Introduction to

Manufacturing
Lecturer: Dian Daruis
Email: dian@upnm.edu.my
Introduction to Manufacturing
 Observe the objects around you:
– How did they become what they are?
 What important role does manufacturing play in
society?
 People involved?
How do we define manufacturing?
– From Latin word manu factus ~ made by hand, also
used is production engineering.
– Manufacturing is the ability to make goods and services
to satisfy societal needs
» Manufacturing processes are strung together to create a
manufacturing system (MS)
– It is the process of converting raw materials (changing)
into products which encompasses design and
manufacture following a well-organized plan for each
activity required.
 Design process
 Product design is a critical activity, 70-80% of the cost of
product development & manufacture occurs at this stage.
(refer Figure 6 in text book).
 Product design is no longer a sequential process but rather
a concurrent process. (read: concurrent engineering or
simultaneous engineering).
– CE is a systematic approach integrating the design and
manufacture of products with view of optimizing all elements
involved in the life cycle of the product. Basic goals – to minimize
product design & engineering changes, hence time & costs.
 Life cycle – all aspects of a product (design, development,
production, distribution, use, disposal and recycling.
 Success determinants for CE;
– Full support from the upper management
– A multifunctional and interactive teamwork and support groups
– Utilizing all available technologies ; CAD, CAE, CAM, rapid
prototyping
 Overdesigns – surveys indicated that many products in the
past have been overdesigned; too bulky, materials of too
high quality, unwarranted precision and quality for the
intended uses.
 DFMA
 A comprehensive approach to production of goods
and integrates the design process with materials,
manufacturing methods, process planning,
assembly, testing and quality assurance at low cost
(economically).
 You can read more on DFMA at
http://www.dfma.com/ and
http://www.npd-solutions.com/dfmguidelines.html
 Material selection and process
selection
 Materials engineer
 How the materials will be processed?
 How the process will affect the materials?
 Time and cost effects consideration to
manufacture the materials
 Types of Goods
 Consumer Goods
– Items which are purchased directly by consumers
» Consumer electronics
» Clothing
 Producer Goods
– Items which are manufactured for other companies to
produce products from
» Sheet metals etc.
» Machine tool builders
» Automotive suppliers
 Products
 Fabricating - Manufacturing of products from
components, pieces, or sub-assemblies. Separate
discrete items such as machined parts, bolts, nuts
etc. are fabricated.
 Processing - Manufacturing a product in a
continuous series of operation . Examples include
wire, beverages, chemicals etc.
 Manufacturing a Product
 Production systems include
– People
– Money
– Equipment
– Materials
– Supplies
– Markets
– Management
– Manufacturing System
– All aspects of commerce
 Manufacturing a Product

 The Manufacturing System

The functions and systems of the production system, which includes (and services) the manufacturing
system. The functional departments are connected by formal and informal information systems
designed to service the manufacturing system that produces the goods.
 Manufacturing a Product

 The Manufacturing System

– Collection of operations and processes to produce a
desired product or component
– Design or arrangement of the manufacturing processes
 Roles of People in Mfg.
 Design engineer responsibilities
– What the design is to accomplish
– Assumptions that can be made
– Service environments the product must withstand
– Final appearance of the product
– Product designed with the knowledge that certain
manufacturing processes will be used
 Roles of People in Mfg.
 Manufacturing engineer responsibilities
– Select and coordinate specific processes and equipment
– Supervise and manage their use
 Industrial (Manufacturing) engineer
– Manufacturing systems layout
 Materials engineers
– Specify ideal materials
– Develop new and better materials
 Roles of People in Mfg.
 Technicians
– QC, machine set-up, machine maintenance, machine
repair, and system integration
 Machinist and Tool Makers
– Producing close tolerance parts and tooling to
specifications
 Operators
– Running production parts and quality
 Aspects of a Manufacturing System
 Mfg. Processes
– The method (s) used to convert a product from one form to
another- example metal removal. A process typically
involves a sequence of steps or operations.
 Characteristics of Process
Technology
 Mechanics
 Economics or costs
 Time Spans
 Constraints
 Uncertainties and process reliability
 Skills
 Flexibility
 Process capability
 Aspects of a Manufacturing System
 Operations
– Distinct action to produce a desired result or effect
– Categories of operations
» Materials handling and transport
» Processing
 Drilling, tapping, turning, milling, injecting

