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Ch1 introduction Erdi Karaçal Mechanical Engineer University of Gaziantep
- 1. ME 333 MANUFACTURING PROCESSES-II INTRODUCTION TO MANUFACTURING & PRODUCTION Lecturer(s): Prof. Dr. Ömer EYERCİOĞLU & Asst.Prof.Dr. Oğuzhan YILMAZ 1
- 2. Chapter 1 INTRODUCTION 1.1. WHAT IS MANUFACTURING? Manus (hand) Factus (make) manufacture Technologically: Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products including assembly of multiple parts. Machinery Tooling Power Labor Manufacturing Process Scrap and Waste Raw Material Processed Material 2
- 3. Chapter 1 INTRODUCTION Economically: Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations. Manufacturing Process Value added Starting material Material in processing Processed material 3
- 4. Chapter 1 INTRODUCTION MANUFACTURED PRODUCTS AND PRODUCTION QUANTITY Final products made by the industries can be divided into two major classes: Consumer goods: products purchased directly by consumers, eg TV, car, tires etc. Capital goods : purchased by other companies to produce goods and supply services, eg. Aircraft, machine tools, construction equipment etc. Production quantity refers to the number of units produced annually of a particular product type. The quantity (Q) of products made annually by a factory can be classified into three ranges: low production Q<100 medium production 100<Q<10 000 high production 10 000<Q 4
- 5. Chapter 1 INTRODUCTION Product variety refers to different product designs or types that are produced in the plant. Product variety 102 104 106 Production quantity Low Medium High 5
- 6. Chapter 1 INTRODUCTION Manufacturing is important: technologically, economically and historically. TECHNOLOGY can be defined as the application of science to provide society and its members with those things that are needed or desired. Manufacturing is the essential factor that makes technology possible. Economically, manufacturing is important means by which a nation creates material wealth. Historically, the importance of manufacturing in the development of civilization is usually underestimated. But throughout history human cultures that were better at making things were more successful. The words PRODUCTION and MANUFACTURING are often used interchangeably. But production has a broader meaning than manufacturing. For example oil production seems better than oil manufacturing. We can use both for metal parts and automobiles. 6
- 7. Chapter 1 INTRODUCTION 7 Manufacturing Processes Processing Operations Assembly Operations Shaping Processes Property Enhancing Processes Surface Processing Operations Casting, Molding, etc. Particulate Processing Deformation Processing Material Removal Heat Treatment Cleaning and Surface Treatments Coating and Deposition Processes Welding Brazing and Soldering Adhesive Bonding Threaded Fasteners Permanent Fastening Methods Permanent Joining Processes Mechanical Fastening
- 8. Chapter 1 INTRODUCTION Manufacturing Process Selection: - Geometric features of the parts to be produced - Dimensional tolerances - Surface Texture - Workpiece Material etc. Example: • Flat parts and thin cross sections can be difficult to cast • Complex parts generally cannot be shaped easily and economically by such metal working techniques • Dimensional tolerances and surface finish in hot-working operations are not a fine as compared to cold working 8
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- 15. Chapter 1 INTRODUCTION Near-shape and Near-net shape Manufacturing • Net-shape and near net-shape manufacturing together constitute an important methodology by which a part is made in only one operation at or close to the FINAL desired dimensions, tolerances, and surface finish. • The difference net-shape and near net-shape is a matter of degree how close the product is to its final dimensional characteristics. Example: • a cast or forged gear • crankshaft crank shaft forging die Additive manufacturing part 15
- 16. Chapter 1 INTRODUCTION Precision and ultra precision Manufacturing Micromechanical and microelectromechanical device fabrication needs highly sophisticated technologies and highly accurate equipments. Micro machining uses 250 micrometer diameter cutting tool nose. The equipments (or machines) used in precision or ultra precision manufacturing should be highly specialized, with very high stiffness ( to minimise deflection as well as vibration and chatter during machining) and should be operated in a temperature controlled enviroment in order to avoid thermal distortions. 16
