OVERVIEW OF MANUFACTURING

After completing this chapter, students are expected to possess the following attributes:

1. Ability to Define Manufacturing: Students should be able to articulate what

manufacturing is and its role in the economy.
2. Understanding of Industry Types: Students will understand the different types of
industries (primary, secondary, and tertiary) and their significance.
3. Knowledge of Manufacturing Operations: Students will be able to differentiate
between various manufacturing operations, including job shop, batch, mass, and
continuous production.
4. Familiarity with Plant Layouts: Students will identify and describe different types of
plant layouts and their suitability for various manufacturing processes.
5. Comprehension of Manufacturing Processes: Students should be able to explain
different manufacturing processes, such as casting, machining, joining, forming, and
additive manufacturing.
6. Analytical Skills: Students will develop the ability to analyze the appropriate type of
manufacturing operation and layout for specific production needs.
7. Critical Thinking: Students will enhance their critical thinking skills by evaluating the
advantages and disadvantages of different manufacturing methods and layouts.
8. Application of Knowledge: Students should be able to apply their knowledge to real-
world scenarios, including selecting appropriate manufacturing processes for specific
products.

Definition of Manufacturing

Manufacturing can be defined two ways, one technologic and the other economic.

Technologic

 Manufacturing is the process of converting raw materials into finished products using
tools, machines, and labor.
 It involves a systematic process of production that adds value to raw materials.
 Can be classified into discrete manufacturing (e.g., car parts, electronics) and process
manufacturing (e.g., chemicals, food).

Economic

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  Economically, manufacturing is the transformation of materials into items of greater
value by means of one or more processing and/or assembly operations

2. Importance in the Economy

 Job Creation: Manufacturing industries provide employment opportunities at various

skill levels.
 Economic Growth: Manufacturing contributes to GDP by producing goods for local
use and export, stimulating trade.
 Technological Innovation: Manufacturing often drives innovation, as new processes,
materials, and techniques are developed.
 Supply Chain and Infrastructure Development: Manufacturing supports a network
of suppliers, distributors, and logistical services.
 Global Competitiveness: Countries with strong manufacturing sectors often
dominate global trade and enhance their economic influence.

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3. History and Evolution of Manufacturing

 Craftsmanship Era (Pre-18th Century): Skilled artisans made products by hand, with
minimal tools, and the production scale was small.
 Industrial Revolution (18th - 19th Century): Introduction of machinery and factories,
mass production techniques emerged, powered by steam engines and mechanized
systems.
 20th Century - Automation and Mass Production: Ford's assembly line
revolutionized the production of automobiles, leading to standardized products at lower
costs.
 Modern Era (Late 20th Century - Today): Introduction of robotics, automation, and
digital manufacturing systems like CNC machines and 3D printing. Concepts like Lean
Manufacturing and Industry 4.0 focus on efficiency, automation, and smart technology
integration.

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TYPE OF INDUSTRIES

Primary Industries

 Definition: Primary industries involve the extraction and harvesting of natural

resources.
 Examples:
o Mining: Extraction of minerals and metals (e.g., coal, gold, copper).
o Agriculture: Cultivation of crops and livestock production for food, fiber, and
other products (e.g., wheat, cattle, dairy).
o Forestry: Harvesting timber and non-timber forest products (e.g., rubber,
resins).
o Fishing: Catching fish and other aquatic organisms for consumption and trade.
 Significance: Provides raw materials for secondary industries and contributes to food
security and economic stability.

2. Secondary Industries

 Definition: Secondary industries process, manufacture, and assemble goods from raw
materials provided by primary industries.
 Examples:
o Manufacturing: Production of goods such as automobiles, electronics, and
textiles.
o Construction: Building infrastructure like roads, bridges, and buildings.
o Food Processing: Transforming raw agricultural products into consumable
goods (e.g., canned goods, frozen foods).
o Textile Production: Converting fibers into fabrics and garments.
 Significance: Adds value to raw materials, creates jobs, and drives economic growth.

