BMM3643

Manufacturing Process

Lecturer: Ms. Nurul Shahida Binti Mohd Shalahim

Phone: 09-4246331
Room: A04-3-1-16

Course Synopsis
This
course
introduces
students
to
manufacturing processes used for converting
raw materials into finished products. Various
processes, machinery, and operations will be
examined
with
emphasis
placed
on
understanding engineering materials and
processing parameters that influence design
considerations,
product
quality,
and
production costs. Sustainable manufacturing
process will be discussed in student project
presentation.
2

Course Introduction
Give you an exposure to
manufacturing processes
Not giving answers to all questions
about manufacturing
Informative in many instances
Sometimes have calculation content

Week Content

Week Content

i.

Course introduction &

Manufacturing Process Intro
ii. Metal solidification

Machining

Metal Casting

Machining

Bulk Metal Forming

10

Metal material removal Process

- Abrasive and finishing
operation

Bulk Metal Forming

11

Joining process

Sheet Metal Forming

12

Joining process

Powder Metallurgy and Plastic

13

Surface Technology

Powder Metallurgy and Plastic

14

Surface Technology
Subject Summary
4

References
i. Manufacturing Engineering &
Technology.
5th ed. S. Kalpakjian & S. Schmidt.
2004 Prentice Hall
ii. Introduction to Manufacturing
Processes. J. A.. Schey,. 2000, 3rd
ed. McGraw-Hill
iii. Fundamentals of Modern
Manufacturing, Mikell P.Groover
2002, Wiley

Course evaluation
Assessment

CO1

CO2

Assignment

2%

2%

2%

Project
(Report and
Presentation)

4%

4%

4%

16%
(2Q)

14%
(2Q)

Mid-Term Exam
Final Exam
Total Marks

CO3 CO4

CO5

Percent
age
(%)

2%

2%

10

4%

4%

20

30
20% 10%

10%

40
100

Assignment Format
Please remember to include the questions in the
assignments. Cover page of the assignment should
include:

oName
oSection
oGroup
oLecturer
oSubmission date
ZERO MARKS for PLAGIARISM !!!
Late submission will be penalized
7

Project Information
A project proposal must be submitted, a
maximum of 2 pages which includes:

i.
ii.

Cover page
Contents ;
Propose an engineering product which is
produced through a single or multiple
manufacturing processes.
Describe full process activities in product
manufacturing processes such as design, bill
of material, costing and etc.

IMPORTANT DATES TO
REMEMBER!!
Date
Project Proposal
Submission

- 6 April 2015 (Monday), 4pm

Project Submission

- 25 May 2015 (Monday), 4pm

Mid-Term Exam

- Week 6 (1 April 2015: Thursday)Topics: CO1-CO2

- 8.00pm-10.00pm
- Venue: DPM & DK300

General Class rules

MUST register in http://
kalam.ump.edu.my/ moodle/padlet
Attendance MUST be 100% (refer UMPs
rule)
Punctuality
Proper attire
Class preparation (make sure all
whiteboards are clean, desktop is in ON
condition)
10

1.0 INTRODUCTION TO
MANUFACTURING
PROCESS

11

Chapter Objectives:
Introduction to Manufacturing
Lesson Objective:
At the end of this lecture, students should be able
to:
Understand the meaning of manufacturing
Understand the importance of manufacturing, and
Differentiate the classification of manufacturing
processes
Page 12

What is Manufacturing?
Manufacturing is the application of tools to
the transformation of raw materials into
finished products.
This effort includes all intermediate processes
required for the production and integration of
a product's components.
Some industries, such as semiconductor and
steel manufacturers use the term fabrication
instead.
Manufacturing derived from manu factus
(Latin word) meaning made by hand.

Page 13

Manufacturing - Engine

Section of an automotive engine - the Duratec V-6 - showing various components

and the materials used in making them. Source: Courtesy of Ford Motor Company.
Illustration by David Kimball.
Page 14

Manufacture of Light Bulbs

Components of a common incandescent

light bulb. Source: Courtesy of General
Electric Company.

Manufacturing steps in making an

incandescent light bulb. Source:
Courtesy of General Electric
Company.

Page 15

The importance of manufacturing

Path of development-the key to

prosperity (e.g. then England, UK,
USSR; now Korea, Taiwan, China)
The foundation of Great Power
Important cause of economic growth
Global trade is based on goods, not
services (World Trade Data)
Manufacturing creates job
Page 16

The importance of manufacturing

Source: World Bank Data, retrieved on March

2015
Page 17

Classification of Manufacturing
Processes
Numerous processes and operations can be
involved in the manufacture of products and
components.
These shape-producing processes are grouped
into four basic families:
1.
2.
3.
4.

Solidification- metal or polymer

Forming and Shaping - bulb metal or sheet metal
Machining removing material
Joining assembly of component

Page 18

1. Solidification - metal Casting

PATTERN ?
MOLD ?

INVESTMENT
CASTING

LOST FOAM
CASTING

SAND
CASTING

DIE
CASTING

Schematic illustration of various casting processes

Page 19

2. Solidification - Polymer

Extrusion
Compression
Molding
Injection
Molding
Blow Molding

Schematic illustration of various polymer processing methods

Page 20

2. Forming and Shaping

Extrusion

Page 21

3. Machining

Schematic illustrations of various machining and finishing processes.

Page 22

4. Joining

Schematic illustration of various joining processes

Page 23

Automated welding of
automobiles
Automated spot welding of
automobile bodies in a mass
production line. Source:
Courtesy of Ford Motor
Company.

Page 24

Application of CAD/CAM to make

sunglasses mold
Machining a mould cavity for making
sunglasses.
(a) Computer model of the sunglass
as designed and viewed on the
monitor.
(b) Machine the die cavity using a
computer numerical-control milling
machine
(c) Final product.
Source: Courtesy of Mastercam/CNC
Software, Inc.

Page 25

Any
questions??
26

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