Production of Materials- IPM Master Program PDF

Production of Materials IPM Master program Assoc. Prof. Dr Ayham Al Rahawi ASFChemEng, Sen. Application Spec., P.Eng., Ph.D & M.Sc Chem. Eng. Manchester Univ. ‘UMIST,’ B.Sc Baghdad Univ. Chem & Eng, B.Sc Ind. Chemistry Mosul Univ.  CHAPTER 1 Manuf...

Production of Materials IPM Master program Assoc. Prof. Dr Ayham Al Rahawi ASFChemEng, Sen. Application Spec., P.Eng., Ph.D & M.Sc Chem. Eng. Manchester Univ. ‘UMIST,’ B.Sc Baghdad Univ. Chem & Eng, B.Sc Ind. Chemistry Mosul Univ.  CHAPTER 1 Manufacturing and Production Engineering  Manufacturing and Production Engineering Manufacturing and Production Engineering is a field that combines principles of engineering, technology, and management to design, analyze, and improve manufacturing systems and production processes. It plays a crucial role in transforming raw materials into finished products efficiently and cost-effectively while ensuring quality, sustainability, and the safety of workers. Manufacturing and Production Engineers work across various industries, including automotive, aerospace, electronics, pharmaceuticals, consumer goods, and more. Their work involves planning, optimizing, and controlling all activities related to production processes. Factors influence the production of materials: Several factors influence the production of materials, particularly in industrial and manufacturing processes. These factors can affect the quality, cost, efficiency, and sustainability of material production. Below are the key factors: 1. Raw Material Availability Quality and Purity: The quality and composition of raw materials significantly impact the production process. Impurities in raw materials may require additional processing, leading to increased costs and production time. Supply Chain: The availability and timely supply of raw materials are crucial for uninterrupted production. Disruptions in the supply chain can halt production or lead to increased prices for materials. Sustainability: Availability of sustainable or renewable raw materials is increasingly important, especially in industries moving toward green production practices. 2. Technology and Equipment Automation: The level of automation and the use of advanced technologies (e.g., robotics, AI, or IoT in smart factories) can enhance production speed, accuracy, and efficiency. Machinery Efficiency: The type and efficiency of machinery used in production determine the output rate and energy consumption. Newer, more efficient machines may reduce downtime and waste. Innovation: Technological advancements, such as new methods of processing or refining materials (e.g., additive manufacturing or advanced electrolysis techniques), can improve production processes. 3. Energy Consumption Energy Source: The cost and availability of energy sources (e.g., electricity, coal, gas, or renewable energy) have a direct impact on production costs. Energy-intensive processes like smelting or chemical reactions rely heavily on affordable and abundant energy. Energy Efficiency: Efficient energy use reduces overall costs and environmental impact. Factories that adopt energy-saving technologies or processes tend to have a competitive advantage. 4. Labor and Expertise Skilled Workforce: The availability of a skilled and trained workforce affects the productivity and quality of the materials produced. Complex production processes often require specialized knowledge and expertise. Labor Costs: Wages, labor regulations, and local labor market conditions can significantly influence production costs. Automation vs. Manual Labor: The balance between human labor and automation affects the overall production efficiency and cost. Highly automated systems may reduce the need for manual labor but require significant capital investment. 5. Environmental Regulations Emissions and Waste: Governments enforce regulations that limit emissions, waste disposal, and other environmental impacts of material production. Complying with environmental laws can increase production costs, but it is necessary for sustainable operations. Sustainability Practices: Companies are increasingly adopting eco-friendly practices, including recycling, using renewable energy, and minimizing waste, to meet regulatory requirements and public expectations. 6. Economic Factors Market Demand: Production is often adjusted based on current and future demand for materials. When demand increases, production scales up, and vice versa. Costs of Inputs: The price of raw materials, energy, and labor affects the overall cost of production. Fluctuations in global markets, such as changes in oil prices or metal prices, can have a significant impact. Capital Investment: High initial investments in production facilities, machinery, and technology affect the overall production cost. Companies with access to better capital often have an advantage in optimizing production processes. 7. Process Efficiency Production Methods: The specific methods used to produce materials, whether through batch processing, continuous flow, or just-in-time manufacturing, affect the efficiency and speed of production. Process Optimization: Lean manufacturing, Six Sigma, and other process optimization strategies can reduce waste and increase production speed, improving overall efficiency and profitability. 8. Material Properties Chemical and Physical Properties: The inherent properties of the materials being produced, such as strength, ductility, thermal stability, and conductivity, affect the processes used in production and the final application of the material. Handling and Processing: Certain materials may require specific conditions (e.g., temperature, pressure, atmosphere) for production, which can increase the complexity and cost of production. 9. Supply Chain Management Logistics and Transportation: Efficient transportation and logistics systems are essential for delivering raw materials to production facilities and finished products to consumers. Poor logistics can lead to delays, higher costs, and material shortages. Inventory Management: Proper management of raw material and finished goods inventory ensures smooth production flow and minimizes waste. 