Design for Manufacturing

Chandan Kr Biswas

Dieter/Schmidt, Engineering Design 5e. 2013. The McGraw-Hill Companies

Role of Manufacturing in Design

Producing the design is a critical link in the chain of events that starts with a creative idea and ends with a successful product in the marketplace. There is confusion of terminology concerning the engineering function called manufacturing. A serious problem facing manufacturing companies has been the tendency to separate the design and manufacturing functions into different organizational units. The need to break down barriers between design and manufacturing is widely recognized today.
3 Dieter/Schmidt, Engineering Design 5e. 2013. The McGraw-Hill Companies

Spectrum of Manufacturing Activities

Dieter/Schmidt, Engineering Design 5e. 2013. The McGraw-Hill Companies

Manufacturing Functions

Most conventional manufacturing is divided into the following functions:

Process engineering Tool engineering Work Standards Plant engineering Administration and Control

Dieter/Schmidt, Engineering Design 5e. 2013. The McGraw-Hill Companies

Manufacturing Functions (2)

Process engineering is the development of a step-by-step sequence of operations for production. Tool engineering is concerned with the design of tools, jigs, fixtures, and gages to produce the part. Work standards are time values associated with each manufacturing operation that are used to determine standard costs to make the part. Plant engineering is concerned with providing the plant facilities needed to carry out the manufacturing process. Administration and control deals with production planning, scheduling, and supervising to assure that materials, machines, tools, and people are available at the right time and in the quantities needed to produce the part.
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Brief Description of the Classes of Manufacturing Processes

Casting Processes:

Molted liquid is poured into a mold and solidified into a shape defined by the contours of the mold. The wise use of polymers has brought about the development of processes tailored to their high viscosity. A material, usually metal, is plastically deformed (hot or cold) to give it improved properties and change its shape. This rapidly developing manufacturing area involves the consolidation of particles of metal, ceramics, or polymers by pressing and sintering, hot compaction, or plastic Engineering Design 5e. deformation. Dieter/Schmidt, 2013. The McGraw-Hill Companies

Polymer processing(molding):

Deformation Processes:

Power processing:

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Brief Description of the Classes of Manufacturing Processes (2)

Material removal or cutting processes:

Material is removed from a workpiece with a hard, sharp tool by a variety of methods such as turning, milling, etc. Included in joining processing are all categories of welding, brazing, soldering, etc. This category includes the improvement of mechanical properties by thermal heat treatment processes as well as the improvement of surface properties by diffusion processes like carburizing. A number of parts are brought together and combined into a Engineering Design 5e. subassembly or Dieter/Schmidt, finished product.
2013. The McGraw-Hill Companies

Joining processing:

Heat treatment and surface treatment:

Assembly Processes:

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Types of Manufacturing Systems

There are four general types of manufacturing systems:

Job shop:

Characterized by small batched of a large number of different part types every year.

Batch (Flexible Manufacturing System) :

Used when the product design is relatively stable and produced in periodic batches but the volume for an individual product is not sufficient to warrant the cost of specialized, dedicated equipment.
The equipment is laid out in the sequence of usage. The most specialized type, e.g. Oil refinary.
Dieter/Schmidt, Engineering Design 5e. 2013. The McGraw-Hill Companies

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Assembly line:

Continuous flow:

Characteristics of Production Systems

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Dieter/Schmidt, Engineering Design 5e. 2013. The McGraw-Hill Companies