3. Tertiary Industries

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 Definition: Tertiary industries provide services rather than goods, facilitating the
distribution and consumption of products.
 Examples:
o Retail: Selling goods directly to consumers through stores, e-commerce, etc.
o Healthcare: Providing medical services and care (e.g., hospitals, clinics).
o Education: Institutions that provide learning and training (e.g., schools,
universities).
o Finance: Banking, insurance, and investment services that support businesses
and individuals.
o Hospitality and Tourism: Services related to travel, accommodation, and
entertainment (e.g., hotels, restaurants).
 Significance: Essential for economic development, job creation, and improving the
quality of life by meeting consumer needs.

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TYPE OF MANUFACTURING OPERATIONS

Job Shop

 Definition: A job shop is a manufacturing operation that produces small quantities of

customized products, often tailored to specific customer requirements.
 Characteristics:
o High variety and low volume of products.
o Flexible equipment and skilled labor to handle diverse tasks.
o Production is typically organized by work centers or departments based on
processes (e.g., machining, assembly).
 Examples: Custom furniture, machine shops, specialized fabrication services.
 Advantages: Ability to customize products, adaptability to changing customer needs.
 Disadvantages: Longer lead times, higher production costs due to lower economies
of scale.

2. Batch Production

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  Definition: Batch production involves producing goods in groups or batches, where a
specific quantity of a product is made at one time before switching to another product.
 Characteristics:
o Moderate variety with moderate volume.
o Set-up times required when changing from one batch to another.
o Production process may involve multiple stages, with items moving through
various operations.
 Examples: Bakery products, clothing manufacturing, electronics assembly.
 Advantages: Greater flexibility than mass production, efficient use of resources, ability
to produce a range of products.
 Disadvantages: Downtime during changeovers, less efficient than mass production
for high-volume items.

3. Mass Production

 Definition: Mass production is a manufacturing process that produces large quantities

of standardized products, typically using assembly lines and automated machinery.
 Characteristics:
o High volume and low variety of products.
o Highly standardized processes with minimal customization.
o Production is often continuous or semi-continuous.
 Examples: Automobiles, consumer electronics, household appliances.
 Advantages: Economies of scale lead to lower per-unit costs, high efficiency, and
consistent product quality.
 Disadvantages: Limited flexibility, reliance on demand forecasting, risk of excess
inventory.

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TYPE OF PLANT LAYOUT

Process Layout

 Definition: A process layout, also known as a functional layout, groups similar

processes or machines together based on the functions they perform.
 Characteristics:
o Designed for flexibility to handle a variety of products.
o Workstations are arranged based on the sequence of operations required for
different products.
o Often used in job shops or batch production environments.
 Examples: Machine shops, hospitals (e.g., by department), print shops.
 Advantages: Flexibility to accommodate different products, easy to adapt to changes
in product design.
 Disadvantages: Longer material handling times, potential for bottlenecks, and higher
transportation costs.

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2. Product Layout

 Definition: A product layout, also known as an assembly line layout, arranges

equipment and workstations in a sequence that supports the flow of the production
process for a specific product.
 Characteristics:
o Typically used for mass production of standardized products.
o Each workstation is dedicated to a specific task, with a fixed sequence.
o Continuous flow of materials from one station to the next.
 Examples: Automobile assembly lines, electronics manufacturing, and canned food
production.
 Advantages: High efficiency, reduced handling time, and consistent product quality.
 Disadvantages: Inflexibility to changes in product design, potential for disruption if one
station fails.

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3. Fixed Position Layout

 Definition: In a fixed position layout, the product remains stationary, and workers,
materials, and equipment are brought to the location where the product is being
assembled or constructed.
 Characteristics:
o Used for large, heavy, or complex products that are difficult to move.
o Workers and resources are organized around the product.
o Often involves significant planning and coordination.
 Examples: Shipbuilding, aircraft assembly, construction sites.
 Advantages: Flexibility to customize large projects, minimized movement of large
products.
 Disadvantages: High complexity in scheduling, potential for inefficiencies due to
movement of materials and workers.

