Warm-Up

• Identify two different ways to change the form of a material.

Warm-Up

• Which type of manufacturing decreases errors and increases quality?

Manufacturing Processes• The form of materials is changed by:

1. Separating

2. Forming

3. Combining

4. Conditioning

Manufacturing is…

• The construction of many of the same item at one time, usually using assembly lines and interchangeable parts.

Objective

• Identify examples of manufacturing processes

• Understand push and pull manufacturing

How does manufacturing affect our lives?

• Cheaper goods• Better quality goods• Jobs, jobs, jobs,• Higher standard of

living

• Food • Fuel• Shoes and Clothes• Cars• Modular Homes• Integrated Circuit

Chip• Pencils and Pens

Manufacturing Processes• The form of materials is changed by:

1. Separating

2. Forming

3. Combining

4. Conditioning

Durable Goods• Do not quickly wear out. • May be used over and over

– Cars– Bricks– Electronics

• Non-durables include:– Food– Clothing– Paper products

Steps in Manufacturing

• Turning raw materials into finished goods on a large scale.– Obtaining and preparing raw materials– Processing the materials mechanically or

chemically– Assembling– Testing– Inspecting– Packaging

Gathering Raw Materials• This is done using

three major methods.

– Mining

– Drilling

– Harvesting

Mining

• Mining involves digging resources out of the earth.– Open-pit mining: a type of

mining used when the resource is close to the surface.

– Underground mining: a mining method that uses digging tunnels to reach the material.

Drilling• A method used to

reach underground liquid resources such as oil and water.

• A small round hole is drilled using a derrick and a drill bit that grinds up the rock as it drills.

Harvesting• Harvesting is a method used to collect a

growing resource. Trees are the major “growing” resource that produce engineering materials.

Also harvested:•Cotton•Sugarcane and corn for ethanol

production

Push Production

• As each person finishes his/her job, it is pushed to the next person.

Faster production.

Increased chance of error - less quality.

Pull Production

• Each person does not start a new part until their last one has been pulled from them.

Increased quality.

Fewer errors

Slower production.

Traditional Manufacturing

• Mass Production – – Uses interchangeable standardized parts that can

quickly be assembled– Breaks complex operations down into simple steps

that can be performed by unskilled workers – Output from the first process in the sequence drives – the second process and so on

New Trends in Manufacturing

• Lean Production – – Less of everything is required to produce the same

quantity that traditional mass production generated– Less materials, equipment, manhours, time, effort,

capital

• A ‘PULL’ Manufacturing system that is driven by customers orders and need for specific parts

New Trends in Manufacturing• KANBAN • Cards that carry information from one process to

processes that come afterward

• Tell about what and how much to produce next.

• Identifies the type of part, how many there are, and other basic information.

• “Pulls” only needed parts

without maintaining extra

inventory

New Trends in Manufacturing

• Quality Circles – Employees, working in teams, set aside time to

review work procedures– Come up with ways of enhancing their

performance.

New Trends in Manufacturing

• KAIZEN – Continuous improvement– an on-going process involving a variety of

activities to reduce waste and inefficiency

New Trends in Manufacturing

• ANDON – A system to notify management, maintenance, and

other workers of a quality or process problem– Uses a signboard incorporating signal lights to

indicate which workstation has the problem

Push Production

• As each person finishes his/her job, it is pushed to the next person.

Faster production.

Increased chance of error - less quality.

Pull Production

• Each person does not start a new part until their last one has been pulled from them.

Increased quality.

Slower production.

Push versus Pull Manufacturing

• PUSH – complete task as quickly as possible– Faster Production (more items made in shorter period of time)

– Less quality (more likely to make mistakes)

• PULL – complete task only when the previously completed item is removed or ‘pulled’– Slower production (more likely to have idle time)

– Increased quality

What is QC rate when 50 shirts are made and only 40 pass inspection?

Quality Control Rate of Pd 8 and 9

Push Pull

Total # made

# passing inspection

5/4 DrillUse the data sheet provided to answer the following:

- How did the amount of waste generated compare between Push and Pull production?

- Use data to support your answer.

• QC=

• QC= 125/200 X 100

= 12500/200 = 125/2 = 62.5%

Number of ObjectsPassing Inspection

Total Number of Objects Made

X 100

• Copy this list of manufacturing processes and give examples of each from our Thanksgiving Card Project.

Process Examples

Forming

Separating

Combining

Conditioning

Fold card

Cut along line, punch Leaf

Glue orange paper

Stamp