1 - Introduction and Overview of

Manufacturing

Manufacturing Processes - 2, IE-352

Ahmed M El-Sherbeeny, PhD
Spring-2016

1 Chapter 1
 INTRODUCTION AND
OVERVIEW OF MANUFACTURING

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems

2 Chapter1- Part1
1- What is manufacturing?

“act of making something (a product)

from raw materials”

3 Chapter 1- Part 1
 Manufacturing is Important
 Technologically
 Economically
 Historically

4 Chapter1- Part1
Manufacturing - Technologically Important
What is technology?

Technology - the application of science to provide society

and its members with those things that are needed or
desired
Technology provides the products that help our society
and its members live better

What do these products have in common?

They are all manufactured

Manufacturing is the essential factor that makes technology
possible

5 Chapter1- Part1
 Manufacturing - Economically Important

U.S. economy:

% of
Sector
GNP*
Manufacturing 20%

Manufacturing is one Agriculture, minerals, etc. 5%

way by which nations Construction & utilities 5%
create material wealth
Service sector – retail, 70%
transportation, banking,
communication, education, and
government
* GNP= Gross Net Product

6 Chapter1- Part1
 What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means “made by hand”

 Most modern manufacturing operations are

accomplished by mechanized and automated
equipment that is supervised by human
workers

7 Chapter1- Part1
 Manufacturing - Technologically
Application of physical and chemical processes to
alter the geometry, properties, and/or appearance
of a starting material to make parts or products
 Manufacturing also includes assembly
 Almost always carried out as a sequence of operations

Figure 1.1 (a)

Manufacturing
as a technical
process

8 Chapter1- Part1
 Manufacturing - Economically
Manufacturing adds value to the material by
changing its shape or properties, or by combining
it with other materials (this is done by means of one or
more processing and/or assembly operations)

Figure 1.1 (b)

Manufacturing
as an economic
process

9 Chapter1- Part1
 Manufacturing Industries
Industry consists of enterprises and organizations
that produce or supply goods and services

Industries can be classified as:

Primary industries - those that cultivate and exploit
natural resources, e.g., farming, mining

Secondary industries - take the outputs of primary

industries and convert them into consumer and capital
goods - manufacturing is the principal activity, other
examples: construction, and electric power generation

Tertiary industries - service sector, e.g. banking

10 Chapter1- Part1
Manufacturing Industries - continued

 Manufacturing includes several industries whose products

are not covered in this book; e.g., apparel, beverages,
chemicals, and food processing

 For our purposes, manufacturing means

production of hardware
 Nuts and bolts, forgings, cars, airplanes,
digital computers, plastic parts, and
ceramic products

11 Chapter1- Part1
 Production Quantity Q

The quantity of products Q made by a factory has

an important influence on the way its people,
facilities, and procedures are organized
 Annual production quantities can be classified
into three ranges:

Production range Annual Quantity Q

Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions

12 Chapter1- Part1
 Product Variety P
Product variety P refers to different product
types or models produced in the plant.

 Different products have different features

 They are intended for different markets
 Some have more parts than others

 When the number of product types made in

the factory is high, this indicates high
product variety

13 Chapter1- Part1
P versus Q in Factory Operations

Figure 1.2 P-Q Relationship

14 Chapter1- Part1
More About Product Variety
Although P is a quantitative parameter, it is much less
exact than Q because details on how much the
designs differ is not captured simply by the
number of different designs

 Soft product variety - small

differences between products, e.g.,
between car models made on the same
production line, with many common parts
among models
 Hard product variety - products differ
substantially, e.g., between a small car
and a large truck, with few common parts (if
any)

15 Chapter1- Part1
 Manufacturing Capability
A manufacturing plant consists of processes and
systems (and people, of course) designed to
transform a certain limited range of materials
into products of increased value.

The three building blocks - materials, processes, and

systems - are the subject of modern manufacturing.