10. External Factors Geopolitical Issues: Trade restrictions, tariffs, or political instability in regions where raw materials are sourced can disrupt material production and increase costs. Climate and Natural Disasters: Weather conditions and natural disasters can impact the availability of materials (e.g., mining operations) or affect the production process (e.g., energy availability or facility damage). Global Economic Trends: Global economic conditions, including inflation, recession, or technological disruptions, can affect the demand for materials and the cost structure of production. 11. Research and Development (R&D) Innovation in Materials: Research into new materials or improved methods of producing existing materials can lead to increased efficiency, reduced costs, or better performance in end products. Sustainability Focused R&D: Efforts to develop eco-friendly or alternative materials to replace traditional ones are essential for future material production, particularly in light of environmental and regulatory pressures. 12. Quality Control Standards and Testing: Maintaining high-quality standards through rigorous testing and quality control is essential for ensuring that the produced materials meet the required specifications. Defect Reduction: Reducing defects in materials and production errors helps minimize waste and improves overall efficiency.  Key Areas of Manufacturing & Production Engineering 1. Manufacturing Processes: When engineers manufacturing any part for a machine or industrial device, it is essential to thoroughly understand the basic properties of each part and the materials used. This knowledge plays a critical role in ensuring the functionality, reliability, and safety of the final product. Manufacturing processes can be broadly classified into the following categories: Casting: Involves pouring molten material (metal, plastics, etc.) into a mold to shape it after cooling. Machining: Removes material from a workpiece using tools like lathes, drills, or milling machines. Forming: Changes the shape of a material by applying force, such as in forging, stamping, or bending. Joining: Combines two or more materials using methods such as welding, brazing, or adhesives. Additive Manufacturing: Builds objects layer by layer, often using 3D printing technologies. 2. Production Planning and Control: This area deals with planning, scheduling, and controlling manufacturing processes to ensure efficient production. Key concepts include: Production Planning: Involves determining what to produce, how to produce it, and when to produce it to meet demand forecasts. Inventory Control: Manages materials and finished goods to avoid shortages or excess stock. Quality Control: Ensures that products meet specified standards through various testing methods and inspections. Lean Manufacturing: Focuses on eliminating waste in production processes to improve efficiency and reduce costs. 3. Automation and Robotics: Automation and robotics have transformed modern manufacturing. Automated systems and robots increase precision, speed, and safety in manufacturing processes. They are particularly useful in repetitive tasks, hazardous environments, or areas requiring high precision, such as in the production of electronic components. CNC (Computer Numerical Control): Machines are automated using pre-programmed sequences, allowing for precision and repeatability in manufacturing. Industrial Robots: Robots are commonly used in applications like welding, painting, assembly, and material handling. 4. Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM): CAD and CAM tools are widely used in manufacturing to design products and plan production processes. CAD: Involves using computer software to create detailed designs and models of products before they are manufactured. CAM: Uses software to control machines and tools in the manufacturing process, reducing errors and increasing production speed. 5. Sustainability and Green Manufacturing: With increasing environmental concerns, manufacturing engineers focus on sustainable manufacturing practices. Green manufacturing involves reducing waste, energy consumption, and the environmental impact of production processes. Energy-efficient Processes: Implementing methods to reduce energy usage during production. Waste Reduction: Recycling materials and reducing waste throughout the product lifecycle. Eco-friendly Materials: Using sustainable or recyclable materials to reduce environmental harm. New development and innovations in Manufacturing & Production Engineering 1. The fourth industrial revolution: Industry 4.0 represents the fourth industrial revolution, characterized by the integration of digital technologies such as IoT (5G), big data, and smart factories into manufacturing processes. This enables more efficient, flexible, and automated production systems. 2. Additive Manufacturing (3D Printing): Additive manufacturing allows for the creation of complex, customized products with less material waste. 3D printing is becoming increasingly important in industries such as aerospace, medical devices, and prototyping. 3. Artificial Intelligence and Machine Learning: AI and machine learning are used to predict equipment failures, optimize production schedules, and improve product quality. These technologies enable predictive maintenance and process optimization, reducing downtime and increasing efficiency. 4. Nanotechnology and manufacturing: Nanotechnology involves manipulating materials at the atomic or molecular scale to create products with enhanced properties. Nanomanufacturing is used in industries like electronics, medical devices, and materials science to produce smaller, faster, and more efficient components. Challenges in Manufacturing and Production Engineering: 1. Globalization and Competition: Manufacturing engineers face increased competition from global markets. They must balance cost efficiency, quality, and lead times while competing with low-cost manufacturing regions. 2. Technological Advancements: Rapid advancements in technology require engineers to stay updated with the latest manufacturing techniques, such as Industry 4.0, smart manufacturing, and the integration of the Internet of Things (IoT) in production systems. 3. Labor and Skills Shortage: The shift toward automation and advanced technologies requires a workforce with specialized skills. There is often a gap between the demand for highly skilled engineers and the availability of such workers. 4. Sustainability Pressures: As industries move toward more sustainable practices, production engineers are challenged to develop processes that reduce energy consumption, waste, and emissions. This requires significant investments in research, new technologies, and production system redesigns.  