Manufacturing Defined & Considerations PDF

#Manufacturing Defined: #one technologic and the other economic. #Technologically, manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; #Economically, manufacturing is the tr...

#Manufacturing Defined: #one technologic and the other economic. #Technologically, manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; #Economically, manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations. # The key point is that manufacturing adds value to the material by changing its shape or properties, or by combining it with other materials that have been similarly altered. # The words manufacturing and production are often used interchangeably. Production has a broader meaning than manufacturing. # Manufacturing Industries and Products: #Manufacturing is an important commercial activity performed by companies that sell products to customers. The type of manufacturing done by a company depends on the kind of product it makes. 1. Primary industries cultivate and exploit natural resources, such as agriculture and mining. 2. Secondary industries take the outputs of the primary industries and convert them into consumer and capital goods. 3. Tertiary industries constitute the service sector of the economy. A list of specific industries in these categories is presented the next Table #Manufactured Products: Final products made by the manufacturing industries can be divided into two major classes: consumer goods and capital goods. Consumer goods :are products purchased directly by consumers, such as cars, personal computers, TVs, tires, and tennis rackets. Capital goods: are those purchased by companies to produce goods and/or provide services. Examples of capital goods include aircraft, computers, communication equipment, medical apparatus, trucks and buses, railroad locomotives, machine tools, and construction equipment. #Manufacturing Considerations Manufacturing Considerations refer to the various factors or variables that can influence the manufacturing process of a product. There are specific factors to consider which include 1) Design for Manufacturability 2) Process Selection 3) Cost-Efficiency in Manufacturing (Economic Production 4. Applying Quality Control Methods in Manufacturing 5. Understanding Environmental Considerations in Manufacturing 1) Design for Manufacturability #Design Evaluation: A critical assessment of the design from the manufacturing perspective. It takes into account several factors such as geometric complexity and alignment with the chosen manufacturing process. #Material Selection: Chosen based on the product's functional requirement. The selection should also be favorable for the manufacturing process and cost effective. #Simplification of Design: Simplifying the parts where possible. A simpler design can lead to fewer complications during manufacturing and less potential for errors. #Standardize parts: Utilizing standardized parts where possible reduces the cost of products. #Prototype: Testing of the product through creation of a prototype before proceeding to full-scale manufacturing. This stage helps to identify and resolve any issues that could potentially surface. 2) Process Selection Process selection is the procedure of deciding on the most suitable manufacturing process for production based on factors such as material requirements, production volumes, and part geometry. Factors Influencing Process Selection in Manufacturing # Material Characteristics: The physical and chemical properties of the raw material have a significant impact on the choice of manufacturing process. # Product Design: The geometry and complexity of the product design also play a key role. Simple shapes might be produced through basic processes while more complex shapes may require advanced techniques. # Production Volume: The number of units to be produced can affect the choice of process. High-volume production often justifies the use of high-speed processes, while low-volume production may utilize more flexible processes. # Cost: The financial aspect is always a consideration, with a constant aim to achieve the lowest possible cost without compromising quality. 3) Cost-Efficiency in Manufacturing (Economic Production) The term "cost-efficiency" in the manufacturing sector refers to the ability to produce goods at the lowest possible cost, whilst maintaining a given level of product quality and meeting the required production capacity. Achieving cost-efficiency in production requires a systematic and strategic approach as follows: # Optimization of Production Processes: Simplifying and rearrangement of processes to eliminate wastage and down-time. This could be done by reducing material waste and minimizing energy consumption. # Automation: Automation of repetitive tasks, such as assembly or testing, can significantly reduce labor costs and minimize errors, leading to more considerable savings. # Preventive Maintenance: Regularly maintaining the machinery proactively can help reduce expensive breakdowns and improve machine performance. # Investment in Training: Training staff can help improve productivity, reduce mistakes and downtime, increase morale, which, in turn, can all contribute to lower production costs. # Inventory