16 Chapter1- Part1
Manufacturing capability includes:

1. Technological processing capability

2. Physical product limitations
3. Production capacity

17 Chapter1- Part1
1. Technological Processing Capability
The available set of manufacturing processes
in the plant (or company)

• Certain manufacturing processes are suited

to certain materials
(By specializing in certain processes, the plant is also
specializing in certain materials)

• Includes not only the physical processes,

but also the expertise of the plant personnel

Examples:
A machine shop cannot roll steel
A steel mill cannot build cars

18 Chapter1- Part1
 2. Physical Product Limitations
Given a plant with a certain set of processes,
there are size and weight limitations on the
parts or products that can be made in the plant

 Product size and weight affect:

 Production equipment
 Material handling equipment

19 Chapter1- Part1
3. Production Capacity (or plant capacity)
Defined as the maximum quantity that a plant
can produce in a given time period (e.g.,
month or year) under assumed operating
conditions

Operating conditions refer to number of shifts

per week, hours per shift, direct labor manning
levels in the plant, and so on

Capacity is measured in terms of output units,

such as tons of steel or number of cars
produced by the plant

20 Chapter1- Part1
2- Materials in Manufacturing

21 Chapter 1- Part 1
 Materials in Manufacturing

Most engineering materials can be classified

into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers

Their chemistries and also their mechanical

and physical properties are different
 These differences affect the manufacturing
processes that can be used to produce products
from them

22 Chapter1- Part1
 1. Metals
Usually alloys, which are composed of two or more
elements, at least one of which is metallic

Two basic groups:

Ferrous metals - based on iron, comprises
about 75% of metal tonnage in the world:
Steel = Fe-C alloy (0.02 to 2.11% C)
Cast iron = Fe-C alloy (2% to 4% C)

Nonferrous metals - all other metallic

elements and their alloys: aluminum, copper,
magnesium, nickel, silver, tin, titanium, etc.

23 Chapter1- Part1
 2. Ceramics
Compounds containing metallic (or semi-metallic)
and nonmetallic elements.
Typical nonmetallic elements are oxygen,
nitrogen, and carbon
 For processing, ceramics divide into:
1. Crystalline ceramics – includes:
 Traditional ceramics, such as clay
(hydrous aluminum silicates)
 Modern ceramics, such as alumina
(Al2O3)
2. Glasses – mostly based on silica
(SiO2)

24 Chapter1- Part1
 3. Polymers

Compound formed of repeating structural units called

mers, whose atoms share electrons to form very large
molecules

25 Chapter1- Part1
 3- Polymers

Three categories:
1. Thermoplastic polymers - can be
subjected to multiple heating and cooling
cycles without altering molecular structure

2. Thermosetting polymers - molecules

chemically transform (cure) into a rigid
structure – cannot be reheated

3. Elastomers - shows significant elastic

behavior

26 Chapter1- Part1
 In addition- Composites
Nonhomogeneous mixtures of the other three basic
types rather than a unique category

Figure 1.3 Venn

diagram of three
basic material types
plus composites

27 Chapter1- Part1
 Composites
Material consisting of two or more phases that
are processed separately and then bonded
together to achieve properties superior to its
constituents
Phase - homogeneous mass of
material, such as grains of identical
unit cell structure in a solid metal

Usual structure consists of particles

or fibers of one phase mixed in a
second phase

Properties depend on components,

physical shapes of components,
and the way they are combined to
form the final material

28 Chapter1- Part1
Composites

29 Chapter1- Part1
3- Manufacturing Processes

30 Chapter1- Part2
Manufacturing Processes
Two basic types:
1. Processing operations -
transform a work material from
one state of completion to a
more advanced state
 Operations that change the geometry,
properties, or appearance of the
starting material

2. Assembly operations - join two

or more components to create a
new entity

31 Chapter1- Part2
Figure 1.4 Classification of manufacturing processes

D
2

32 Chapter1- Part2
 Processing Operations

Alters a material’s shape, physical

properties, or appearance in order to
Click to see figure 1-4 again
add value
 Three categories of processing
operations:
1. Shaping operations - alter the
geometry of the starting work material

2. Property-enhancing operations -
improve physical properties without
changing shape

3. Surface processing operations - to

clean, treat, coat, or deposit material on
exterior surface of the work
33 Chapter1- Part2
A
Shaping Processes – Four Categories
1. Solidification processes - starting material
is a heated liquid or semifluid
2. Particulate processing - starting material
consists of powders
3. Deformation processes - starting material
is a ductile solid (commonly metal)
4. Material removal processes - starting
material is a ductile or brittle solid

