Scribd
Upload
74 views6 pages

Workshop/ Manufacturing Practices: Lecture - 1 Introduction To Manufacturing Methods

Manufacturing transforms raw materials into finished goods through various processing and assembly operations. It can be defined technically as altering the geometry, properties, or appearance of materials, or economically as transforming materials into items of greater value. There are two main types of manufacturing processes: processing operations alter the state of individual components, while assembly operations join two or more components. A product's life cycle and the appropriate manufacturing system are related - new products may use low-volume start-up systems while mature products employ standardized high-volume systems. Successful manufacturing requires understanding how the overall system works from a technical, economic, and human perspective.

Uploaded by

Sasthi Hens
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
74 views6 pages

Workshop/ Manufacturing Practices: Lecture - 1 Introduction To Manufacturing Methods

Manufacturing transforms raw materials into finished goods through various processing and assembly operations. It can be defined technically as altering the geometry, properties, or appearance of materials, or economically as transforming materials into items of greater value. There are two main types of manufacturing processes: processing operations alter the state of individual components, while assembly operations join two or more components. A product's life cycle and the appropriate manufacturing system are related - new products may use low-volume start-up systems while mature products employ standardized high-volume systems. Successful manufacturing requires understanding how the overall system works from a technical, economic, and human perspective.

Uploaded by

Sasthi Hens
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 6

WORKSHOP/ MANUFACTURING PRACTICES

Lecture - 1

Introduction to Manufacturing Methods

Figure – 1 Cross section of a jet engine

Take few moments and inspect various objects around you: your pen, watch, calculator, chair
and light fixture. You will soon realize that all these objects had a different shape at one time.
You could not find them in nature as they appear in your room. They had been transformed from
various raw materials and assembled into the shapes that you now see.

Product Number of parts


Rotary lawn mower 300
Grand piano 12000
Automobile 15000
C-5A transport plane ˃ 4,000,000
Boeing 747-400 ˃ 6,000,000
What is “Manufacturing”?
The English word manufacture is several centuries old. The term manufacture comes from two
Latin words, manus (hand) and factus (make). As per oxford English dictionary manufacture
refers “to make or produce goods in large quantities, using machinery”.

Working definition of manufacturing


There are two types of working definitions available for manufacturing: as a technical process
and as an economic process.

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 product
as shown in Figure 2.

Figure 2: Definition of manufacturing in terms of technology.

Economically: Manufacturing is the transformation of materials into items of greater value by


means of one or more process and or assembly operation as shown in Figure 3.
Figure 3: Definition of manufacturing in terms of economic value

Classification of manufacturing processes


Manufacturing processes can be classified as (Refer Figure 4) processing operation and assembly
operation.

In processing operation the work material is transformed from one state to other advanced state.
Through this operation value is added to the work material by changing the geometry; shape
properties, appearance etc. of the starting work material. Usually processing operations are
performed on individual component. But in some cases like aerospace industry, the processing
operations are performed on assembled items also.

In assembly operation two or more components are joined to create a new entity. The new entity
is called assembly, subassembly based on its state in the product. If the entity is an intermediate
state of the product, it is called subassembly. Some other terms are also referred based on the
joining process. The assembly created by welding operation is called weld met.

Job and Station


In classical manufacturing, a job is defined as the total work or duties a worker performs. A
station is a location or area where a production worker performs tasks and jobs. A job at an
assembly station may consist of the following tasks:

1) Attach carburetor
2) Connect gas line
3) Connect vacuum line
4) Connect accelerator rod.

Jobs and stations are now applied to unmanned machines also. A simple machine may have only
station. A complex machine may have multiple stations.

Operation
An operation is a distinct action performed to produce a desired result. Operations can be
1) Materials handling and transporting
2) Processing
3) Packaging
4) Inspecting and testing
5) Storing

Treatments
Treatments operate continually on the work piece. These modify the product in process without
tool contact. Some examples include heat treating, curing, galvanizing, plating, finishing,
(chemical) cleaning and painting. These are often done in large tanks or furnaces or rooms, away
from workers as they can be harmful.

Basic Manufacturing Processes


It is described as the manufacturing processes which create or add value to a product. The
manufacturing processes can be classified as:

• Casting, foundry, or moulding processes


• Forming or metalworking processes
• Machining (material removal) processes
• Joining and assembly
• Surface treatments (finishing)
• Rapid prototyping
• Heat treating
• Other
Other manufacturing operations include inspection, testing, transportation, automated material
handling and even packaging. In casting, the metal is heated sufficiently to make it into liquid
and then poured into moulds of desired shapes. Various machining operations are turning,
drilling and milling. Joining processes include welding, soldering, brazing and adhesive bonding.
The process of heat treating is carried out to enhance various properties and include annealing
and strengthening processes for metals and glasses. Surface processing includes cleaning,
coating and thin film deposition, electroplating, anodising etc.

Figure 4: Classification of manufacturing process


Product Life cycle and life cycle cost

Manufacturing systems are dynamic and liable to change over time. Thus there is a traditional
relation between a product's life cycle and the kind of manufacturing system used to make it. The
life cycle consists of the following steps:

1) Start-up: new product or new company, low volumes


2) Rapid growth: product becomes standardized in the market, higher volumes
3) Maturation: designs become standard, process development becomes important
4) Commodity: long life, standard of the industry type of product
5) Decline: product replaced by improved products.

Manufacturing System Design


A manufacturing system must consider two customers namely, the external that buys that the
product and the internal that makes the product. The external customer may be global in scope,
but the internal customer is critical in determining the design and manufacturing stages. The
complexity of the manufacturing system design where choices of system design trade off with
parts variety.

Summary
Manufacturing becomes successful by understanding how the system works, how goods are
controlled, the decision making at the correct level. Engineers must possess a broad fundamental
knowledge of design, metallurgy, processing, economics, accounting and human relations.

You might also like