Lecture 2, Fundamentals of Manufacturing PDF

Lecture 2 Fundamentals of Manufacturing  Fundamentals of Manufacturing Basic manufacturing fundamentals: Materials: Understanding the properties and functionalities of different materials used in manufacturing (e.g., metals, plastics, composites). Processes: Knowledge of diverse man...

Lecture 2 Fundamentals of Manufacturing  Fundamentals of Manufacturing Basic manufacturing fundamentals: Materials: Understanding the properties and functionalities of different materials used in manufacturing (e.g., metals, plastics, composites). Processes: Knowledge of diverse manufacturing processes like machining, casting, forming, 3D printing, and assembly. Production Systems: Planning and managing efficient production flows, considering factors like scheduling, inventory control, and quality assurance. Manufacturing Management: Optimizing processes, resources, and personnel to achieve production goals. Quality Management: Establishing and maintaining quality standards throughout the production process.  Resources of Production Resources of production are inputs procured (purchased) from the outside and used in the production processes for the making of goods. The classical classification for resources of production from the economist’s viewpoint is into the following three groups: (1) land—natural resources; (2) labor—human effort (physical and mental); (3) capital—economic goods for reproduction (tools, machinery, factory, building, raw materials, etc.).  Resources of Production for Manufacturing Systems Resources of production for manufacturing systems are classified into the following four categories; (1) Production objects—materials on which activities of production are performed. They consist of: (a) primary materials—converted into products through the production processes, such as raw materials, parts, etc. that construct the products; (b) auxiliary materials—added to the primary materials—e.g., paints—or supplementary to their production—e.g., electricity and lubrication oils consumed in the process of production, light and air-conditioning which support the productive labor, and others.,  Resources of Production for Manufacturing Systems (2) Production means—media by which the raw materials are converted into products. They include: (a) direct production means or production facilities which directly work on raw materials—e.g., machines, equipment, apparatus, jigs and tools, materials-handling equipment, etc.; (b) indirect production means which do not directly run productive activities, such as land, buildings, warehouses, etc. (3) Productive labor—human ability, including the physical, spiritual, and mental ability of an individual worker, with which production activities are performed.  Resources of Production for Manufacturing Systems (4) Production information—knowledge/intelligence/know-how to implement effectively, i.e., efficiently and economically, the productive processes for manufacturing. It includes production methods—technical procedures for implementing the productive processes. These methods include: (a) production technology, which follows objective engineering laws including empirical rules; (b) production techniques, which are subjective skills gained by training of individuals wherein experiences and intuition are highly relied upon; (c) production knowledge-bases, which are expert systems based upon production rules.  Production Processes The production process is the process of conversion production resources, in particular, raw materials into tangible products.  Production Processes 1. Design and Product Development Concept and Planning: This involves ideating and planning the product's design, functionality, and feasibility. Prototyping: Creating a preliminary version of the product to test and refine the design.2. 2. Materials and Material Science Material Selection: Choosing appropriate materials based on the product requirements, including strength, flexibility, and durability. Material Properties: Understanding properties like tensile strength, hardness, and thermal conductivity to ensure they meet product specifications.  Production Processes 3. Manufacturing Processes Forming: Shaping materials through methods like casting, forging, and extrusion. Machining: Removing material from a workpiece using tools and machines (e.g., milling, turning, drilling). Joining: Assembling parts through welding, soldering, riveting, or adhesive bonding. Finishing: Enhancing the surface quality and appearance, including processes like painting, coating, and polishing. 4. Quality Control and Assurance Inspection and Testing: Ensuring that products meet specified standards and tolerances through various inspection methods. Quality Standards: Adhering to industry standards and regulations (e.g., ISO, ANSI) to ensure consistency and reliability.  