MANUFACTURING

ENGINEERING
CHAPTER 40
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
MANUFACTURING ENGINEERING
A technical staff function that is concerned with
planning the manufacturing processes for the
economic production of high-quality products.
Principal role: to engineer the transition of the
product from design specification to physical
product.
Overall goal: to optimize production.
The usual activities include the following:
1. Process planning.
2. Problem solving and continuous improvement.
3. Design for manufacturability.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
PROCESS PLANNING
It involves
determining the most appropriate
manufacturing processes and
the order in which they should be performed
It includes
a)deciding what processes and methods should
be used and in what sequence,
b)determining tooling requirements,
c) selecting production equipment and systems,
and
d)estimating costs of production for the selected
processes, tooling, and equipment.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
TRADITIONAL PROCESS PLANNING
Traditionally, based on the knowledge, skill, and
experience, of manufacturing engineers develop
the processing steps in the most logical sequence
required to make each part.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Process Planning for Parts
Material selection largely determine the processes
needed to manufacture a given part.
The material is selected by the product designer
based on functional requirements.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
The Route Sheet
The process plan is prepared on a form called a
route sheet, (some companies use other names).
It specifies the sequence of operations and
equipment that will be visited by the part during its
production.
The route sheet is to the process planner what the
engineering drawing is to the product designer.
For each operation, the following should be listed:
1. a brief description of the operation, with
references to the part drawing, and dimensions;
2. the equipment on which the work is to be
performed; and
3. any special tooling required, e.g. dies, molds,
cutting tools, jigs or fixtures, and gages.
In addition some companies include cycle time
standards, setup times, etc.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
The Route Sheet
FIGURE 40.3
Typical route sheet for specifying the process plan.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Process Planning for Assemblies
It involves preparation of the assembly instructions
that must be performed.
For single stations, the documentation is similar to
the processing route sheet.
contains a list of the assembly steps in the
order in which they must be accomplished.
For assembly line production,
it consists of allocating work elements to
particular stations along the line (called line
balancing).
As with process planning for parts,
any tools and fixtures needed to accomplish a
given assembly work element must be decided,
and
the workplace layout must be designed.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
MAKE OR BUY DECISION
Inevitably, the question arises as to whether a
given part should be purchased from an outside
vendor or made internally.
First of all, it should be recognized that virtually all,
manufacturers purchase their starting materials
from suppliers.
The answer to the question is the make or buy
decision.
Cost is the most important factor in this decision.
1. the internal production cost is greater than the
purchase price.
2. purchasing the part results in idle equipment in
the factory,
an apparent cost advantage for the vendor may
be a disadvantage for the home factory.
Example 40.1
Make or Buy Cost Comparison
Suppose that the quoted price for a certain component from
a vendor is $8.00 per unit for 1000 units. The same part made
in the home factory would cost $9.00. The cost break- down on
the make alternative is as follows:
Unit material cost = $2:25 per unit
Direct labor = $2:00 per unit
Labor overhead at 150% = $3:00 per unit
Equipment fixed cost = $1:75 per unit
Total = $9:00 per unit
Should the component by bought or made in-house?
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
MAKE OR BUY DECISION
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
COMPUTER-AIDED PROCESS
PLANNING (CAPP)
CAPPautomating the process planning function
by means of computer systems.
CAPP systems are designed around either of two
approaches:
1. retrieval systems and
2. generative systems.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Retrieval CAPP Systems
(variant CAPP systems)
Based on group technology (GT) and parts
classification and coding.
GT is a manufacturing philosophy in which the
parts having similarities (Geometry,
manufacturing process and/or function) are
grouped together to achieve higher level of
integration between the design and
manufacturing functions of a firm.
In these systems, a standard process plan is
stored in computer files for each part code number.
The standard plans are based on current part
routings in use in the factory, or
on an ideal plan that is prepared for each
family.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Retrieval CAPP Systems
(variant CAPP systems)
FIGURE 40.4
Operation of a retrieval computer-aided process planning system. (Source: [5].)
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Generative CAPP Systems
These are an alternative to retrieval systems.
It creates the process plan using systematic
procedures that might be applied by a human
planner.
In a fully generative CAPP system, the process
sequence is planned without human assistance
and without predefined standard plans.
Designing this system is a problem in the field of
expert systems, a branch of artificial intelligence.
Several ingredients required in a fully generative
CAPP system:
1. Knowledge base.
2. Computer-compatible part description.
3. Inference engine.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Benets of CAPP
1. process rationalization and standardization
2. increased productivity of process planners
3. reduced lead time to prepare process plans;
4. improved legibility compared to manually prepared
route sheets; and
5. ability to interface CAPP programs with other
application programs, such as cost estimating,
work standards, and others.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
DESIGN FOR MANUFACTURING
AND ASSEMBLY (DFM/A)
It is an approach to product design that
systematically includes considerations of
manufacturability and assemblability in the design.
It includes organizational changes and design
principles and guidelines.
It also includes principles and guidelines that
indicate how to design a given product for
maximum manufacturability.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
CONCURRENT ENGINEERING (
simultaneous engineering)
It refers to an approach to product design in which
companies attempt to reduce the elapsed time
required to bring a new product to market by
integrating design engineering, manufacturing
engineering, and other functions in the company.
In concurrent engineering, manufacturing planning
begins while the product design is being
developed.
All of the functions can contribute to aproduct
design that not only performs well functionally, but
is also manufacturable, assemblable, inspectable,
testable, serviceable, maintainable, free of defects,
and safe.
All viewpoints are combined to design a product of
high quality that will deliver customer satisfaction.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
CONCURRENT ENGINEERING (
simultaneous engineering)
FIGURE 40.5
Comparison of:
(a) traditional product
development cycle, and (b)
product development
using concurrent
engineering.
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
Other Objectives for Design
Design for quality
Design for life cycle
Design for product cost