Industrial Materials and Processes Introduction PDF

INDUSTRIAL MATERIALS AND PROCESSES AN INTRODUCTION - PRODUCTION SYSTEM - PRODUCTION FACILITIES - LANGUAGE OF MANUFACTURING - PRODUCT LIFE CYCLE PREFACE  The standard of living in any society is determined, primarily, by the goods and services that are available to its people. I...

INDUSTRIAL MATERIALS AND PROCESSES AN INTRODUCTION - PRODUCTION SYSTEM - PRODUCTION FACILITIES - LANGUAGE OF MANUFACTURING - PRODUCT LIFE CYCLE PREFACE  The standard of living in any society is determined, primarily, by the goods and services that are available to its people. In most cases, materials are utilized in the form of manufactured goods. Converting materials from one form to another add value to them. The more efficiently materials can be produced and converted into the desired products that function with the prescribed quality, the greater the companies’ productivity and the better standard of living.  HISTORICAL PERSPECTIVE  Development and 35000 YEARS 1800 YEARS 3300 YEARS advancement of STONE AGE BRONZE AGE IRON AGE human societies is closely related with materials and its development 60 YEARS 50 YEARS 35 YEARS  Civilization have been CONCRETE/STEEL POLYMER AGE SILICON AGE AGE named based on the level of their material development 15 YEARS INFORMATION AGE Production System and Manufacturing System: Differentiated  Manufacturing is the economic term for making goods and services available to satisfy human wants. Manufacturing implies creating value by applying useful mental or physical labor.  The manufacturing process are collected together to form manufacturing system (MS).  The production system includes the manufacturing system and services it. Production system will refer to the total company and will include within it the manufacturing systems. Production system (PS)  a.k.a. production operation  include the following areas: systems Marketing and Sales Department  serve and support the Finance manufacturing processes and manufacturing system by Accounting Department providing and transmitting Personnel Department information, energy, knowledge, skills and services Research and Development to the plant areas, to the Design Engineering company’s vendors and to the Purchasing Department customers Production Planning and Scheduling Inventory Control Quality Control Plant Engineering Marketing and Sales Department  Provides information and services  Sales order information is central to concerning: production planning and control. it determine how many, how much, 1. Sales forecast of demand when, and what kinds of products or 2. Sales Order data services must be produced. 3. Customer quality requirements  Quality – concerned with the 4. Customer reliability requirements prevention of defects and the conformance to specifications at the 5. New products or modifications for same time the product is made or sold. existing products  Reliability – concerned with the 6. Customer feedback on products performance of the product or services 7. Customer service (repair or replace over time, while in service with the defective products) customer. Finance  involve management of the  Internal financing includes the review of company’s assets budgets for operating sections, evaluation of proposed capital investments for  Provides information and services production facilities and preparation of concerning the following financial statement. 1. Internal capital financing  Budgeting – allocation of financial 2. Budgeting resources. 3. Investment analysis  Investment analysis – for future company growth and expansion; rate of return, depreciation, sinking funds, payback periods and the like and the constantly changing tax structure, tax regulations and other financial legal matters. Accounting Department  Maintains the company’s financial  Cost accounting information records where money is used to indicates the level of efficiency of keep score on how the business various departments and the cost operates. of the products being manufactured  Provides information and services on the following: 1. Cost accounting 2. Special reports 3. Data processing Personnel  represent workforces of the company  provides information and services concerning 1. Recruitment 2. Training 3. Labor Relation 4. Safety Research and Development (R&D)  Involves invention or discovery and innovation and their development in terms od achievable ends, such as new materials, products, processes, tools and technique. Engineering  A staff functions in the production system  Provides information and services on the following 1. Product design engineering 2. Manufacturing engineering 3. Industrial engineering 4. Plant engineering 5. Quality engineering Procurement and Purchasing  Involves in the acquisition of specified materials, equipment, services and supplies in proper quality, in the correct quantities, at the best prices, at the correct time. Production Planning and Control  Translates sales forecast and/or order by part number.  The authority to manufacture the product is translated into master production schedule that specify the products to be manufactured, the quantity to be produced and the delivery date to the customer. Inventory Control  Reasons for having inventory:  Governs finished goods, raw materials, purchased components 1. Fluctuation in demand and/or and work-in-process within the supply factory. 