Management: Effective inventory management can minimize holding cost and other associated costs related to surplus stock 4. Applying Quality Control Methods in Manufacturing Numerous quality control methods are incorporated across all stages of the manufacturing process. Here are some commonly adopted quality control methods: # Statistical Process Control (SPC): SPC involves applying statistical methods to monitor and control a process. It's aimed at ensuring that the process operates efficiently, producing more specification-conforming products with less wastage. # Inspections : Regular inspections can catch deviations from standards and specifications in the production line early, preventing defective products from reaching customers. # Audits: Internal or external audits can be used to review an operating system's compliance with governing protocols and standards. # Control Charts: These are used to study how a process changes over time. Data points are plotted on a chart with predefined control limits. Any variations outside these limits imply a non-random process variation. 5. Understanding Environmental Considerations in Manufacturing Environmental considerations in manufacturing refer to the integration of ecologically friendly practices and strategies into the production steps. This involves several components which include, but are not limited to: # Resource Efficiency: This involves using raw materials, energy, and water as efficiently as possible to reduce environmental impact. # Waste Minimization: Implementing ways to reduce waste production and promote recycling and reuse of waste materials. #Emissions Control: Strategies to limit harmful emissions produced during manufacturing, promoting cleaner air and reducing the manufacturer's carbon footprint. #Energy Efficiency: Focusing on energy-saving manufacturing processes and facilities, using renewable energy sources, and reducing the overall energy consumption. #Safe Disposal of Waste: Ensuring the safe and environmentally-friendly disposal of manufacturing waste. Engineering Materials (MATERIAL IN MANUFACTURING): Most engineering materials can be classified into one of three basic categories: (1) metals, (2) ceramics, and (3) polymers. Their chemistries are different, their mechanical and physical properties are different, and these differences affect the manufacturing processes that can be used to produce products from them. In addition to the three basic categories, there are (4) composites-nonhomogeneous mixtures of the other three basic types rather than a unique category. The classification of the four groups shown in Figure 1) METALS Metals used in manufacturing are usually alloys, which are composed of two or more elements, with at least one being a metallic element. Metals and alloys can be divided into two basic groups: (1) ferrous and (2) nonferrous. Ferrous Metals Ferrous metals are based on iron; the group includes steel and cast iron. These metals constitute the most important group commercially, more than three fourths of the metal tonnage throughout the world. Pure iron has limited commercial use, but when alloyed with carbon, iron has more uses and greater commercial value than any other metal. Alloys of iron and carbon form steel and cast iron. Steel can be defined as an iron–carbon alloy containing 0.02% to 2.11%carbon. It is the most important category within the ferrous metal group. Its composition often includes other alloying elements as well, such as manganese, chromium, nickel, and molybdenum, to enhance the properties of the metal. Applications of steel include construction (bridges, I-beams, and nails), transportation (trucks, rails, and rolling stock for railroads), and consumer products (automobiles and appliances). Cast iron is an alloy of iron and carbon (2% to 4%) used in casting (primarily sand casting). Silicon is also present in the alloy (in amounts from 0.5% to 3%), and other elements are often added also, to obtain desirable properties in the cast part. Cast iron is available in several different forms, of which gray cast iron is the most common; its applications include blocks and heads for internal combustion engines. Nonferrous Metals Nonferrous metals include the other metallic elements and their alloys. In almost all cases, the alloys are more important commercially than the pure metals. The nonferrous metals include the pure metals and alloys of aluminum, copper, gold, magnesium, nickel, silver, tin, titanium, zinc, and other metals. 2. CERAMICS A ceramic is defined as a compound containing metallic (or semi-metallic) and nonmetallic elements. Typical nonmetallic elements are oxygen, nitrogen, and carbon. Ceramics include a variety of traditional and modern materials. Traditional ceramics, some of which have been used for thousands of years, include: clay (abundantly available, consisting of fine particles of hydrous aluminum silicates and other minerals used in making brick, tile, and pottery); silica (the basis for nearly all glass products); and alumina and silicon carbide (two abrasive materials used in grinding). Modern ceramics include some of the preceding materials, such as alumina, whose properties are enhanced in various ways through modern processing methods. Newer ceramics include: carbides—metal carbides such as tungsten carbide and titanium carbide, which are widely used as cutting tool materials; and nitrides—metal and semimetal nitrides such as titanium nitride and boron nitride, used as cutting tools and grinding abrasives. For processing purposes, ceramics can be divided into crystalline ceramics and glasses. Different methods of manufacturing are required for the two types. Crystalline ceramics are formed in various ways from powders and then fired (heated to a temperature below the melting point to achieve bonding between the powders). The glass ceramics (namely, glass) can be melted and cast, and then formed in processes such as traditional glass blowing. 