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Introduction to Industrial Materials and Processes …requires a sound and broad understanding of materials, processes, and equipment on the part of the decision makers, …accompanied by an understanding of the manufacturing systems University of Santo Tomas Industrial Engineering Department Faculty of Engineering Learning Objectives Describe the course of Industrial Materials and Processes as a scientiﬁc discipline Understand and appreciate the challenges and complexities involved in the design and construction of a product (all major classes of materials) Introduce the broad spectrum of manufacturing processes to individual who will be involved in the design and manufacture of ﬁnished products Learning Objectives Provide a good theoretical background and a sound practical knowledge to the engineering students Be aware of the following terms for better understanding of the scope of the study Introduction All of us live in a world of dynamic change, and materials are no exception. The advancement of civilization has historically depended on the improvement of materials to work with.  Over time, they moved from the materials Stone Age into the newer Copper (Bronze) and Iron Ages.  Today’s competitive manufacturing era of high industrial development and research, is being Introduction called the age of mechanization, automation and computer integrated manufacturing. Manufacturing is the backbone of any industrialized nation. Since products require materials, engineers should be knowledgeable about the internal structure and properties of materials so that they can choose the most suitable ones for each application and develop the best processing methods. History of Materials The development of materials and man’s ability to process them is linked to the history of man  Stone Age  Copper and Bronze Age  Iron Age  Steel Age The current age is that of plastics, composite materials, and exotic alloys Introduction Manufacturing and technical staﬀ in industry must know the various manufacturing processes, materials being processed, tools and equipment for manufacturing diﬀerent components or products with optimal process plan using proper precautions and speciﬁed safety rules to avoid accidents. Introduction Future engineers must know the basic requirements of manufacturing activities in terms of man, machine, material, methods, money and other infrastructure facilities needed to be positioned properly for optimal shop layouts or plant layout and other support services eﬀectively adjusted or located in the industry or plant within a well planned manufacturing organization. Introduction In many cases what was impossible yesterday is a reality today!  Thirty years ago, many people would not have believed that some day computers would become a common household item similar to a telephone or a refrigerator.  And today, we still ﬁnd it hard to believe that some day space travel will be commercialized and we may even colonize Mars. Introduction Nevertheless, science and engineering push and transform our most unachievable dreams to reality. New Researchers in the Manufacturing Field The advancement has come to this extent that every diﬀerent aspect of this technology has become a full-ﬂedged fundamental and advanced study in itself.  This has led to introduction of optimized design and manufacturing of new products.  New developments in manufacturing areas are deciding to transfer more skill to the machines for considerably reduction of manual labor. New Researchers in the Manufacturing Field  It speciﬁes the need of greater care for man, machine, material and other equipment involving higher initial investment by using proper safety rule and precautions. Materials, Manufacturing, and the Standard of Living Standard of living of a society is determined by the goods and services that are available to its people Manufactured goods  Producer goods: Intermediate goods used to manufacture either producer or consumer goods  Consumer goods: Purchased directly by the consumer Product Development Sustaining technology:  Innovations bring more value to the consumer  Improvements in materials, processes, and design Product growth normally follows the “S” curve Figure 1-1a) A product development curve Simpliﬁed Steps of the Product Life Cycle Start up—new product or new company, low volume, small company Rapid Growth—products become standardized and volume increases rapidly. Company’s ability to meet demand stresses its capacity Maturation—standard designs emerge. Process development is very important. Simpliﬁed Steps of the Product Life Cycle Commodity or Declined  Commodity—long-life, standard-of-the-industry type of product or  Decline—product is slowly replaced by improved products Figure 1-15 Product life- cycle costs change with the classic manufacturing system designs. The stage of the product life cycle aﬀects --the product design stability, --the length of the product development cycle, --the frequency of Note: All of which engineering have implications change orders, for manufacturing and process --the commonality technology of components Interactive Factors in Manufacturing Factors  Product design  Materials  Labor costs  Equipment Figure 1-2  Manufacturing costs Manufacturing cost is the largest part of the selling price, Strategies to reduce usually around 40%. cost The largest part of the manufacturing  Lean manufacturing cost is materials, usually 50%.  