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4. Cellular Layout

 Definition: A cellular layout organizes workstations into small groups or "cells," each
responsible for a specific set of tasks or processes to produce a family of similar
products.
 Characteristics:
o Combines aspects of both process and product layouts.
o Each cell operates semi-autonomously, allowing for flexibility and teamwork.
o Designed to reduce waste and improve efficiency.
 Examples: Textile manufacturing, assembly of small electronic devices, machining
operations.
 Advantages: Reduced lead times, improved communication among team members,
enhanced quality control.
 Disadvantages: Requires careful planning and coordination, potential for
inefficiencies if cell design is not optimal.

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TYPE OF PROCESS

Casting

 Definition: Casting is a manufacturing process where molten material (usually metal

or plastic) is poured into a mold and allowed to solidify, forming the desired shape.
 Characteristics:
o Can produce complex geometries with good surface finishes.
o Suitable for large production runs or intricate parts.
o Common materials include metals (steel, aluminum) and plastics.
 Examples: Engine blocks, jewelry, sculptures.
 Advantages: Ability to create complex shapes, minimal machining required, and
efficient for large parts.
 Disadvantages: Potential for defects (e.g., voids, cracks), longer lead times due to
mold preparation.

2. Machining

 Definition: Machining is a subtractive manufacturing process that involves removing

material from a workpiece to achieve the desired dimensions and surface finish.
 Characteristics:
o Can be performed on various materials (metals, plastics, wood).
o Common methods include turning, milling, drilling, and grinding.
o High precision and tight tolerances can be achieved.
 Examples: Precision components for aerospace, automotive parts, and custom tools.
 Advantages: High accuracy, versatility in materials, and capability for complex
features.
 Disadvantages: Waste of material (due to cutting), slower production rates compared
to casting or forming.

3. Joining

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  Definition: Joining processes involve combining two or more materials to form a single
entity. This can be achieved through various techniques, such as welding, brazing,
soldering, and adhesive bonding.
 Characteristics:
o Can join similar or dissimilar materials.
o Techniques may be permanent or temporary, depending on the application.
o Requires consideration of joint design and material compatibility.
 Examples: Welding steel structures, soldering electronic components, adhesive
bonding in automotive applications.
 Advantages: Strong joints can be achieved, versatility in materials joined, and ability
to repair products.
 Disadvantages: Potential for joint defects, requires skilled labor for certain techniques
(e.g., welding).

4. Forming

 Definition: Forming processes shape materials (typically metals) by applying force to

deform them without removing material, often using tools or dies.
 Characteristics:
o Common methods include bending, stamping, forging, and extrusion.
o Can be performed at room temperature (cold forming) or elevated
temperatures (hot forming).
 Examples: Metal parts for vehicles, structural components, and kitchen utensils.
 Advantages: High strength due to work hardening, efficient production for large
volumes, and less waste compared to machining.
 Disadvantages: Equipment and tooling can be expensive, limited to certain materials.

5. Additive Manufacturing

 Definition: Additive manufacturing, commonly known as 3D printing, builds objects

layer by layer from digital models, adding material rather than removing it.
 Characteristics:
o Can use a variety of materials, including plastics, metals, and ceramics.
o Allows for complex geometries and customization.
o Techniques include Fused Deposition Modeling (FDM), Selective Laser
Sintering (SLS), and Stereolithography (SLA).
 Examples: Prototypes, custom medical implants, and aerospace components.

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 Advantages: Design flexibility, reduced material waste, and rapid prototyping
capabilities.
 Disadvantages: Slower production rates for large volumes, potential limitations in
material properties compared to traditional processes.

