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OVERVIEW OF MANUFACTURING
1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
5. Trends in Manufacturing
6. Organization of the Book
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufacturing is Important
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Technological Importance
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Economic Importance
U.S. Economy
Sector: %GDP
Agriculture and natural resources 5
Construction and public utilities 5
Manufacturing 15
Service industries* 75
100
* includes retail, transportation, banking,
communication, education, and government
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
What is Manufacturing?
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufacturing - Technological
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufacturing - Economic
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufacturing Industries
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufacturing Industries -
continued
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufactured Products
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Production Quantity Q
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Product Variety P
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
P vs Q in Factory Operations
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
More About Product Variety
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufacturing Capability
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
1. Technological Processing
Capability
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
2. Physical Product Limitations
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
3. Production Capacity
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Materials in Manufacturing
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
In Addition: Composites
Venn diagram of
three basic
material types
plus composites
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
1. Metals
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Charging a
basic oxygen
furnace in
steelmaking:
molten pig iron
is poured into
the BOF.
Temperatures
are around
1650C (3000F).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
2. Ceramics
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
4. Composites
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Processing Operations
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Shaping Processes – Four
Categories
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Solidification Processes
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Particulate Processing
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Deformation Processes
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Material Removal Processes
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Metal chips fly in a high
speed turning operation
performed on a computer
numerical control turning
center (photo courtesy of
Cincinnati Milacron).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Waste in Shaping Processes
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Property‑Enhancing Processes
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
A batch of silicon wafers enters a furnace heated to
1000°C (1800°F) during fabrication of integrated
circuits under clean room conditions (photo courtesy
of Intel Corporation).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Surface Processing Operations
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Photomicrograph of the cross section of multiple
coatings of titanium nitride and aluminum oxide on
a cemented carbide substrate (photo courtesy of
Kennametal Inc.).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Assembly Operations
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Two welders perform
arc welding on a
large steel pipe
section (photo
courtesy of Lincoln
Electric Company).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Automated dispensing
of adhesive onto
component parts prior
to assembly (photo
courtesy of EFD, Inc.).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Production Machines and Tooling
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
A robotic arm performs
unloading and loading
operation in a turning
center using a dual
gripper (photo courtesy
of Cincinnati Milacron).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Production Systems
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Production Facilities
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Facilities vs Product Quantities
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Low Production
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Fixed-Position Plant Layout
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Medium Production
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Cellular Plant Layout
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
High Production
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Quantity Production
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Flow Line Production
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Product Plant Layout
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Assembly workers on
an engine assembly
line (photo courtesy of
Ford Motor Company).
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Manufacturing Support Systems
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Trends in Manufacturing
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Lean Production and Six Sigma
Lean production
Doing more work with fewer resources, yet
achieving higher quality in the final product
Underlying objective: elimination of waste in
manufacturing
Six Sigma
Quality-focused program that utilizes worker
teams to accomplish projects aimed at improving
an organization’s organizational performance
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Globalization
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Outsourcing
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Environmentally Conscious
Manufacturing
Determining the most efficient use of materials and
natural resources in production, and minimizing the
negative consequences on the environment
Associated terms: green manufacturing, cleaner
production, sustainable manufacturing
Basic approaches:
1. Design products that minimize environmental
impact
2. Design processes that are environmentally
friendly
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Microfabrication and
Nanotechnology
Microfabrication
Processes that make parts and products whose
feature sizes are in the micron range (10-6 m)
Examples: Ink-jet printing heads, compact disks,
microsensors used in automobiles
Nanotechnology
Materials and products whose feature sizes are in
the nanometer range (10-9 m)
Examples: Coatings for catalytic converters, flat
screen TV monitors
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
Overview of Major Topics
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version