materials Selection of Materials General types of materials used: Properties of Materials 1. Ferrous metals 1. Mechanical properties 2. Nonferrous metals 2. Physical properties 3. Plastics (polymers) 3. Chemical properties 4. Ceramics, glasses 4. Manufacturing properties 5. Composite materials 5. Appearance 6. Nanomaterials 7. Shape-memory alloys, semiconductors and superconductors Selection of Materials Selection of Materials Availability Service Life  If materials are not available in the desired quantities, A shortened service life of a product is due to: shapes, dimensions, and surface texture, substitute 1. Improper selection of materials materials can be considered 2. Improper selection of production methods  Reliability of supply is important in order to meet 3. Insufficient control of processing variables production schedules 4. Defective parts or manufacturing-induced defects  A country’s self-reliance on resources is a political goal! 5. Poor maintenance 6. Improper use of the product 8  08.10.2024. Selection of Materials Selection of Materials Example 2 Material Substitution in Products Baseball Bats We would want to consider the following substitutions:  Cross sections of baseball 1. Metal vs. wooden handle for a hammer bats made of aluminium and composite material 2. Aluminium vs. cast-iron lawn chair 3. Aluminium vs. copper wire 4. Plastic vs. steel car bumper 5. Plastic vs. metal toy 6. Alloy steel vs. titanium submarine hull Selection of Materials Example 3 U.S. Pennies Materials used undergone changes throughout history due to Selection of Manufacturing Processes periodic material shortages and the cost of appropriate raw materials Selection of Manufacturing Processes Metal forming and shaping technologies Some examples of manufacturing methods are: 1. Metal forming and shaping 2. Casting 3. Machining 4. Joining 5. Finishing 6. Microfabrication and nanofabrication 9  08.10.2024. Sheet metal forming technologies Casting technologies Polymer processing technologies Machining technologies Joining processes Selection of Manufacturing Processes Process Selection  Selection of process depends on geometric features of the parts and workpiece material and properties  Some mechanical tools are being replaced by laser cutting  Size of manufactured products are getting smaller such as microscopic gears 10  08.10.2024. Selection of Manufacturing Processes Selection of Manufacturing Processes Net-shape and Near-net-shape Manufacturing  Part is made in only one operation to the final desired Net-shape and Near-net-shape Manufacturing dimensions, tolerances and surface finish  Examples of net-shape manufacturing are:  Difference between the two is the degree of how close the ▪ precision casting, product is to its final dimensional characteristics ▪ Precision forging, ▪ forming sheet metal, ▪ powder metallurgy, ▪ injection moulding of metal powders and ▪ injection moulding of plastics Net-shape and Near-net-shape Manufacturing Types of Production Based on the number of pieces produced, production can be divided into:  Job shops: less than 100 pcs.  Small-batch production: 10 to 100  Batch production: 100 and 5000  Mass production: over 100,000 Types of Production Selection of Manufacturing Processes Example 4 Saltshaker and Pepper Mill  The two metal pieces for the pepper mill are made by powder-metallurgy techniques 11  08.10.2024. Computer-integrated Manufacturing Computer-integrated manufacturing (CIM) integrates Computer-integrated Manufacturing computer graphics, computer-aided modelling, and computer-aided design and manufacturing activities Capable of making possible 1. Responsiveness to rapid changes 2. Better use of materials, machinery, and personnel 3. Reduction in inventory 4. Better control of production and management Computer-integrated Manufacturing Computer-integrated Manufacturing Various elements in CIM include: 1. Computer numerical control (CNC) 2. Adaptive control (AC) 3. Industrial robots 4. Automated materials handling 5. Automated assembly systems 6. Computer-aided process planning (CAPP) 7. Group technology (GT) 8. Just-in-time production (JIT) 9. Cellular manufacturing (CM) 10. Flexible manufacturing systems (FMS) 11. Expert systems (ES) 12. Artificial intelligence (AI) 13. Artificial neural networks (ANN) Computer-integrated Manufacturing Example 5 Mold for Making Sunglasses Frames Quality Assurance and Total Quality  Machining a mold cavity for making sunglasses  Computer model of the sunglasses as designed and viewed on Management the monitor  Machining of the die cavity using a computer numerical-control (CNC) milling machine 12  08.10.2024. Product Quality Product Quality In general, items with good product quality:  Product quality refers to how well a product: ✓ satisfies customer needs,  Perform well ✓ serves its purpose and  Are reliable and don’t wear out quickly ✓ meets industry standards.  Are consistent in terms of manufacturing  Product quality refers to the characteristics, features,  Look appealing and are well packaged and attributes of a product that determine its ability to  Are intuitive to use meet customer expectations.  Meet the customer’s expectation of what the product should be Quality Assurance and Total Quality Management Quality Assurance and Total Quality Management  Product quality influences customer satisfaction  Quality must be built into the product from its initial design  Quality assurance and total quality management (TQM) are the responsibility of everyone involved in the design and manufacture of products and their components  Product integrity define the degree to which a product 1. Functions reliably 2. Suits its intended purposes 3. Can be maintained with relative ease Quality Assurance and Total Quality Management Quality Assurance and Total Quality Management  At six sigma concept, defective parts are reduced to only 3.4 per million parts made.  Level reached only through manufacturing process capabilities to reduce variability in product quality Quality Standards  Global manufacturing and competitiveness lead to international quality control methods  Thus the establishment of ISO 9000 and QS 9000 standards 13  08.10.2024. Quality Assurance and Total Quality Management Human-factors Engineering  Human-factors approach results in ergonomics design Lean Production and Agile  Defined as the study of a workplace and the design of Manufacturing machinery and equipment Product Liability  Involved with product design, manufacture and marketing  Product’s malfunction or failure can cause bodily injury or even death Lean Manufacturing Lean Production and Agile Manufacturing  Lean manufacturing is a production process based Lean production involves a thorough assessment of each on an ideology of maximising productivity while activity of a company simultaneously minimising waste within a Lean production focuses on: manufacturing operation. 1. Efficiency and effectiveness of each and every  The lean principle sees waste is anything that manufacturing operation, doesn’t add value that the customers are willing to 2. Efficiency of the machinery and equipment used pay for. 3. Activities of the personnel involved in each operation Manufacturing Costs and Global Competition Manufacturing Costs and Global Competition  Manufacturing cost is about 40% of its selling price  Total cost of manufacturing a product consists of: 1. Materials 2. Tooling 3. Fixed Costs 4. Capital 5. Labour 14