9/12/05

Manufacturing
Group #3
Erica Velarde
David Pincus
Sean Clifton
Ruben Sosa

What is Manufacturing?
It is defined as, the process of converting
raw materials into products.
The word manufacturing is derived from the
Latin word manu factus meaning made by
hand.

It usually involves activities in which the

manufactured product is used to
manufacture other products.
Products are seldemly made of just a single
part, such as a nail or bolt.
Most objects are constructed by assembling
a number of single parts, and these
components can be made from a variety
of materials.

Number of Single Parts in

Some Products
Rotary Lawn Mower
Grand Piano
Automobile
C-5A transport plane
Boeing 747-400

300 parts
12,000 parts
15,000 parts
>4,000,000 parts
>6,000,000 parts

Duratec V-6 engine components and

materials used to manufacture them

Manufacturing is a complex activity that

involves a variety of resources and
activities:

Product Design
Machinery and Tooling
Process Planning
Materials
Purchasing
Manufacturing
Production Control
Support Services
Marketing
Sales
Shipping
Customer Service

Manufacturing Steps and

Components of a Light Bulb

Manufacturing is a vital part of a nations

economy. It is said that a nations level of
manufacturing activity is directly related to
its economic health; the higher the level of
manufacturing activity in a country, the
higher the standard of living of its people.

The History of Manufacturing

It dates back to about 5000 B.C.
It is older than recorded history
Primitive cave and rock markings made with
tools that were manufactured for these
purposes.
Primitive manufacturing of products for various
specific uses began with articles made of wood
and stone.

Environmentally
Conscious Design
and Manufacture

Environmentally Conscious Design and Manufacturing

Facts:
In the United States alone, nine million passenger cars and

about 300 million tires are discarded each year; about 100
million of those tires are reused in various ways.
More than five billion kilograms of plastic products are
discarded each year.
Every three months, industries and consumers discard
enough aluminum to rebuild the countrys commercial air fleet.

What Pollutes the Environment?

Lubricants and coolants are often used in most manufacturing

operations.
Various fluids and solvents are used in cleaning manufactured
products, some of these fluids pollute the air and water during their use.
Many by-products from manufacturing plants have been discarded for
years (i.e., sand containing additives used in metal-casting processes;
water, oil and other fluids from heat-treating facilities and from planting
operations; slag from foundries and from welding operations.)
A variety of metallic and non-metallic scrap, produced in operations
such as sheet forming, casting and molding.

 The effects of these activities, their damage to our environment and to

the earths ecosystem, and, ultimately, their effect on the quality of human
life are well recognized.
Major concerns are water and air pollution, acid rain, ozone depletion,
the greenhouse effect, hazardous wastes, landfill seepage and global
warming.
Many laws have been set in place in the United States and other
industrialized countries to help reduce the pollution.

What Can We Do?

Reduce waste of materials, by refinements in product design and
reducing the amount of materials used
Reducing the use of hazardous materials in products and processes.
Conducting research and development into environmentally safe
products and into manufacturing technologies.
Ensuring proper handling and disposal of all waste.
Making improvements in recycling, waste treatment and reuse of
materials.

Computer-Integrated Manufacturing
What is computer-integrated Manufacturing (CIM)?
Software and hardware are integrated from product concept

through product distribution in the marketplace.

Why is it effective?
Responsiveness to rapid changes in market demand

and product modifications.

Better use of materials, machinery, and personnel,
and reduction in inventory.
Better control of production and management of the
total manufacturing operation.
The manufacturing of high quality products at low
cost.

Major Applications of Computers in Manufacturing

Computer Numerical Control (CNC): Method of controlling the

movements of machine components by direct insertion of coded

instructions in the form of numerical data.
Adaptive Control (AC): The parameters in a manufacturing process are
adjusted automatically to optimize production rate and product quality,
and to minimize cost.
Automated Handling of Materials: Computers have made possible
highly efficient handling of materials and components in various stages
of completion, such as when being moved from storage to machines,
from machine to machine, and at points of inspection, inventory and
shipment.

Industrial Robots: introduced

in the early 1960s, industrial
robots have been replacing
humans in operations that are
repetitive, dangerous and
boring, thus reducing the
possibility of human error and
improving productivity.
Robots with sensoryperception capabilities have
been developed with
movements that simulate
those of humans.

 Automated and Robotic assembly systems: These systems mainly

have replaced costly assembly by human operators, although humans
still have to perform some of these operations. Products are now
designed or redesigned so that they can be assembled more easily and
faster by machines.
Computer-Aided Process Planning (CAPP): This system is capable of
improving productivity by optimizing process plans, reducing planning
costs and improving the consistency of product quality and reliability.
Group Technology (GT): The concept of group technology is that parts
can be grouped and produced by classifying them into families,
according to similarities in design and similarities in the manufacturing
processes employed to produce the parts.
Just-In-Time Production (JIT): The principal of JIT is that supplies of
raw materials, parts and components are delivered to the manufacture
just in time to be used, parts and components are produced just in time to
be made into subassemblies and assemblies and products are finished
just in time to be delivered to the comsumer.

 Cellular Manufacturing (CM): This system utilizes workstations that

usually contain several production machines controlled by a central
robot, each machine performing a different operation on the part.
Flexible Manufacturing Systems (FMS): These systems integrate
manufacturing cells into a large unit, all interfaced with a central
computer.
Expert Systems (ES): These systems basically are complex computer
programs; they have the capability to perform various tasks and solve
difficult real life problems much as human experts would.
Artificial Intelligence (AI): This important field involves the use of
machines and computers to replace human intelligence. Computer
controlled systems are now capable of learning from experience and of
making decisions that optimize operations and minimize costs.
All of these help keep production costs down and also speed up the
manufacturing process.

Lean Production and Agile Manufacturing

What is it?
Lean Production: A methodology that involves a thorough
assessment of each of the activities of a company in order to
minimize waste at all levels.
These include the efficiency and effectiveness of all its operations,
the efficiency of the machinery and equipment, the number of
personnel involved in each operation and the possible dispensing of
some of its operations and managers.
This approach continues with a comprehensive analysis of the
costs of each activity, including those due to productive and
nonproductive labor.

Agile Manufacturing: A term indicating the implementation of the

principles of lean production on a broad scale.
The principal behind agile manufacturing is ensuring agility in the
manufacturing enterprise, so that it can respond rapidly to changes in
product demand and in customer needs.
This flexibility is to be achieved through people, equipment, computer
hardware and software and advanced communication systems.

Design for Manufacture,

Assembly, Disassembly,
and Service
(DFMA)

What is DFM?

Design for Manufacture integrates the

design process with materials,
maufacturing methods, process planning,
assembly, testing and quality assurance.

Considerations

Characteristics,
capabilities, and
limitations of
materials
Manufacturing
process
Machinery
Equipment

Machine performance
Dimensional accuracy
Surface finish
Processing time
Effects of processing
method on part
quality

Design for Assembly (DFA)

Requires consideration
of ease, speed, and
cost of putting all the
parts together.
Disassembly must also
be possible for good
design.
Easy assembly = easy
disassembly

Benefits of DFA
Easy disassembly makes for easy service
of parts.
Software is available to expedite the
process and minimize cost.
The end result is Design for Manufacture
and Assembly (DFMA)

Methods of Assembly

Fasteners or adhesives
Welding, soldering, brazing

Methods of Assembly (cont.)

Hand/Machine assembly?
#

of parts
Amount of care/protection required
Cost of labor

Selecting Materials
Properties, Cost & Availability,
and Service Life

Types of Material

Ferrous metals
Nonferrous metals
Plastics (Polymers)
Ceramics, glass,
diamond
Composites
Wood

General Manufacturing Characteristics of Various

Alloys
Alloy
Castability
Weldability Machinability
*Aluminum

E-G

G-F

G-F

*Gray cast
iron

*White cast
iron

VP

VP

*Nickel

*Steel

*Zinc

*Copper

Note: E, excellent; G, good; F, fair; D, difficult; VP, Very Poor

Types of Material (cont.)

Nanomaterials

Shape-memory alloys
Amorphous alloys
Semiconductors
Superconductors, etc.