2. Protection against process  The goal is to achieve a balance breakdowns between too little inventory (with 3. Replacement parts for lost batches possible stock outs of raw materials) or defective lots and too much inventory (with investment and storage space tied 4. Overproduction in anticipation of up) future demand 5. Protection from defective parts 6. Goods in transport 7. Just in case it is needed 8. Quantity purchasing  Manufacturing System  Collection of operations and processes used Materials to obtain a desired product or component Finished Components Machine Manpower  The actual Product conversion of Supplies input to output resulting to the desired product (value adding INPUT PROCESS OUTPUT processes)  Types of Manufacturing System  job shop - characterized by large varieties of components, general purpose machines, and a functional layout. This means that machines are collected by function and the parts are routed around the shop in containers to the various machines. The material on the cart or container is called the lot.  Flow shops - characterized by larger build quantities, special purpose machines, less variety, and more mechanization. Flow shop layouts are typically either continuous or interrupted. If continuous, they basically run one large- volume complex product in great quantity and nothing else. If interrupted, the line manufactures large quantities but is periodically “changed over” to run similar but different components.  linked- cell manufacturing system - composed of manufacturing cells connected together using a unique form of inventory and information control.  project shop - characterized by the immobility of the item being manufactured. The job shop usually supplies parts and sub assemblies to the project shops in small lots  continuous process - deals primarily with liquids, gases rather than solids or discrete parts. Job Shop Flow Shop Project Shop Continuous Process Linked Cells Types of Manufacturing System Characteristics Job Shop Flow Shop Project Shop Continuous Process Linked Cells Types of machine Flexible, general Single purpose, General purpose, Specialized, High Simple customized purpose single function mobile, manual technology single cycle automation Design of processes Functional or Product flow layout Project or fixed product U-shaped, process position layout sequenced to flow for family of parts, overlapping Set up time Long, variable, Long and complex variable Rare and expensive Short, frequent, one frequent touch Workers Single functioned; One function, low- Specialized, highly Skill level varies multifunctional highly skilled; one skilled, one worker- skilled worker –one one machine machine Inventories (WIP) Large inventory to Large to provide variable Very small small provide large buffer storage variety Lot sizes Small to medium Large lot Small lot Very large small Manufacturing lead Long, variable Short, constant time Long, variable lead Very fast, constant Short, constant time time  LANGUAGE OF MANUFACTURING OR PROCESS TECHNOLOGY  MACHINE or MACHINE TOOL- a specific piece of equipment designed to accomplish specific processes, often called a machine tool; machine tools link together to make a manufacturing system.  JOB (sometimes called a station) - a collection of operations done on machine or a collection of tasks performed by one worker at one location on the assembly line.  OPERATION (sometimes called a process)- a specific action or treatment, the collection of which make up the job of a worker.  TOOLS or TOOLING- refers to the implements used to hold, cut, shape, or deform the work materials; called cutting tools if referring to machining; can refer to jigs, and fixtures in workholding and punches and dies in metal forming.  Fabricating is the manufacture of a product from pieces such as parts, components or assemblies.  Processing is also used to refer to the manufacture of a product by continuous means, or by a series of continuous operations, for a specific purpose. **The terms fabricating industries and manufacturing industries are used when referring to fabricators or manufacturers of large products composed of many parts.  Roles of Engineer in Manufacturing  Design Engineer - better than any other person, should know what the design is to accomplish, what assumptions can be made about service loads and requirements, what service environment the product must withstand, and what appearance the final product is to have. It is thus apparent that design engineers are a vital factor in the manufacturing process, and it is indeed a blessing to the company if they can design for manufacturing, that is, design the product so that it can be manufactured and/ or assembled automatically  Manufacturing Engineers - select and coordinate specific processes and equipment to be used, or supervise and manage their use. Some design special tooling that is used so that the standard machines can be utilized in producing specific products. These engineer must have a broad knowledge of manufacturing processes and of material behavior so that the desired operations can be done effectively and efficiently without overloading or damaging machines and without adversely affecting the materials being processed.  Industrial or manufacturing engineers - who design (or layout) factories have the same concerns of the same interrelationship of design, the properties of the materials that the machines are going to process, and the interaction of the materials and the machines.  Materials engineers - devote their major efforts to developing new and better materials. They, too, must be concerned with low these materials can be processed and with the effects that the processing will have on the properties of the materials.  PRODUCT LIFE CYCLE 1. START- UP - New product or new company, low volume, small company. 2. RAPID GROWTH - Product becomes standardized and volume increases rapidly. Company’s ability to meet demand stresses its capacity. 3. MATURATION - Standard designs emerge. Process development is very important. 4. COMMODITY - Long- life, standard- of- the- industry type of product or 5. DECLINE. Product is slowly replaced by improved products Product Life Cycle Illustration: