INTRODUCTION AND

OVERVIEW OF MANUFACTURING

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems

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 What is Manufacturing?
 The word manufacture is derived from two Latin words
manus (hand) and factus (make); the combination means
“made by hand”
 “Made by hand” accurately described the fabrication
methods that were used when the English word
“manufacture” was first coined around 1567 A.D.
 Manufacturing in its comprehensive sense, is the process of
converting raw materials into finished products.
 Most modern manufacturing operations are accomplished
by mechanized and automated equipment that is
supervised by human workers

Ancient axe
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Robotic milling
Manufacturing
 Product must meet design requirements, product
specifications, and standards.
 Product must be manufactured economically with
environmental friendly.
 Quality must built into the product at each stage,
from design to assembly, rather than relying on
quality testing.
 Must be manufactured with flexible system taking
into account changing market demand.
 Activities must be viewed as large system.
 Manufacturer must work with the customer for
timely feedback for continuous product
improvement.

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 Manufacturing is Important

 Technologically

 Economically

 Historically

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 Manufacturing - Technology

 Technology - the application of science to provide

society and its members with those things that are
needed or desired
 Technology provides the products that help our
society and its members live better
 What do these products have in common?
 They are all manufactured
 Manufacturing is the essential factor that makes
technology possible HOW???

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 Manufacturing - Economically
Important
U.S. economy:

% of
Sector
GNP
Manufacturing is Manufacturing 20%
one way by which Agriculture, minerals, etc. 5%
nations create Construction & utilities 5%
material wealth
Service sector – retail, 70%
transportation, banking,
communication, education, and
government
©2007 John Wiley &
Sons, Inc. M P Groover,
Fundamentals of
Modern Manufacturing
 Manufacturing - Historically
 Throughout history, human cultures that were
better at making things were more successful
 Making better tools meant better crafts & weapons
 Better crafts allowed people to live better

 Better weapons allowed them to conquer other

cultures in times of conflict
 To a significant degree, the history of civilization is
the history of humans' ability to make things

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Classification of manufacturing processes

3rd Phase
2nd Phase

1st Phase

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 Manufacturing - Technologically
 Application of physical and chemical processes to
alter the geometry, properties, and/or appearance
of a starting material to make parts or products
 Manufacturing also includes assembly
 Almost always carried out as a sequence of
operations

Figure 1.1 (a)

Manufacturing as
a technical
process

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 Manufacturing - Economically
 Transformation of materials into items of
greater value by means of one or more
processing and/or assembly operations
 Manufacturing adds value to the material by
changing its shape or properties, or by
combining it with other materials

Figure 1.1 (b)

Manufacturing
as an economic
process

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 Manufacturing Industries
 Industry consists of enterprises and organizations that
produce or supply goods and services
 Industries can be classified into three categories:
1. Primary industries - those that cultivate and exploit
natural resources, e.g., farming, mining, any natural
resources
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and
capital goods - manufacturing is the principal
activity
3. Tertiary industries - service sector-like post,
telephone, government sectors.

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 Manufacturing Industries -
continued
 Secondary industries include manufacturing,
construction, and electric power generation
 Manufacturing includes several industries
whose products are not covered in this book;
e.g., apparel, beverages, chemicals, and
food processing
 For our example, manufacturing production
of hardware
 Nuts and bolts, forgings, cars, airplanes,
digital computers, plastic parts, and
ceramic products

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For GENERAL Types of Products
 Capital goods – machine tools, aircraft,
construction equipments, mainframe
computers, railroad equipments and
services.

 Consumer goods – TVs, tires, cars, sport

goods, beverages, etc.

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 Essential requirements of
manufacturing
 Meet design requirements, specifications and
standards.
 Economically and environmentally friendly – Green
Tech
 Quality, flexible, affordability
 Continuous developments on materials, methods,
 Work with customer feed back systems.

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 Manufacturing Capability
 A manufacturing plant consists of processes
and systems (and people, of course)
designed to transform a certain limited range
of materials into products of increased value.
 The three building blocks ‑ materials,
processes, and systems ‑ are the subject of
modern manufacturing
 Manufacturing capability includes:
1. Technological processing capability

2. Physical product limitations

3. Production capacity

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 1. Technological Processing
Capability
 The available set of manufacturing processes in the
plant (or company)
 Certain manufacturing processes are suited to
certain materials
 By specializing in certain processes, the plant is
also specializing in certain materials
 Includes not only the physical processes, but also
the expertise of the plant personnel
 Examples:
 A machine shop cannot roll steel

 A steel mill cannot build cars

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2. Physical Product Limitations
 Given a plant with a certain set of processes, there
are size and weight limitations on the parts or
products that can be made in the plant
 Product size and weight affect:
 Production equipment