- 17. Chapter 1 INTRODUCTION Computer-Integrated Manufacturing (CIM) CIM integrates the software and hardware needed for computer graphics, computer-aided modelling and computer aided design and manufacturing activities, from initial product concept through its production and distribution in the market place. Elements of CIM: 1. Computer numerical control (CNC) 2. Adaptive Control (AC) 3. Industrial robots 4. Automated materials handling 5. Automated assembly systems 6. Computer-aided process planning (CAPP) : improving productivity, product quality, reducing costs. Cost estimating and monitoring etc. 7. Group technology (GT) 8. Just-in-time production (JIT): (1) supplies of the raw material and parts are delivered to the manufacturer just in time to be used, (2) parts and components are produced just in time to be made into subassemblies, and (3) products are assebled and finished just in time to be delivered to the customer 17
- 18. Chapter 1 INTRODUCTION Computer-Integrated Manufacturing (CIM) 9. Cellular Manufacturing (CM): Different operations are made in different cell 10. Flexible manufacturing systems (FMS): 11. Expert Systems (ES) 12. Artificial Intelligence (AI) 13. Artificial Neural network (ANN): simulates human brain with such capabilities as modelling and simulating production facilities, monitoring and controlling manufacturing process, diagnosing problems in machine performance etc. 18
- 19. Chapter 1 INTRODUCTION 1.2. PRODUCTION SYSTEMS CONTINUOUS MASS & FLOWLINE BATCH GROUP TECHNOLOGY SINGLE ONE OFF TYPES OF PRODUCTION Continuous Production: The material or product to the same specification is produced continuously for 24 hrs daily throughout the year except for maintenance or seasonal variation of raw material supply. •highly automated and specialised process: uses special machinery and equipment •if the process is stopped even for a short time, damage of materials and equipment will occur •oil refineries, iron and steel production are the examples. 19
- 20. Chapter 1 INTRODUCTION Mass and flowline production: It covers mechanical items to be manufactured one after the other to the same specifications throughout the year in 1, 2, or 3 shifts until the model changes • the demand must be in large quantities • highly automated transfer and special purpose machines are used involves heavy capital expenditure on plant • manufacture of motor cars is an example. Batch Production (Job lot or intermittent): Processes items when and as ordered. Small lot of items is ordered and once the lot is completed it is likely that it will never be manufactured again. • flexibility of operations is very important • general purpose automatic machines are used • degree of automation depends on production volume (generally small volume items) • same product may be produced several times a year at different dates 20
- 21. Chapter 1 INTRODUCTION Group Technology (GT or cellular) Production: GT is the definition of identifying and bringing together related or similar parts in a production process in order to utilize the inherent economy of flow production methods. GT in manufacturing is the replacing of traditional job lot manufacture by analysis and grouping of work into families (size, shape, material, tolerance, surface finish and required production operations) and formation of groups of machines to manufacture these families on a flowline principle with the object of minimising setting times and throughput times. One Off Production to Order: (Single Production) Single or few machinery, equipment or vessels are manufactured to a specified design. general purpose machine tools for specific sizes are used automation is not considered general except welding production of marine gearboxes, ship building are the examples. Production for Repair and Maintenance: No new end product except that the present one is repaired. 21
- 22. Chapter 1 INTRODUCTION 1.3. ORGANIZATION OF PRODUCTION Plant Layout is a plan, or the act of planning, an optimum arrangement of industrial facilities, including personal, operating equipment, storage space, material handling equipment, and all other supporting services with the design of the best structure to contain these facilities. MEN MACHINE Materials Supporting activities THE BEST LAYOUT FIXED POSITION LAYOUT PROCESS LAYOUT CELLULAR LAYOUT PRODUCT LAYOUT TYPES OF LAYOUT In practice, most factories are laid out using a combination of these layouts 22
- 23. Chapter 1 INTRODUCTION Product remains in a fixed position 1.3.1. FIXED POSITION LAYOUT Tools Labour Materials Characteristics: least important today e. g. shipbuilding, house building, large assembly works Advantages: Allows worker to identify with a particular product which can results in high job satisfaction and high quality standards Flexible: allows frequent product or design changes May reduce investment in mechanical handling equipment Adaptable to changes in demand. Disadvantages: High degree of skill required. This can limit flexibility and put up cost of labour May cause scheduling problems where more than one group of workers is involved. 23
