1 Processing Overview

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Introduction to Manufacturing and

Processing

MSE 319 August 25, 2014Chapter 1: Groover (See Blackboard)


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1. What is Manufacturing?2. Materials in Manufacturing3. Manufacturing Processes4. Production Systems5. Trends in Manufacturing

INTRODUCTION AND

OVERVIEW OF MANUFACTURING


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Manufacturing is Important

Making things has been an essential human activitysince before recorded history

Today, the term manufacturing is used for thisactivityManufacturing is important to the United States andmost other developed and developing nations

TechnologicallyEconomically


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Economic Importance

U.S. EconomySector: %GDP

Agriculture and natural resources 5Construction and public utilities 5Manufacturing 15Service industries* 75

100* includes retail, transportation, banking,

communication, education, and government


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0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

16.00%

18.00%

2003 2004 2005 2006 2007 2008 2009 2010

Wood products

Nonmetallic mineral products

Primary metals

Fabricated metal products

Machinery

Computer and electronic products

Electrical equipment, appliances, andcomponentsMotor vehicles, bodies and trailers, andpartsOther transportation equipment

Furniture and related products

Miscellaneous manufacturing

Food and beverage and tobaccoproductsTextile mills and textile product mills

Apparel and leather and allied products

Paper products

Printing and related support activities

Petroleum and coal products

Chemical products

Plastics and rubber products


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What is Manufacturing?

The word manufacture is derived from two Latinwords manus (hand) and factus (make); the

combination means

made by hand

Made by hand

accurately described the fabricationmethods that were used when the English word

manufacture

was first coined around 1567 A.D.

Most modern manufacturing operations areaccomplished by mechanized and automatedequipment that is supervised by human workers


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Manufacturing - Technological

Application of physical and chemical processes toalter the geometry, properties, and/or appearance of

a starting material to make parts or products


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Manufacturing - Economic

Transformation of materials into items of greater valueby one or more processing and/or assembly operations


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Manufactured Products

Final products divide into two major classes:1. Consumer goods - products purchased directly by

consumersCars, clothes, TVs, tennis rackets

2. Capital goods - those purchased by companies toproduce goods and/or provide services

Aircraft, computers, communicationequipment, medical apparatus, trucks,machine tools, construction equipment


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Production Quantity Q

The quantity of products Q made by a factory has animportant influence on the way its people, facilities, and

procedures are organized Annual quantities can be classified into three ranges:

Production range Annual Quantity Q Low production 1 to 100 unitsMedium production 100 to 10,000 unitsHigh production 10,000 to millions of units


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Product Variety P

Product variety P refers to different product types ormodels produced in the plant

Different products have different featuresThey are intended for different marketsSome have more parts than others

The number of different product types made eachyear in a factory can be countedWhen the number of product types made in thefactory is high, this indicates high product variety


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P vs Q in Factory Operations


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More About Product Variety

Although P is quantitative, it is much less exact than Qbecause details on how much the designs differ is not

captured simply by the number of different designsSoft product variety - small differences betweenproducts, e.g., between car models made on the sameproduction line, with many common parts

Hard product variety - products differ substantially, e.g.,between a small car and a large truck, with fewcommon parts (if any)


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Materials in Manufacturing

Most engineering materials can be classified into oneof three basic categories:

1. Metals2. Ceramics3. PolymersTheir chemistries are different, and their mechanicaland physical properties are differentThese differences affect the manufacturing processesthat can be used to produce products from them


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In Addition: Composites

Venn diagram ofthree basicmaterial typesplus composites

Nonhomogeneous mixtures of the other three basictypes rather than a unique category


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Shaping Processes Four Categories

1. Solidification processes - starting material is a heatedliquid or semifluid

2. Particulate processing - starting material consists ofpowders

3. Deformation processes - starting material is a ductilesolid (commonly metal)

4. Material removal processes - starting material is aductile or brittle solid


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Solidification Processes

Starting material is heated sufficiently to transform itinto a liquid or highly plastic state

Casting process at left and casting product at right


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Particulate Processing

(1) Starting materials are metal or ceramic powders,which are (2) pressed and (3) sintered


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Deformation Processes

Starting workpart is shaped by application of forcesthat exceed the yield strength of the material

Examples: (a) forging and (b) extrusion


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Material Removal Processes

Excess material removed from the starting piece so whatremains is the desired geometry

Examples: (a) turning, (b) drilling, and (c) milling


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Property-Enhancing Processes

Processes that improve mechanical or physicalproperties of work material

Examples:Heat treatment of metals and glassesSintering of powdered metals and ceramics

Part shape is not altered, except unintentionallyExample: unintentional warping of a heat treatedpart


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A batch of silicon wafers enters a furnace heated to 1000

C(1800

F) during fabrication of integrated circuits under clean room

conditions (photo courtesy of Intel Corporation).


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Surface Processing Operations

Cleaning - chemical and mechanical processes toremove dirt, oil, and other surface contaminants

Surface treatments - mechanical working such assand blasting, and physical processes like diffusionCoating and thin film deposition - coating exteriorsurface of the workpart. Examples:

ElectroplatingPhysical vapor depositionPainting


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Facilities vs Product Quantities

A company designs its manufacturing systems andorganizes its factories to serve the particular mission

of each plantCertain types of production facilities are recognized asmost appropriate for a given type of manufacturing:1. Low production 1 to 100

2. Medium production 100 to 10,0003. High production 10,000 to >1,000,000


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Manufacturing Support Systems

A company must organize itself to design theprocesses and equipment, plan and control

production, and satisfy product quality requirements Accomplished by manufacturing support systems The people and procedures by which acompany manages its production operations

Typical departments:Manufacturing engineering, Productionplanning and control, Quality control


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Trends in Manufacturing

Lean production and Six SigmaGlobalization and outsourcing

Environmentally conscious manufacturingMicrofabrication and Nanotechnology


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Lean Production and Six Sigma

Lean productionDoing more work with fewer resources, yet

achieving higher quality in the final productUnderlying objective: elimination of waste inmanufacturing

Six Sigma

Quality-focused program that utilizes workerteams to accomplish projects aimed at improvingan organization

s organizational performance


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Globalization

The recognition that we have an international economy inwhich barriers once established by national boundarieshave been reducedThis has enabled the freer flow of goods and services,capital, technology, and people among regions andcountriesOnce underdeveloped countries such as China, India,and Mexico have developed their manufacturinginfrastructures and technologies so that they are nowimportant producers in the global economy


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Outsourcing

Use of outside contractors to perform work that wastraditionally accomplished in-house

Local outsourcingJobs remain in the U.S.

Outsourcing to foreign countriesOffshore outsourcing - production in China andother overseas locationsNear-shore outsourcing - production in Canada,Mexico, and Central America


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Environmentally Conscious Manufacturing

Determining the most efficient use of materials andnatural resources in production, and minimizing thenegative consequences on the environment

Associated terms: green manufacturing, cleanerproduction, sustainable manufacturingBasic approaches:1. Design products that minimize environmental

impact2. Design processes that are environmentally

friendly


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Microfabrication and Nanotechnology

MicrofabricationProcesses that make parts and products whose

feature sizes are in the micron range (10-6

m)Examples: Ink-jet printing heads, compact disks,microsensors used in automobiles

NanotechnologyMaterials and products whose feature sizes are inthe nanometer range (10 -9 m)Examples: Coatings for catalytic converters, flatscreen TV monitors


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Overview of Major Topics

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