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General Information
Course number: INME 4055 Course title: Manufacturing Processes Credit hours: 3 Instructor: Pedro O. Quintero Aguil Office: L-100 B Office hours: Tue and Thu 12:30-2:00, Wed 12:30-2:30 E-mail: pedro.quintero@upr.edu
Assessment
The course will be assessed in the following manner:
Partial Exams (3) 60% Class Attendance / Participation 10% (*) Quizzes / Homework 5% Final Exam 25% * After the second absence one (1) point will be deducted for each nonauthorized absence.
Grades
Final grade range 100 90 89 80 79 70 69 60 59 - 0 Final letter grade A B C D F
Attendance
Attendance and participation in the lecture are mandatory and will be considered in the grading process. Students should bring all the required materials to be used during the lectures. Students are expected to keep up with the assigned reading and be prepared to answer questions on these readings during lectures.
References
Textbook: Manufacturing Processes for Engineering Materials, Serowe Kalpakjian and Steven R. Schmid, Prentice Hall, 5th ed. 2007. Other References:
Manufacturing Engineering and Technology, Serowe Kalpakjian and Steven R. Schmid, Prentice Hall, 2001. Manufacturing Processes and Equipment, George Tlusty, Prentice Hall, 2000. Introduction to Manufacturing Processes, John A. Schey, McGraw Hill, 3rd ed., 2000. Introduction to Manufacturing Processes and Materials, Robert C. Creese, Marcel Dekker, 1999. Principles of Manufacturing Processes, J. Beddoes and M.J. Bibby, Arnold Publishers, 1999. SME Tool and Manufacturing Engineering Handbook, SME Press, 1989 Volumes 1-7
INME 4055 Pedro Quintero, Ph.D.
Exams
Exam will be conducted during lectures periods at the assigned classroom on the date specified by the lecturer with at least two weeks in advance. The only items allowed for use during the exams are calculators, pencils, pen, and ruler. Neatness and order will be taken into consideration and may affect your grade.
What is Manufacturing?
Manufacturing is the process of converting raw material into products; it encompasses the design and fabrication of goods by means of various production methods and techniques.
from Latin, manu factus, meaning made by hand
Manufacturing represents ~ 20% to 30% of the value of all goods and services produced in industrialized countries. Because a manufactured item has undergone a number of changes during which the raw material has become an useful product, it has added value ($$$).
INME 4055 Pedro Quintero, Ph.D.
Manufacturing Processes
Processing operation:
raw material is transformed into individual parts
Assembly operation:
individual parts are combined together to form an specific product
100
100
80 60
80 60
40 20 0
40
80% of the cost and performance is committed in the first 20% of the design cycle
INME 4055 Pedro Quintero, Ph.D.
Production Marketing
Manufacturing
Marketing Sales Redesign Maintenance Training Service Warranty
Sustainment
End of Life
Requirements Capture
http://www.williamson-labs.com/design.htm
Design Implementation
Verification
Product Assembly
After individual parts have been manufactured, they are assembled into a product. Assembly is an important phase of the overall manufacturing operation and requires consideration of the ease, speed, and cost of putting parts together. Products must be designed so that disassembly is possible with relative ease and little time. DFMA recognizes the inherent and important interrelationships among design, manufacturing, and assembly.
INME 4055 Pedro Quintero, Ph.D.
Efforts have been more successful when there is value added, such as reducing energy requirements or substituting materials that have cost and environmental design benefits (DFR and DFE). Sustainable Manufacturing is the realization that natural resources are vital to economic activity and that energy and materials management are essential to ensure that resources are available for future generations.
INME 4055 Pedro Quintero, Ph.D.
Product Life Cycle Management (PLCM) is defined as the strategies employed by the manufacturer as the product goes through its life cycle.
INME 4055 Pedro Quintero, Ph.D.
Selecting Materials
The types of materials generally used in manufacturing are:
Ferrous metals: carbon steels, alloy steels, stainless steels Nonferrous metals: aluminum, magnesium, copper, nickel, titanium, low-melting alloys (lead, zinc, and tin), and precious metals Plastics: thermoplastics, thermosets, and elastomers Ceramics: glass ceramics, glasses, graphite Composite materials: reinforced plastics, metal-matrix and ceramic matrix, honeycomb structures; (these are known as engineered materials). Nanomaterials, shape-memory alloys, metal foams, amorphous alloys, semiconductors.
Material Properties:
Mechanical properties: strength, toughness, ductility, hardness, elasticity, fatigue, creep Physical properties: density, specific heat, CTE, conductivity, melting point Manufacturing properties: determine whether they can be processed (cast, formed, shaped, machined) with relative ease.
INME 4055 Pedro Quintero, Ph.D.
Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces. INME 4055 Pedro Quintero, Ph.D.
Manufacturing engineers are constantly challenged to find new solutions to production problems as well as finding means for significant cost reduction.
INME 4055 Pedro Quintero, Ph.D.
Size, thickness, and shape complexity of a part have a major bearing on the process selected. The size and shape of manufactured products vary widely.
Lean Manufacturing
Major assessment of each activity of a company regarding the efficiency and effectiveness of its operation. Efficiency of the machinery and equipment used in the operation while maintaining and improving quality. Number of personnel involved in a particular operation. A thorough analysis in order to reduce the cost of each activity. Lean aims at continuously improving the efficiency and profitability by removing all types of waste from its operation. Agile manufacturing indicate the use of the principles of lean production in a broader scale.
ensure flexibility so that it can quickly respond to changes reconfigurable machines and modular components
INME 4055 Pedro Quintero, Ph.D.
Modern approach: Quality cannot be inspected into the product; it must be built into it from the early stages through all subsequent stages. We need to control processes not products! Ultimately, the major goal is to prevent defects from occurring rather than to detect defects in products.
SPC, Control Charts DOE
INME 4055 Pedro Quintero, Ph.D.
Manufacturing Activities
Product design (conceptual, requirements, specifications) Selecting materials Selecting manufacturing processes Process design Customer satisfaction Quality control Regulations (EPA, OSHA, ISO) Lean Manufacturing
INME 4055 Pedro Quintero, Ph.D.
The first was never to accept anything for true which I did not clearly know to be such; that is to say, carefully to avoid precipitancy and prejudice, and to comprise nothing more in my judgment than what was presented to my mind so clearly and distinctly as to exclude all ground of doubt. The second, to divide each of the difficulties under examination into as many parts as possible, and as might be necessary for its adequate solution. The third, to conduct my thoughts in such order that, by commencing with objects the simplest and easiest to know, I might ascend by little and little, and, as it were, step by step, to the knowledge of the more complex; assigning in thought a certain order even to those objects which in their own nature do not stand in a relation of antecedence and sequence.
Discourse on the Method of Rightly Conducting the Reason, and Seeking Truth in the Sciences Rene Descartes, 1637 INME 4055 Pedro Quintero, Ph.D.
Summary
Manufacturing is the process of converting raw materials into products be means of a variety of processes and methods. Product design is an integral part of manufacturing, as evidenced by trends in in concurrent engineering and DFX. A key task is to select appropriate materials and optimal manufacturing methods, given product design goals, process capabilities, and cost considerations. Ensuring product quality is a concurrent engineering process rather than a last step in the manufacturing of a product. Lean production and agile manufacturing are approaches that focus on the efficiency and flexibility of the organization. Manufacturing engineers have the major responsibilities regarding all the above aspects.
INME 4055 Pedro Quintero, Ph.D.