 Material handling equipment

 Production, material handling equipment, and plant

size must be planned for products that lie within a
certain size and weight range

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 3. Production Capacity
 Defined as the maximum quantity that a plant can
produce in a given time period (e.g., month or year)
under assumed operating conditions
 Operating conditions refer to number of shifts per
week, hours per shift, direct labor manning levels in
the plant, and so on
 Usually measured in terms of output units, such as
tons of steel or number of cars produced by the plant
 Also called plant capacity

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 Materials in Manufacturing
 Most engineering materials can be classified
into one of three basic categories:
1. Metals

2. Ceramics

3. Polymers
 Their chemistries are different
 Their mechanical and physical properties are
dissimilar
 These differences affect the manufacturing
processes that can be used to produce
products from them
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 In Addition: Composites
 Non-homogeneous mixtures of the other three
basic types rather than a unique category

Figure 1.3 Venn

diagram of three
basic material
types plus
composites

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 1. Metals

 Usually alloys, which are composed of two or

more elements, at least one of which is metallic
 Two basic groups:
1. Ferrous metals - based on iron, comprises
about 75% of metal tonnage in the world:
 Steel = Fe‑C alloy (0.02 to 2.11% C)
 Cast iron = Fe-C alloy (2% to 4% C)
2. Nonferrous metals - all other metallic
elements and their alloys: aluminum,
copper, magnesium, nickel, silver, tin,
titanium, etc.
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 TYPES OF FERROUS METALS
 Some of ferrous metals and their chemical
characteristics are according to carbon presents:
 01.Plain carbon steel – 0.05 to 0.30 %
 02. Medium carbon steel – 0.03 to 0.06 %
 03. High carbon steel – 0.60 to 1.50 %
 04. Tool steel - 0.90 to 1.50 %

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 Alloying elements:
 01. Nickel – provides corrosion resistance, provides toughness
& deep hardening.
 02. Manganese – improves corrosion resistance, toughness
and hardenability.
 03. Silicon – raises the temperature
 04. Molybdenum – promotes hardenability, increase tensile
strength, and creep strength at high temperature.

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Alloying elements:

 05.Vanadium – promote fine grained structure.

 06. Copper – increases resistance to corrosion
and acts as strengthening agent.
 07. Aluminum- promotes fined grained structure.
 08. Boron – increase hardening effect.

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 2. Ceramics
 Compounds containing metallic (or semi-metallic) and
non-metallic elements.
 Typical non-metallic elements are oxygen, nitrogen, and
carbon
 For processing, ceramics divide into:
1. Crystalline ceramics – includes:
 Traditional ceramics, such as clay (hydrous
aluminum silicates), oxides, nitrides, carbides,
glass, diamond and nano-materials
 Modern ceramics, such as alumina (Al2O3)
2. Glasses – mostly based on silica (SiO2)

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 3. Polymers
 Compound formed of repeating structural units called
polymers, whose atoms share electrons to form very large
molecules
 Three categories:
1. Thermoplastic polymers - can be subjected to multiple
heating and cooling cycles without altering molecular
structure-Acrylics, PVC, polyethylene.
2. Thermosetting polymers - molecules chemically
transform (cure) into a rigid structure – cannot be
reheated – Epoxies, polyamides.
3. Elastomers - shows significant elastic behavior-
rubbers, silicones and polyurethanes

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 4. Composites
 Material consisting of two or more phases that are processed
separately and then bonded together to achieve properties
superior to its constituents
 Phase - homogeneous mass of material, such as grains of
identical unit cell structure in a solid metal
 Properties depend on components, physical shapes of
components, and the way they are combined to form the final
material
 Eg. Reinforced plastics, Metal matrix, laminates.

Carbon Fiber Reinforced Plastic (CFRP)

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 PRODUCT DESIGN
 Serious consideration to the ease of assembly of the
product or subassembly during production and field service
 A systematic analysis of product assimilability should be
performed
 DFA tool is needed;
 to effectively analyze the ease of assembly of the
products or subassemblies
 Provide quick results, simple and easy to use

 Provide manufacturing input at the conceptualization stage

of the design process in a logical and organized fashion
 Functions as a tool for motivating designers by evaluating
their own design and improve them
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Products in Various Stages of Life Cycle
 Maturity
 Competitors now established
 High volume, innovative production may be needed – mobile
phone
 Improved cost control, reduction in options, paring down of
product line

Decline
 Unless product makes a special contribution, must plan
to terminate offering
Product Life Cycle, Sales, Cost, and Profit

I G M D
ANY QUESTION ?

END OF SLIDE

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