Production Processes 5. Production Planning and Control Scheduling: Planning production runs, managing timelines, and optimizing resource use. Inventory Management: Controlling raw materials, work-in-progress, and finished goods to balance supply and demand. 6. Automation and Technology Automation: Implementing machinery and systems that perform tasks with minimal human intervention. Industry 4.0: Integrating advanced technologies like IoT, AI, and robotics to improve efficiency and data analytics in manufacturing.  Production Processes 7. Safety and Ergonomics Workplace Safety: Ensuring that manufacturing processes are safe for workers and comply with safety regulations. Ergonomics: Designing workspaces and processes to minimize physical strain and improve productivity. 8. Sustainability and Environmental Impact Waste Management: Minimizing and managing waste produced during manufacturing. Energy Efficiency: Reducing energy consumption and improving the sustainability of manufacturing processes. 9. Supply Chain Management Supplier Relationships: Managing relationships with suppliers to ensure timely and cost-effective procurement of materials. Logistics: Coordinating the movement and storage of materials and finished products.  Manufacturing Productivity Productivity is a measure of the effectiveness of the transformation process from raw material into final product, which is also defined as the ratio between input and output: 𝑰𝒏𝒑𝒖𝒕 Productivity = 𝑶𝒖𝒕𝒑𝒖𝒕 Examples: Individual Productivity: Tasks completed: Imagine you complete 10 tasks in 2 hours. Your productivity could be defined as 5 tasks per hour (tasks completed / time spent). Organizational Productivity: Units produced: A factory produces 1000 products in 8 hours. The productivity could be 125 products per hour (units produced / time spent).  Manufacturing Efficiency Efficiency is the capacity of performing a given task within the specified standard time. 𝑆𝑡𝑎𝑛𝑑𝑒𝑟𝑑 𝑡𝑖𝑚𝑒 Efficiency = X 100 (%) 𝐴𝑐𝑢𝑎𝑙 𝑡𝑖𝑚𝑒 If this figure exceeds 100, the manufacturing activity is efficient. Raising the efficiency depends upon two factors: (1) Subjective factors: (a)workers’ qualitative capability—skills, technical ability, etc. (b) workers’ quantitative capability—working effort, increase of working hours, etc. (2) Objective factors—technological innovation such as factory automation, enhancing the work environments (quality of working life), etc. Production Organization Industrial Engineering Role in Manufacturing The key functions of industrial engineers in manufacturing include: 1. Process Design and Improvement: Analyzing and optimizing production layouts: Evaluate current layouts, identify bottlenecks, and design efficient workflows that minimize movement and waste. Selecting and implementing production processes: Assess various manufacturing methods and equipment options, considering factors like cost, quality, and output quantity, to choose the most suitable approach for the specific product and production goals. Developing and implementing quality control systems: Establish procedures and metrics to ensure product consistency and adherence to quality standards. 2. Production Planning and Scheduling: Forecasting demand and planning production: Analyze historical data and market trends, forecast future demand, and establish production schedules that meet those requirements while optimizing resource allocation. Inventory management: Oversee inventory levels, ensuring sufficient materials are available for production without incurring unnecessary holding costs. Scheduling maintenance and downtime: Plan preventive maintenance schedules for equipment and facilities to minimize disruptions and ensure long-term operability. Industrial Engineering Role in Manufacturing 3. Ergonomics and Work-Study: Designing workstations and tasks for worker comfort and efficiency: Analyze worker movements and physical demands to design workstations that minimize fatigue and promote safety and productivity. Conducting time and motion studies: Observe and analyze work processes to identify opportunities for streamlining tasks and improving worker efficiency. 4. Data Analysis and Continuous Improvement: Collecting and analyzing production data: Gather data on various aspects of the production process, such as machine performance, production times, and defect rates. Identifying trends and areas for improvement: Analyze the data to identify trends, bottlenecks, and potential areas for improvement in efficiency, quality, and cost. Implementing continuous improvement initiatives: Develop and implement solutions to optimize the production process based on their data analysis, striving for ongoing improvement.