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Basic Manufacturing ConceptsThe objective of this lecture is to introduce somegeneral manufacturing concepts.

Professor Rick Valentin, Ph.D.January 13, 2006

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Todays Agenda Abstract manufacturing flows, Performance attributes, Schemes of manufacturing processes, Engineering drawings, Process plans, Flow shop and job shop.

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Basic Concepts Manufacturing Processes

1. Flows2. Performance

Attributes3. ClassificationSchemes

ManufacturingCommunication Tools1. Engineering

Drawings2. Process Plans3. System Designs

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Abstraction of a Mfg Processes

ProcessProcess

Noise

Raw material

Energy

Information

Hardware

Scrap & Waste

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Material flows (resources)

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Efficiencies (resources)

= _____________= _____________

Useful outputUseful output

Total InputTotal Input

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Performance measures1. _______________2. _______________3. _______________

4. _______________5. _______________6. _______________

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Time Customer lead time (order to receipt)

1. ___________________2. ___________________

3. Processing1. ___________________2. ___________________3. ___________________

4. ___________________

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Some important equations for Rate, Time and Cost Littles law (inventory units in system): L = W Takt Time = available time/units required Profit = I___________ - E______________ Manufacturing Cost = M___________ +

L______________+T___________ + E______________ Economies of scale

C = F + V*N

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Quality Two different quality viewpoints:

1. ________________________________2. ________________________________

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Quality Process Capability Index, Cp

Cp = (USL-LSL) / 6 What definesWhat defines ??

USL = Upper Specification Limit

LSL = Lower Specification Limit

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Flexibility Ability to accommodate different ___________,

___________, ___________ Measured as cost, time, etc,

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Environmental performance Material efficiency Energy efficiency Consumption and Releases to the environment Toxic and/or harmful effects

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Process Classification Materials Machines

Applications

Geometry Time

Energy

vs.vs.

Geometrical transformation

Subtractive / Additive /Net

Time sequence

Serial / Parallel

Energy domainMechanical / Thermal /Chemical /Electrical

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Process Classification

Taken from Manufacturing Processes and Process Control, David E. Hardt, 1994.

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Mfg Communication tools

System Designrocess PlanngineeringDrawing

1. Equipmentarrangement

2. Flows3. Skill Levels

1. Equipment

2. Tools3. Set points andparameters

1. PhysicalRepresentation

2. Materials3. Tolerances

Systemrocessesign

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Engineering Drawing; Rod Support and Connecting Link

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Design Identification What is the product?

Loads, environment, annual part volume

What is the material?

Color, hardness, magnetic, surface Surface finish

Roughness, tool marks, gate location, trim line

Shape Curvatures, undercuts, internal passages, draft angles, threaded

sections, warping, sink marks

Size

Thickness, aspect ratio, implied size of machine

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Process PlanRodSupport

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Mfg. System Designs;(a) jobshop

(b) flowshop

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At the end of the conferencea) draw a basic manufacturing flows,b) enumerate performance attributes,c) classify schemes of manufacturing processes,

d) create an engineering drawings,e) create a process plans , andf) draw a flow shop and job shop.

AssignmentsAssignments1. Read Competitive Attributes

Mfg Processes and ControlGeometric Tolerancing