3. POLYMERS A polymer is a compound formed of repeating structural units called mers, whose atoms share electrons to form very large molecules. Polymers usually consist of carbon plus one or more other elements, such as hydrogen, nitrogen, oxygen, and chlorine. Polymers are divided into three categories: (1) thermos-plastic polymers, (2) thermosetting polymers, Thermoplastic polymers can be subjected to multiple heating and cooling cycles without substantially altering the molecular structure of the polymer. Common thermos-plastics include polyethylene, polystyrene, poly vinyl chloride, and nylon. Thermosetting polymers chemically transform (cure) into a rigid structure on cooling from a heated plastic condition; hence the name thermosetting. 4. COMPOSITES Composites do not really constitute a separate category of materials; they are mixtures of the other three types. A composite is a material consisting of two or more phases that are processed separately and then bonded together to achieve properties superior to those of its constituents. The term phase refers to a homogeneous mass of material, such as an aggregation of grains of identical unit cell structure in a solid metal. The usual structure of a composite consists of particles or fibers of one phase mixed in a second phase, called the matrix. The synthesized type is of greater interest here, and it includes glass fibers in a polymer matrix, such as fiber-reinforced plastic; polymer fibers of one type in a matrix of a second polymer, such as an epoxy-Kevlar composite; and ceramic in a metal matrix, such as a tungsten carbide in a cobalt binder to form a cemented carbide cutting tool. Properties of a composite depend on its components, the physical shapes of the components, and the way they are combined to form the final material. Some composites combine high strength with light weight and are suited to applications such as aircraft components, car bodies, boat hulls, tennis rackets, and fishing rods. Other composites are strong, hard, and capable of maintaining these properties at elevated temperatures, for example, cemented carbide cutting tools. Manufacturing Processes A manufacturing process is a designed procedure that results in physical and/or chemical changes to a starting work material with the intention of increasing the value of that material. A manufacturing process is usually carried out as a unit operation, which means that it is a single step in the sequence of steps required to transform the starting material into a final product. Manufacturing operations can be divided into two basic types: (1) Processing operations A processing operation transforms a work material from one state of completion to a more advanced state that is closer to the final desired product. It adds value by changing the geometry, properties, or appearance of the starting material. In general, processing operations are performed on discrete work-parts. (2) Assembly operations An assembly operation joins two or more components to create a new entity, called an assembly, subassembly, or some other term that refers to the joining process. Define the manufacturing process with sketch? Give examples for Specific Industries in Primary, Secondary and Tertiary Categories. Differentiate between Consumer goods & Capital goods. What are the Manufacturing Considerations? The implementation of Design for Manufacturability involves a structured approach through the following key steps: ---------------------,---------------------,---------------------,-------- -------------,-------------- What is meant by production volume? The term "cost-efficiency" in the manufacturing sector refers to----------------------- The importance of inspections ------------------------ Show the classification of engineering materials Differentiate between ferrous and nonferrous metals with examples According the following image, define composites materials Name the following images: Manufacturing is an important commercial activity performed by companies that sell products to customers True False Primary industries cultivate and exploit natural resources, such as agriculture and mining True False Consumer goods are products purchased directly by Investors, such as cars, personal computers, TVs, tires, and tennis rackets True False Prototype: Testing of the product through creation of a prototype before proceeding to full-scale manufacturing True False The physical and chemical properties of the raw material is not important on the choice of manufacturing process True False