TYPES OF PRODUCTION Depending upon the scale of production and the kind of product, the production can be classified as: The following are the major types: 1 Job Production Job production is a system where products are manufactured according to customer specifications. Each product is unique, and production is typically done on a small scale. Examples include shipbuilding, specialized machinery, and custom-designed machine. The advantages: High customization, flexibility, and quality. The Disadvantages: High cost per unit, longer production time, and less efficiency for large-scale needs. 2. Batch Production Batch production involves producing goods in specific quantities, or "batches." Each batch undergoes the complete production process before the next batch starts. It is often used for moderate production volumes, such as in food processing, pharmaceuticals, or apparel manufacturing. Advantages: Economies of scale, flexibility in design changes between batches. Disadvantages: Idle times between batches, lower efficiency compared to mass production. 3. Mass Production Mass production is a system designed for the large-scale, continuous production of standardized goods. This method is used in industries such as automobile manufacturing, consumer electronics, gasoline and household appliances, where products are made in high volume. Advantages: High efficiency, low cost per unit, faster production times. Disadvantages: Inflexibility in product design, high initial investment in machinery. 4. Continuous Production Continuous production is an advanced production system that operates without interruption. It is common in industries such as oil refining, chemical production, and electricity generation. The system involves a constant flow of materials through highly automated and often computer- controlled processes. Advantages: Extremely high efficiency, low operational costs, and minimal waste. Disadvantages: High setup costs, inflexibility, and limited ability to handle product variation. Choice of continuous versus batch production The following rules can be used as a guide. Continuous 1. Production rate greater than 5 x 106 kg/h 2. Single product 3. No severe fouling 4. Good catalyst life 5. Proven processes design 6. Established market Batch 1. Production rate less than 5 x 106 kg/h 2. A range of products or product specifications 3. Severe fouling 4. Short catalyst life 5. New product 6. Uncertain design 20  Production Systems A production system is the framework that describes; 1. The process, 2. The methods, and 3. The technologies involved in transforming raw materials into finished goods. These systems are the backbone of manufacturing industries, Production system ensure that the necessary products are produced; 1. In the right quantity, 2. At the right time, and with 3. At the required quality. The primary focus of any production system is; 1. to efficiently manage resources like labor, materials, machinery, and information. 2. to achieve optimal productivity. Components of a Production System A production system consists of several key components that work together to ensure the seamless transformation of raw materials into finished goods. These include (as in the figure): 1 Input: The input stage includes raw materials, human resources, energy, and equipment. This stage is critical because the quality and availability of inputs directly affect production efficiency and output quality. 2 Process: The process involves the transformation of inputs into outputs. It includes all activities required to manufacture the product, such as machining, assembling, and testing. This is the most critical part of the production system and often involves advanced technologies and process optimization techniques. 3 Output: The output is the final product or service delivered to the customer. The effectiveness of a production system is measured by how well the output meets customer specifications in terms of quality, quantity, and delivery time. 4 Feedback Mechanism: A feedback mechanism is essential for monitoring the production process and ensuring it meets quality standards. This system enables manufacturers to adjust processes, reduce defects, and improve efficiency.  Accordingly, for any flow system; Process Output Input SYSTEM Input : Enters into the system boundaries Process SYSTEM; Any industrial unit (s) Output : Leaves out of the system boundaries Primary: Felder, R. M. and Rousseau, R. W. , Elementary Principles of Chemical Processes (3rd Edition), John Wiley & Sons, Inc. Himmelblau, D.M., Basic Principles and Calculations in Chemical Engineering, 8th Edition, Prentice Hall, 2004. ISBN -13-123368-8, p.101 Starting Industrial process design The major activities are: a) Collect data, (Library, Books, Search sites) b) Select process, c) Know how to select and analyze data. d) Be familiar with design steps. Steps for Project Design: 1. Processes & Process selection 2. Flow sheet: 3. Estimate plant production rate 4. Mass and energy Balance 5. Process equipment design 6. Plant Location (discuss in chapter 2) 7. Plant & equipment layout (discuss in chapter 2) 8. Control system 9. Process economics (Feasibility study and cost estimation) Dr Ayham Al Rahawi 24  Processes & Process selection There are sometimes different processes to the same product. Which process is to be selected? a) Simplicity b) Raw material: 1. Availability 2. Cost 3. Pre-treatment c) Productivity of process d) Yield, conversion of process e) Byproducts f) Purity of products f) Pollution g) Power consumption h) Process hazards i) Safety analysis methods Engg plant / Dr Ayham Al Rahawi 25  PRODUCTIVITY Productivity is the ratio of what is produced to what is required to produce it. Or it define as “a measure of economic performance that compares the amount of goods and services produced (output) with the amount of inputs used to produce those goods and services.” Usually this ratio expressing the total output of some category of goods divided by the total input of raw materials. PRODUCTION AND PRODUCTIVITY Production and productivity are two different words with different meaning. Production refers to quantity of production while productivity means the efficient use of resources consumed for achieving that production. Resources are of several types; 1.material, 2. men, 3. machine hours, 4. energy consumed, 5. space utilised. END