Systems approach Materials and Processes Manufacturing cost is the largest cost in the selling price.  The largest manufacturing cost is material costs, not direct labor. Materials, men, methods, and equipment are interrelated factors in manufacturing that must be combined properly to achieve low cost, superior quality, and on-time delivery. Materials and Processes Materials to be used must be selected and speciﬁed to meet the design engineer’s requirements. Must have a broad knowledge of manufacturing processes and of material behavior so that desired operations can be done eﬀectively and eﬃciently without overloading or damaging machines and without adversely aﬀecting the materials being processed Materials and Processes The elements of design, materials, and processes are closely related, each having its eﬀect on the others. A design change would have a signiﬁcant impact on the entire manufacturing process and on the cost. Key to Success: To build a Manufacturing system that can deliver on time to the customer, superior- quality goods at the lowest possible cost in a ﬂexible way. Manufacturing and Production Systems Goods  Material things Services  Nonmaterial things Service Production Systems (SPSs)  Nonmaterial systems that do not provide a product (i.e. banking, health care, education, etc.) Manufacturing and Production Systems Manufacturing is the ability to make goods and services to satisfy societal needs  Manufacturing processes are strung together to create a manufacturing system (MS) Production system is the total company and includes manufacturing systems Figure 1-3 The manufacturing system converts inputs to outputs using processes to add value to the goods for the external customer. Manufacturing and Production Systems Production System--process of converting or transforming raw materials in manufacturing the right products for the right customers, at the right quality , right quantity, right location at the least possible cost (Satisfy the customer). Manufacturing System--process of conversion or transforming raw materials into usable products at the least possible cost. Figure 1-4 The functions and systems of the production system, which includes (and services) the manufacturing system. The functional departments are connected by formal and informal information systems designed to service the manufacturing system that produces the goods. Production System- The Enterprise Production systems include  People  Money  Equipment  Materials  Supplies  Markets  Management  Manufacturing System  All aspects of commerce Manufacturing Systems Manufacturing systems  Collection of operations and processes to produce a desired product or component  Design or arrangement of the manufacturing processes Manufacturing processes  Converts unﬁnished materials to ﬁnished products Often is a set of steps  Machine tool is an assembly that produces a desired result Basic Manufacturing Processes Casting, foundry, or molding process Forming or metalworking processes Machining (material removing/removal) processes Joining and assembly Surface treatments (ﬁnishing) Rapid prototyping Heat treating 7 Basic Machining Processes Shaping Drilling Turning Milling Sawing Broaching Abrasive Machining 8 Basic Types of Machine Tools Shapers (Planers) Drill Presses Lathes Boring Machines Milling Machines Saws Broaches Grinders Common Aspects of Manufacturing Job and station  Job is a group of related operations generally done at one station  Station is the location or area where production is done Operations  Distinct action to produce a desired result or eﬀect  Categories of operations Materials handling and transport Processing Packaging Inspecting and testing Storing Common Aspects of Manufacturing Treatments operate continuously on a workpiece  Heat treating, curing, galvanizing, plating, ﬁnishing, chemical cleaning, painting Tools, tooling and workholders  Lowest mechanism in the production is a tool Used to hold, shape or form the unﬁnished product Tooling for measurement and inspection  Rulers, calipers, micrometers, and gages  Precision devices are laser optics or vision systems that utilize electronics to interpret results Products and Fabrications Products result from manufacture  Manufacturing can be from either fabricating or processing Fabricating is the manufacture of a product from pieces such as parts, components, or assemblies Processing is the manufacture of a product by continuous operations Workpiece and its conﬁguration  Primary objective of manufacturing is to produce a component having a desired geometry, size, and ﬁnish Roles of Engineers in Manufacturing