Post on 01-Jun-2018
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INTRODUCTION AND
OVERVIEW OF MANUFACTURING
1. What is Manufacturing?
2. Matria!s in Manufacturing
". Manufacturing #r$csss
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Manufacturing is I%&$rtant
Tchn$!$gica!!'
Ec$n$%ica!!'
(ist$rica!!'
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Manufacturing ) Tchn$!$gica!!' I%&$rtant
Tchn$!$g' ) th a&&!icati$n $f scinc t$ &r$*i+s$cit' an+ its %%,rs -ith th$s things thatar n++ $r +sir+
Tchn$!$g' &r$*i+s th &r$+ucts that h!& $ur
s$cit' an+ its %%,rs !i* ,ttr What +$ ths &r$+ucts ha* in c$%%$n?
Th' ar a!! %anufactur+
Manufacturing is th ssntia! fact$r that
%as tchn$!$g' &$ssi,!
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Manufacturing ) Ec$n$%ica!!' I%&$rtant
Manufacturing is $n
-a' ,' -hich nati$ns
crat %atria! -a!th
U.S. economy:
Sector % ofGNP
Manufacturing 2/0
Agricu!tur %inra!s tc. 0
C$nstructi$n 3 uti!itis 0
4r*ic sct$r 5 rtai!trans&$rtati$n ,aningc$%%unicati$n +ucati$n an+g$*rn%nt
6/0
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Manufacturing ) (ist$rica!!' I%&$rtant
Thr$ugh$ut hist$r' hu%an cu!turs that -r,ttr at %aing things -r %$r
succssfu!
Maing ,ttr t$$!s %ant ,ttr crafts 3
-a&$ns 7ttr crafts a!!$-+ &$&! t$ !i* ,ttr
7ttr -a&$ns a!!$-+ th% t$ c$n8ur
$thr cu!turs in ti%s $f c$nf!ict
T$ a significant +gr th hist$r' $f
ci*i!i9ati$n is th hist$r' $f hu%ans: a,i!it' t$
%a things
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What is Manufacturing?
Th -$r+ manufacture is +ri*+ fr$% t-$ ;atin-$r+s manus
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Manufacturing ) Tchn$!$gica!!'
Figur 1.1
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Manufacturing ) Ec$n$%ica!!'
Figur 1.1
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Manufacturing In+ustris
In+ustr' c$nsists $f ntr&riss an+ $rgani9ati$nsthat &r$+uc $r su&&!' g$$+s an+ sr*ics
In+ustris can , c!assifi+ as
1. #ri%ar' in+ustris ) th$s that cu!ti*at
an+ &!$it natura! rs$urcs .g.far%ing %ining
2. 4c$n+ar' in+ustris ) ta th $ut&uts $f
&ri%ar' in+ustris an+ c$n*rt th% int$
c$nsu%r an+ ca&ita! g$$+s )%anufacturing is th &rinci&a! acti*it'
". Trtiar' in+ustris ) sr*ic sct$r
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Manufacturing In+ustris ) c$ntinu+
4c$n+ar' in+ustris inc!u+ %anufacturingc$nstructi$n an+ !ctric &$-r gnrati$n
Manufacturing inc!u+s s*ra! in+ustris
-h$s &r$+ucts ar n$t c$*r+ in this ,$$>
.g. a&&ar! ,*rags ch%ica!s an+f$$+ &r$cssing
F$r $ur &ur&$ss %anufacturing %ans
&r$+ucti$n $f har+-ar
Nuts an+ ,$!ts f$rgings cars air&!ans+igita! c$%&utrs &!astic &arts an+
cra%ic &r$+ucts
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#r$+uct Varit' P
#r$+uct *arit' P rfrs t$ +iffrnt &r$+uctt'&s $r %$+!s &r$+uc+ in th &!ant
Diffrnt &r$+ucts ha* +iffrnt faturs
Th' ar intn++ f$r +iffrnt %arts
4$% ha* %$r &arts than $thrs Th nu%,r $f +iffrnt &r$+uct t'&s %a+
ach 'ar in a fact$r' can , c$unt+
Whn th nu%,r $f &r$+uct t'&s %a+ in
th fact$r' is high this in+icats high&r$+uct *arit'
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P *rsus Q in Fact$r' O&rati$ns
Figur 1.2 #) R!ati$nshi&
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M$r A,$ut #r$+uct Varit'