» Packaging
» Inspecting and testing
» Storing
Aspects of a Manufacturing System

Figure 1-6 The component called a pinion

shaft is manufactured by a “sequence of
operations” to produce various geometric
surfaces.
 Aspects of a Manufacturing System
 Job and station
– Job is a group of related operations generally done at one station
– Station is the location or area where production is done
 Treatments operate continuously on a workpiece
– Heat treating, curing, galvanizing, plating, finishing, chemical
cleaning, painting
 Tools, tooling and workholders
– Lowest mechanism in the production is a tool
» Used to hold, shape or form the unfinished product
 Tooling for measurement and inspection
– Rulers, calipers, micrometers, and gages
– Precision devices are laser optics or vision systems that utilize
electronics to interpret results
 Factory Layouts
 Job Shop
 Flow Shop
 Linked-Cell Shop
 Project Shop
 Continuous Process
Factory Layouts

Figure 1-15 Different manufacturing

system designs produce goods at different
production rates.
 Seven Basic Processes
 Casting
 Forming
 Machining
 Joining and Assembly
 Surface Treatment
 Heat Treatment
 Other
 Casting
 Molten metal fills a cavity in a mold.
 Quick method to transform a raw material into a
desired shape.
 Two types of casting methods:
– Expendable mold
» Sand casting
– Permanent mold
» Die casting
 Plastic, composite manufacturing, and PM
 Forming & Shearing
 Changing materials into a desired shape by:
– Squeezing
– Bending
– Shearing
– Drawing
 Utilizes Materials that have been previously cast or
molded
 Performed at “cold” or “hot” temperatures
– cold = room temp to .3 of the melt temperature material
– hot = above .3 of the melt temperature of the material
 Metal Removal - Machining
 Seven basic processes
– Shaping
– Turning
– Drilling
– Milling
– Sawing
– Broaching
– Abrasive machining
– Non-Traditional
» Examples: EDM & Water-Jet
 Joining
 Mechanical Fastening
 Welding
 Adhesive bonding
 Assembly
 Surface Treatment
 Aesthetic requirements
– Painting
 Product requirements
– Safety
» Burrs
– Surface treatment
» chemical plating to resist rust
 Heat Treatment
 Altering the mechanical properties of a material.
– Strength
– Wear resistance
– Resistance to penetration
 Other
 Inspection
 Packaging
 Transportation
 Waste disposal
– Scrap
– Chemical by-products
Product Life Cycle Cost
 Changing World Competition
 Globalization has impacted manufacturing
– Worldwide competition for global products and their
manufacture
– High tech manufacturing for advanced technology
– New manufacturing systems, designs, and management

 China as the next manufacturing superpower? (as

reported by Deloitte 2010).
 How Do We Plan For
Manufacturing?
 Definition of a need
 Conceptual design
 Review of initial design
 Design Prototype
 Production plan
 Resource specifications
 Manufacturing Prototype
 Manufacturing
 Inspection--quality checks
 Packaging - shipping
 Customer response
 New Manufacturing Systems
 Toyota Production System (just in time philosophy
and practice) (since 1948-1975)
– Lean manufacturing system
– 100% good units flow without interruption
– Integrated quality control
– Responsibility for quality is given to manufacturing
– Constant quality improvement
– Continuous improvement
New issues -Environmental issues /
sustainability
 Recently, concern for the environment has led
manufacturing industry to take a proactive role in
the development of cleaner manufacturing
processes and the design of recyclable products.
 The goal is sustainable development, where the
waste from one process becomes the raw material
for another in a large cycle which imitates the
natural food chain.