Design engineer responsibilities  What the design is to accomplish  Assumptions that can be made  Service environments the product must withstand  Final appearance of the product  Product designed with the knowledge that certain manufacturing processes will be used Roles of Engineers in Manufacturing Manufacturing engineer responsibilities  Select and coordinate speciﬁc processes and equipment  Supervise and manage their use Industrial (Manufacturing) engineer  Manufacturing systems layout Materials engineers  Specify ideal materials  Develop new and better materials 3 Major Changes in the World of Goods Manufacturing Worldwide or global competition Advanced technology New manufacturing systems structure, strategies, and management Changing World Competition Globalization has impacted manufacturing  Worldwide competition for global products and their manufacture  High tech manufacturing for advanced technology  New manufacturing systems, designs, and management Manufacturing Systems Designs Job shop is characterized by large varieties of components, general-purpose machines, and a functional layout.  Machines are collected by function.  Material is moved from machine to machine in carts or containers and is called the lot or batch.  To be the least cost-eﬃcient of all the systems because of its design Manufacturing Systems Designs Flow shop are characterized by larger volumes of the same part or assembly, special-purpose machines and equipment, less variety, less ﬂexibility, and more mechanization.  Common light bulb  A transfer line producing an engine block  If interrupted, the line manufactures large lots but is periodically “changed over” to run a similar but diﬀerent component. Manufacturing Systems Designs Linked-cell shop is composed of manufacturing and subassembly cells connected to ﬁnal assembly (linked) using a unique form of inventory and information control called Kanban.  Used in lean production systems where manufacturing processes and subassemblies are restructured into U-shaped cells so they can operate on a one-piece-ﬂow basis, like ﬁnal assembly. Manufacturing Systems Designs Project shop is characterized by the immobility of the item being manufactured.  In the construction industry, bridges and roads  In the manufacture of goods, large airplanes, ships, large machine tools, and locomotives  Workers, machines, and materials come to the site  Job shop usually supplies parts and subassemblies to the project shop in small lots. Manufacturing Systems Designs Continuous process are used to manufacture liquids, oils, gases, and powders.  Usually large plants producing goods for other producers or mass-producing canned or bottled goods for consumers. Figure 1-7 Schematic layouts of factory designs:. Other Manufacturing Operations Testing Transportation Automation Removal of material waste Packaging Storage Characteristics of Process Technology Mechanics (static or dynamic) Economics or costs Time Spans Constraints Uncertainties and process reliability Skills Flexibility Process capability New Manufacturing Systems Toyota Production System  Lean manufacturing system  100% good units ﬂow without interruption  Integrated quality control  Responsibility for quality is given to manufacturing  Constant quality improvement World Class Manufacturing (WCM) RAPID e.g., TOYOTA Cycle Time 64 days 32 days 16 days 8 days 4 days 30 minutes World Class Manufacturing (WCM) Is it a Philosophy? Concept? System? Method? Techniques? Tool? World Class Manufacturing (WCM) A concept of continual rapid improvement Everything we do, it should be viewed as a process-there is always a better way. Time-Based Manufacturing—the faster customer lead time the better How do we measure leadtime? WCM measures the reduction in customer, production, and manufacturing’s lead time. Manufacturing Systems and Production Volumes Figure 1-17 This ﬁgure shows in a general way the relationship between manufacturing systems and production volumes. 5 Major Dimensions Quality Cost Lead Time – Responsiveness Flexibility – Flexibility Customer Satisfaction Summary Economical and successful manufacturing requires knowledge of the relationships between labor, materials, and capital Design a manufacturing system that everyone understands Engineers must possess a knowledge of design, metallurgy, processing, economics, accounting, and human relations Summary Giving a great deal of attention to design, selection of materials, selection of processes, selection of equipment used for manufacturing (tooling), and utilization of personnel could such a result be achieved Back Up University of Santo Tomas Industrial Engineering Department Faculty of Engineering Joining Processes Mechanical fastening Soldering and brazing Welding Press, shrink, or snap ﬁttings Adhesive bonding Assembly processes Surface Treatments Finishing operations Cleaning Removing burrs left by machining Providing protective/decorative surfaces  Painting  Plating  Buﬃng  Galvanizing  Anodizing

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