A!th$ugh P is a 8uantitati* &ara%tr it is%uch !ss act than Q ,caus +tai!s $n
h$- %uch th +signs +iffr is n$t ca&tur+
si%&!' ,' th nu%,r $f +iffrnt +signs
Soft product variety ) s%a!! +iffrncs
,t-n &r$+ucts .g. ,t-n car %$+!s
%a+ $n th sa% &r$+ucti$n !in -ith %an'
c$%%$n &arts a%$ng %$+!s
Hard product variety ) &r$+ucts +iffr
su,stantia!!' .g. ,t-n a s%a!! car an+ a!arg truc -ith f- c$%%$n &arts
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Manufacturing Ca&a,i!it'
A %anufacturing &!ant c$nsists $f processes an+systems
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1. Tchn$!$gica! #r$cssing Ca&a,i!it'
Th a*ai!a,! st $f %anufacturing &r$csss inth &!ant
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2. #h'sica! #r$+uct ;i%itati$ns
Gi*n a &!ant -ith a crtain st $f &r$csssthr ar si9 an+ -ight !i%itati$ns $n th
&arts $r &r$+ucts that can , %a+ in th &!ant
#r$+uct si9 an+ -ight affct
#r$+ucti$n 8ui&%nt
Matria! han+!ing 8ui&%nt
#r$+ucti$n %atria! han+!ing 8ui&%nt an+
&!ant si9 %ust , &!ann+ f$r &r$+ucts that !i
-ithin a crtain si9 an+ -ight rang
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". #r$+ucti$n Ca&acit'
Dfin+ as th %ai%u% 8uantit' that a &!antcan &r$+uc in a gi*n ti% &ri$+
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Matria!s in Manufacturing
M$st nginring %atria!s can , c!assifi+int$ $n $f thr ,asic catg$ris
1. Mta!s
2. Cra%ics
". #$!'%rs
Thir ch%istris ar +iffrnt
Thir %chanica! an+ &h'sica! &r$&rtis
ar +issi%i!ar
Ths +iffrncs affct th %anufacturing
&r$csss that can , us+ t$ &r$+uc
&r$+ucts fr$% th%
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In A++iti$n C$%&$sits
Figur 1." Vnn
+iagra% $f thr
,asic %atria! t'&s
&!us c$%&$sits
N$nh$%$gn$us %iturs $f th $thr thr,asic t'&s rathr than a uni8u catg$r'
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1. Mta!s
Usua!!' alloys -hich ar c$%&$s+ $f t-$ $r %$r!%nts at !ast $n $f -hich is %ta!!ic
T-$ ,asic gr$u&s
1. Frr$us %ta!s ) ,as+ $n ir$n c$%&riss
a,$ut 60 $f %ta! t$nnag in th -$r!+ 4t! F C a!!$'
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2. Cra%ics
C$%&$un+s c$ntaining %ta!!ic
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". #$!'%rs
C$%&$un+ f$r%+ $f r&ating structura! unitsca!!+ mers -h$s at$%s shar !ctr$ns t$
f$r% *r' !arg %$!cu!s
Thr catg$ris
1. Thr%$&!astic &$!'%rs ) can , su,ct+t$ %u!ti&! hating an+ c$$!ing c'c!s
-ith$ut a!tring %$!cu!ar structur
2. Thr%$stting &$!'%rs ) %$!cu!s
ch%ica!!' transf$r%
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H. C$%&$sits
Matria! c$nsisting $f t-$ $r %$r &hass thatar &r$css+ s&arat!' an+ thn ,$n++
t$gthr t$ achi* &r$&rtis su&ri$r t$ its
c$nstitunts
Phase ) h$%$gn$us %ass $f %atria!such as grains $f i+ntica! unit c!! structur
in a s$!i+ %ta!
Usua! structur c$nsists $f &artic!s $r fi,rs
$f $n &has %i+ in a sc$n+ &has
#r$&rtis +&n+ $n c$%&$nnts &h'sica!
sha&s $f c$%&$nnts an+ th -a' th' ar
c$%,in+ t$ f$r% th fina! %atria!
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Manufacturing #r$csss
T-$ ,asic t'&s
1. #r$cssing $&rati$ns ) transf$r% a -$r
%atria! fr$% $n stat $f c$%&!ti$n t$ a
%$r a+*anc+ stat
O&rati$ns that chang th g$%tr'&r$&rtis $r a&&aranc $f th starting
%atria!