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METAL CASTING

Expandable Molds

 Definition: Expandable molds are single-use molds that are destroyed to remove the
cast part. Typically made of sand, plaster, or other materials.
 Processes:
o Sand Casting:
 The most common casting process.
 Uses sand mixed with a binder to form a mold.
 Molten metal is poured into the sand mold and allowed to cool and
solidify.
o Shell Molding:
 A variation of sand casting.
 The mold is created by applying a thin layer of resin-bonded sand to a
heated pattern, creating a thin, hard shell.
 Provides better surface finish and dimensional accuracy than traditional
sand casting.
o Investment Casting (Lost Wax):
 A wax pattern is coated with a refractory material to create a mold.
 The wax is melted out, leaving a cavity into which metal is poured.
 High precision and excellent surface finish, often used for complex and
small parts.
o Plaster Molding:
 Uses plaster as the mold material.
 Suitable for non-ferrous metals.
 Provides a smooth surface finish and good detail for intricate designs.
 Advantages:
o Good for complex geometries.
o Can accommodate a wide range of metals.
 Disadvantages:
o Molds are single-use, leading to higher costs in large-scale production.
o Mold-making can be time-consuming.

2. Permanent Molds

 Definition: Permanent molds are made of metal and used repeatedly to produce
multiple castings. These molds are typically made of steel or cast iron and can
withstand high temperatures.
 Processes:
o Gravity Die Casting:
 Molten metal is poured into a permanent metal mold by gravity.
 Suitable for non-ferrous metals like aluminum and magnesium.
 Provides better surface finish and faster cooling rates than sand
casting.
o Pressure Die Casting:
 Molten metal is injected into a mold under high pressure.
 Often used for high-volume production of small to medium-sized parts.
 Excellent dimensional accuracy and surface finish.
o Centrifugal Casting:
 The mold is rotated rapidly around its axis, and molten metal is poured
in.
 Used to produce hollow cylindrical parts like pipes and tubes.
 The centrifugal force pushes the metal against the mold wall.

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 o Continuous Casting:
 A method used to produce long lengths of metal products by
continuously pouring molten metal into a mold while the solidified
portion is extracted.
 Commonly used for metals like steel, aluminum, and copper alloys.
 Advantages:
o High production rates with reusable molds.
o Superior surface finish and dimensional accuracy.
o Good for mass production.
 Disadvantages:
o High initial cost for mold fabrication.
o Limited to simpler geometries compared to expandable molds.

3. Casting Defects

 Common Defects:
o Porosity:
 Gas trapped in the molten metal forms bubbles in the cast part, resulting
in voids.
 Can weaken the material and reduce surface finish quality.
 Causes: Improper degassing, excessive moisture in molds, or
excessive metal turbulence.
o Shrinkage:
 Occurs when the metal shrinks as it cools, causing cavities in thicker
sections of the casting.
 Causes: Inadequate feeding of molten metal into the mold during
solidification.
o Cold Shuts:
 Two streams of molten metal fail to fuse together during casting, leaving
a weak seam.
 Causes: Low pouring temperature or slow pouring speed.
o Misruns:
 The molten metal solidifies before completely filling the mold cavity,
resulting in incomplete castings.
 Causes: Low metal temperature, poor fluidity, or improper mold design.
o Mold Shift:
 Occurs when the top and bottom halves of the mold are misaligned,
leading to an offset in the casting.
 Causes: Poor mold assembly or improper clamping during casting.
o Hot Tears (Cracks):
 Form when the metal contracts during cooling, leading to cracks in the
part.
 Causes: Poor design (sharp corners), uneven cooling, or material
properties.

4. Process Comparison

 Expandable Molds:
o Ideal for complex, low-volume, and intricate designs (e.g., turbine blades,
sculptures).
o Higher flexibility in mold design and material choice.
 Permanent Molds:
o Best suited for high-volume production of simpler parts (e.g., automotive
components, pipes).

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 o Higher efficiency and repeatability once the mold is made.

5. Process Selection Considerations

 Part complexity: Expandable molds for complex shapes, permanent molds for
simpler, repetitive parts.
 Material type: Most casting processes can handle a wide range of materials; however,
permanent molds are generally limited to non-ferrous metals.
 Production volume: Permanent molds are cost-effective for high-volume production,
while expandable molds are ideal for low-volume or specialized parts.

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