- 24. Chapter 1 INTRODUCTION 1.3.2. PRODUCT LAYOUT C D T M G Raw Material Finished product Characteristics: only one type of product are produced, machines are arranged in the order of operation the product must be standardized and manufactured in large quantities Advantages: high through-put usually less skilled labour required lower total material handling cost lower total production time less work-in-progress high level of performance due to greater incentive for group of workers less floor area required per unit of production simple production control, fewer records and lower accounting cost Disadvantages: Inflexible to design, processing and volume changes High initial capital investment required Susceptible to absenteeism, breakdown and dispute Difficult lo balance lines 24
- 25. Chapter 1 INTRODUCTION 1.3.3. PROCESS LAYOUT (FUNCTIONAL LAYOUT) M M Characteristics: M M groups together all operations of the same workpiece passes from department to department according to sequence of operations to be performed Advantages: flexible: can cope with a wide variety of products, frequent design changes and varying demand easy to maintain continuity in the case of breakdown or absenteeism by transferring work to another machine less duplication of equipment, hence lower total investment in equipment better and more efficient supervision possible through specialization high level of performance better control of process Disadvantages: high cost of material handling lower through-put high work-in-progress skilled labour is required extensive scheduling and control required 25 T T T T G G : G G C C C
- 26. Chapter 1 INTRODUCTION USE PRODUCT LAYOUT WHEN USE PROCESS LAYOUT WHEN One or few standard product Many types or styles of products Large volume of production of each item Relatively low volume of individual product Possibility of motion and time studies to determine rate of work Adequate motion and time studies difficult or impossible to make Possibility of good labour and equipment balance Difficult to achieve labour and equipment balance Minimum of inspection required during sequence of operations Many inspection required during sequence of operations Minimum of very heavy equipment requiring special facilities High portion of very heavy equipment requiring special facilities Materials and products permit bulk or continuous handling by mechanical means Materials and products are too large or too heavy to permit bulk or continuous handling by mechanical means Little or no need to use same machine or work station for more than one operation Frequent need to use same machine work station for more than one operation 26
- 27. Chapter 1 INTRODUCTION 1.3.4. GROUP TECHNOLOGY (CELLULAR LAYOUT) G M G M M M T T T T : C C G C Characteristics: groups together similar parts Mass and flowline principle is applied to each cell 27
- 28. Chapter 1 INTRODUCTION MANUFACTURING COSTS The economics of manufacturing has become even more so with; (a) ever-increasing global compition (b) The demand for the high quality products Typically, the manufacturing cost of a product represents about 40% ot its selling price, which often is the overriding consideretion in a product marketability and general customer satisfaction The total costs of manufacturing of a product generally consits of the following components: 1. Materials: raw material costs 2. Tooling: cutting tools, dies, molds, workholding devices, and fixtures. 3. Fixed: Cost of energy, rent for facilities, insurance and real-estate taxes 4. Capital: production machinery, equipment, buildings, and land 5. Labor: Direct and indirect costs. Direct labor is productive labor which directly related to the production. Indirect laboring is for servicing of the total manufacturing operations. 28
- 29. Chapter 1 INTRODUCTION Product Design and Concurent Engineering Product design involves the creative and systematic prescription of the shape and the characteristics of an artifact to achieve specified objectives while simultaneously satisfiying several constraints. 29
- 30. Chapter 1 INTRODUCTION Concurent Engineering (Simultaneous engineering): The applications of tools, techniques, methodologies, and behavioral, initiatives used to minimize product development timescales by maximizing the degree of overlap of design activities 30
- 31. Chapter 1 INTRODUCTION Green Design and Manufacturing OR Green Manufacturing Every year millions of cars, tires, lamps, plastic prodcuts etc are discarded. From manufacturing point of view; manufacturing operations generally produce waste, such as: - chips - slag - additives (sand casting operations) - hazardous waste - lubricants and coolants - processed liquids - solvents - smoke and pollutants Green design concerns with selection of enviromentally friendly design, selection of material and manufacturing processes. Green manufacturing is now concerning of reusing the waste products and recylicing them in an effective way. 31