2. Ass%,!' $&rati$ns ) $in t-$ $r %$r
c$%&$nnts t$ crat a n- ntit'
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Figur 1.H C!assificati$n $f %anufacturing &r$csss
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#r$cssing O&rati$ns
A!trs a %atria!s sha& &h'sica! &r$&rtis$r a&&aranc in $r+r t$ a++ *a!u
Thr catg$ris $f &r$cssing $&rati$ns
1. 4ha&ing $&rati$ns ) a!tr th g$%tr'
$f th starting -$r %atria!2. #r$&rt' nhancing $&rati$ns )‑
i%&r$* &h'sica! &r$&rtis -ith$ut
changing sha&
". 4urfac &r$cssing $&rati$ns ) t$c!an trat c$at $r +&$sit %atria! $n
tri$r surfac $f th -$r
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4ha&ing #r$csss 5 F$ur Catg$ris
1. 4$!i+ificati$n &r$csss ) starting %atria!is a hat+ !i8ui+ $r s%if!ui+
2. #articu!at &r$cssing ) starting %atria!
c$nsists $f &$-+rs
". Df$r%ati$n &r$csss ) starting %atria!is a +ucti! s$!i+
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4$!i+ificati$n #r$csss
4tarting %atria! is hat+ sufficint!' t$transf$r% it int$ a !i8ui+ $r high!' &!astic stat
Ea%&!s %ta! casting &!astic %$!+ing
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#articu!at #r$cssing
4tarting %atria!s ar &$-+rs $f %ta!s $rcra%ics
Usua!!' in*$!*s &rssing an+ sintring in
-hich &$-+rs ar first c$%&rss+ an+ thn
hat+ t$ ,$n+ th in+i*i+ua! &artic!s
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Df$r%ati$n #r$csss
4tarting -$r&art is sha&+ ,' a&&!icati$n $ff$rcs that c+ th 'i!+ strngth $f th
%atria!
Ea%&!s
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Matria! R%$*a! #r$csss
Ecss %atria! r%$*+ fr$% th starting &ics$ -hat r%ains is th +sir+ g$%tr'
Ea%&!s %achining such as turning +ri!!ing
an+ %i!!ing> a!s$ grin+ing an+ n$ntra+iti$na!
&r$csss
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Wast in 4ha&ing #r$csss
Dsira,! t$ %ini%i9 -ast in &art sha&ing Matria! r%$*a! &r$csss ar -astfu! in
unit $&rati$ns si%&!' ,' th -a' th' -$r
M$st casting %$!+ing an+ &articu!at
&r$cssing $&rati$ns -ast !itt! %atria! Tr%in$!$g' f$r %ini%u% -ast &r$csss
Net shape &r$csss ) -hn %$st $f th
starting %atria! is us+ an+ n$
su,s8unt %achining is r8uir+ Near net shape &r$csss ) -hn
%ini%u% a%$unt $f %achining is r8uir+
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#r$&rt' Enhancing #r$csss‑
#rf$r%+ t$ i%&r$* %chanica! $r &h'sica!&r$&rtis $f -$r %atria!
#art sha& is n$t a!tr+ c&t
unintnti$na!!'
Ea%&! unintnti$na! -ar&ing $f a hattrat+ &art
Ea%&!s
(at trat%nt $f %ta!s an+ g!asss
4intring $f &$-+r+ %ta!s an+ cra%ics
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4urfac #r$cssing O&rati$ns
C!aning ) ch%ica! an+ %chanica!&r$csss t$ r%$* +irt $i! an+ $thr
c$nta%inants fr$% th surfac
4urfac trat%nts ) %chanica! -$ring
such as san+ ,!asting an+ &h'sica!&r$csss !i +iffusi$n
C$ating an+ thin fi!% +&$siti$n ) c$ating
tri$r surfac $f th -$r&art
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Ass%,!' O&rati$ns
T-$ $r %$r s&arat &arts ar $in+ t$ f$r% an- ntit'
T'&s $f ass%,!' $&rati$ns
1. J$ining &r$csss 5 crat a &r%annt
$int W!+ing ,ra9ing s$!+ring an+
a+hsi* ,$n+ing
2. Mchanica! ass%,!' 5 fastning ,'
%chanica! %th$+s Thra++ fastnrs &rss fitting &ansi$n fits
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#r$+ucti$n 4'st%s
#$&! 8ui&%nt an+ &r$c+urs us+ f$r thc$%,inati$n $f %atria!s an+ &r$csss that
c$nstitut a fir%:s %anufacturing $&rati$ns
A %anufacturing fir% %ust ha* s'st%s an+
&r$c+urs t$ fficint!' acc$%&!ish its t'&$f &r$+ucti$n
T-$ catg$ris $f &r$+ucti$n s'st%s
#r$+ucti$n faci!itis
Manufacturing su&&$rt s'st%s
7$th catg$ris inc!u+ &$&!