Properties of Materials

Mechanical strength, toughness, ductility hardness,

elasticity, fatigue, etc.
Physical density, specific heat, thermal expansion,
conductivity, melting point, and electrical/magnetic
properties
The combination of Mech./Phys. Properties give us
strength-to-weight ratios (Important to aerospace)
Chemical oxidation, corrosion, general degradation,
toxicity, flammability
Manufacturing determines if can be cast, formed, etc.

Cost and Availability

Depends on Reliability of Supply and
Demand for Material
Specialized machinery
Extensive Labor
Personnel with special skills/training

Appearance, Service Life, and

Recyclability
Color, feel, surface texture
Wear, fatigue can affect performance and
service life
Consideration for disposal after end of
service life
Ex. Baseball bats

Selecting Manufacturing Processes

Casting Expendable/Permanent mold

Forming/Shaping Rolling, forging, etc.
Machining Turning, milling, grinding, etc.
Joining Welding, adhesive, mechanical
Finishing Honing, lapping, polishing
Nanofabrication NEMS operate on the same
level as biological molecules

Selecting Manufacturing Processes

(cont.)

Depends on: shape to

be produced and its
properties
Dimensional

Accuracy
& Surface Finish
Operational &
Manufacturing Costs

Consequences of Improper
Selection of Materials and
Processes

Temperature
Dimensional

Design and cost for tooling tool/die life

Availability

changes; surface oxidation; warping

of equipment; experience of personnel

Pollution
Affects

job safety and cost

Consequences

It stops functioning
It does not function properly or within specs
It becomes unreliable or unsafe to use

Net Shape Manufacturing

The first operation made on the part is

made as close to the final dimensions,
tolerances, surface finish, and
specifications as possible.

Quality Assurance
and Total Quality
Management

What is Quality Assurance?

Most important aspect of manufacturing

Influences the marketability of a product

Influences customer satisfaction

Product integrity

Is the term usually used to define a product

Is

the product suitable for its intended purpose

Does the product meets the market demand
Does the product performs reliably during its life
expectancy
Can the product be maintained with relative ease

Example of Quality Assurance. The Little

giant latter system.

Total Quality Management

Is the responsibility of everyone involved in

design and manufacturing a product
Management

commitment to product quality

Pride of workmanship at all levels of
production
Use of statistical process control (SPC) and
the use of control charts for on-line monitoring
of part production

Control chart is a device for describing in a

precise manner what is meant by
statistical control.
It

is a proven technique for improving

productivity
It is effective in defect prevention
It prevents unnecessary process adjustments
It provides diagnostic information
It provides information about process
capability

Example of control chart

Why do we care about quality

Assurance and total Quality
management?

Product Liability
Product malfunctioning
Laws and regulations
Human factor

As

engineers we have the responsibility to

design and manufacture safe products that
meet the public demand

Human Factor
It is impossible to totally eliminate a
product safety hazard.
Human versus machine interactions

A chainsaw
A table

saw
A car lift

References

Kalpakjan and Schmid. Manufacturing Engineering and Technology.

5th ed. Pearson Education Inc. 2006
Lindbeck. Product Design and Manufacture. Prentice-Hall, Inc.
1995
http://en.wikipedia.org/wiki/Industrial_robot
http://www.engineering.com
http://www.encarta.msn.com
http://www.hotdot-bullseye.com/Taguchi.html
http://www.skymark.com/resources/leaders/juran.asp
http://reliability.sandia.gov
https://bigdealsnetwork.com/littlegiantladder/view_product.php?
product=LG-10101

Questions
1. Which of the following is not a major application of computer in manufacturing:
a. Computer Numerical Control
b. Adaptive Controls
c. Industrial Robots
d. Quality Control
2. Total quality management relates to:
a. Commitment to product quality
b. Pride of workmanship at all levels of production
c. Identifying sources of quality problems
d. All of the above
3. The history of manufacturing dates back to:
a. 1800
b. 5000BC
c. 1910
d. 1600
4. Which is not a method of assembly:
a. Mechanical fasteners
b. Welding
c. Wrapping
d. Adhesive
5. Net shape manufacturing involves:
a. Manufacturing the part as close to final tolerances as possible
b. Manufacturing the part in as many pieces as possible
c. Manufacturing the part as quickly as possible
d. Manufacturing the part as cheap as possible