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Faci!itis *rsus #r$+uct uantitis
A c$%&an' +signs its %anufacturing s'st%s
an+ $rgani9s its fact$ris t$ sr* th
&articu!ar %issi$n $f ach &!ant
Crtain t'&s $f &r$+ucti$n faci!itis ar
rc$gni9+ as th %$st a&&r$&riat f$r a
gi*n t'& $f %anufacturing
1. ;$- &r$+ucti$n 5 1 t$ 1//
2. M+iu% &r$+ucti$n 5 1// t$ 1////
". (igh &r$+ucti$n 5 1//// t$ L1//////
Diffrnt faci!itis ar r8uir+ f$r ach $f th
thr 8uantit' rangs
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;$- #r$+ucti$n
Job shop is th tr% us+ f$r this t'& $f&r$+ucti$n faci!it'
A $, sh$& %as !$- 8uantitis $f
s&cia!i9+ an+ cust$%i9+ &r$+ucts
#r$+ucts ar t'&ica!!' c$%&! .g.s&ac ca&su!s &r$t$t'& aircraft s&cia!
%achinr'
E8ui&%nt in a $, sh$& is gnra! &ur&$s
;a,$r f$rc is high!' si!!+ Dsign+ f$r %ai%u% f!i,i!it'
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M+iu% #r$+ucti$n
T-$ +iffrnt t'&s $f faci!it' +&n+ing $n&r$+uct *arit'
Batch production
4uit+ t$ har+ &r$+uct *arit'
4tu&s r8uir+ ,t-n ,atchs
Cellular manufacturing
4uit+ t$ s$ft &r$+uct *arit'
W$rr c!!s $rgani9+ t$ &r$css &arts-ith$ut stu&s ,t-n +iffrnt &art st'!s
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(igh #r$+ucti$n
Oftn rfrr+ t$ as mass production (igh +%an+ f$r &r$+uct
Manufacturing s'st% ++icat+ t$ th
&r$+ucti$n $f that &r$+uct
T-$ catg$ris $f %ass &r$+ucti$n
1. uantit' &r$+ucti$n
2. F!$- !in &r$+ucti$n
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uantit' #r$+ucti$n
Mass &r$+ucti$n $f sing! &arts $n sing!%achin $r s%a!! nu%,rs $f %achins
T'&ica!!' in*$!*s stan+ar+ %achins 8ui&&+
-ith s&cia! t$$!ing
E8ui&%nt is ++icat+ fu!!)ti% t$ th&r$+ucti$n $f $n &art $r &r$+uct t'&
T'&ica! !a'$uts us+ in 8uantit' &r$+ucti$n ar
&r$css !a'$ut an+ c!!u!ar !a'$ut
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F!$- ;in #r$+ucti$n
Mu!ti&! %achins $r -$rstati$ns arrang+ ins8unc .g. &r$+ucti$n !ins
#r$+uct is c$%&!
R8uirs %u!ti&! &r$cssing an+B$r
ass%,!' $&rati$ns W$r units ar &h'sica!!' %$*+ thr$ugh th
s8unc t$ c$%&!t th &r$+uct
W$rstati$ns an+ 8ui&%nt ar +sign+
s&cifica!!' f$r th &r$+uct t$ %ai%i9fficinc'
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O*r*i- $f Ma$r T$&ics
Figur 1.1/ O*r*i- $f &r$+ucti$n s'st% an+ %a$rt$&ics in Fundamentals of Modern Manufacturing .
A t ! i t ! i i h i f , i
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A s&ctacu!ar scn in st!%aing is charging $f a ,asic $'gn
furnac in -hich %$!tn &ig ir$n &r$+uc+ in a ,!ast furnac is
&$ur+ int$ th 7OF. T%&raturs ar ar$un+ 1/C
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A %achining c!! c$nsisting $f t-$ h$ri9$nta! %achining cntrs
su&&!i+ ,' an in)!in &a!!t shutt!
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A r$,$tic ar% &rf$r%s
un!$a+ing an+ !$a+ing
$&rati$n in a turning
cntr using a +ua! gri&&r
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Mta! chi&s f!' in a high
s&+ turning $&rati$n
&rf$r%+ $n a c$%&utr
nu%rica! c$ntr$! turningcntr
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#h$t$%icr$gra&h $f th cr$ss scti$n $f %u!ti&! c$atings $f
titaniu% nitri+ an+ a!u%inu% $i+ $n a c%nt+ car,i+
su,strat
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A ,atch $f si!ic$n -afrs ntrs a furnac hat+ t$ 1/// C
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T-$ -!+rs &rf$r% arc
-!+ing $n a !arg st!
&i& scti$n
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Aut$%at+ +is&nsing $f
a+hsi* $nt$ c$%&$nnt
&arts &ri$r t$ ass%,!'
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Ass%,!' -$rrs $n an
ngin ass%,!' !in
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Ass%,!' $&rati$ns
$n th 7$ing 666