34 Chapter1- Part2
A
1- Solidification Processes
Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
 Examples: metal casting, plastic molding

35 Chapter1- Part2
 A
2- Particulate Processing
Starting materials are powders of metals or
ceramics
 Usually involves pressing and sintering, in which
powders are first compressed and then heated to bond
the individual particles

Steps: Pressing and sintering

Sintering is a method for making

objects from powder, by heating the
material (below its melting point) until its
particles adhere to each other.
36 Chapter1- Part2
A
3- Deformation Processes
Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
 Examples: (a) forging, (b) extrusion

A press machine performs extrusion.

37 Chapter1- Part2
A
4- Material Removal Processes
Excess material removed from the starting piece
so what remains is the desired geometry
 Examples: machining such as turning, drilling,
and milling; also grinding and nontraditional
processes

38 Chapter1- Part2
 A
Waste in Shaping Processes
Desirable to minimize waste in part shaping
 Material removal processes are wasteful in unit
operations, simply by the way they work
 Most casting, molding, and particulate
processing operations waste little material

 Terminology for minimum waste processes:

 Net shape processes - when most of the
starting material is used and no
subsequent machining is required
 Near net shape processes - when
Click to see figure 1-4 again
minimum amount of machining is required

39 Chapter1- Part2
 B
Property-Enhancing Processes
Performed to improve mechanical or physical
properties of work material
 Part shape is not altered, except
unintentionally
 Example: unintentional warping of a heat treated
part

 Examples:
 Heat treatment of metals and glasses
 Sintering of powdered metals and ceramics
Click to see figure 1-4 again

40 Chapter1- Part2
C
Surface Processing Operations
 Cleaning - chemical and mechanical
processes to remove dirt, oil, and other
contaminants from the surface
 Surface treatments - mechanical working
such as sand blasting, and physical
processes like diffusion
 Coating and thin film deposition - coating
exterior surface of the workpart

Click to see figure 1-4 again

41 Chapter1- Part2
D
Assembly Operations
Two or more separate parts are joined to
form a new entity
 Types of assembly operations:
1. Joining processes – create a
permanent joint
 Welding, brazing, soldering, and
adhesive bonding
2. Mechanical assembly – fastening by
mechanical methods
 Threaded fasteners (screws, bolts
and nuts); press fitting, expansion
fits
42 Chapter1- Part2
Production Systems

43 Chapter1- Part2
 Production Systems

People, equipment, and procedures used for the

combination of materials and processes that
constitute a firm's manufacturing operations

 A manufacturing firm must have systems and procedures to

efficiently accomplish its type of production

Two categories of production systems:

1. Production facilities
2. Manufacturing support systems

Both categories include people (people make the systems work)

44 Chapter1- Part2
 Production systems

Production systems

Manufacturing
Production facilities
support systems
Low production: Job shop
Manufacturing engineering
Medium production: Batch production
Production planning and
and cellular manufacturing
control
High production: quantity production
Quality control
and flow line production

45 Chapter1- Part2
 1- Production Facilities

The factory, production equipment, and

material handling systems
 Production facilities "touch" the product
 Includes the way the equipment is arranged
in the factory - the plant layout

Equipment usually organized into logical

groupings, called manufacturing systems

Examples:
Automated production line
Machine cell consisting of an industrial
robot and two machine tools

46 Chapter1- Part2
Facilities versus Product Quantities
A company designs its manufacturing systems
and organizes its factories to serve the
particular mission of each plant

 Certain types of production facilities are

recognized as the most appropriate for a
given type of manufacturing:
1. Low production – 1 to 100
2. Medium production – 100 to 10,000
3. High production – 10,000 to >1,000,000
 Different facilities are required for each of the
three quantity ranges

47 Chapter1- Part2
 Low Production
Job shop is the term used for this type of
production facility
 A job shop makes low quantities of
specialized and customized products
 Products are typically complex, e.g., space
capsules, prototype aircraft, special machinery
• Equipment in a job shop
is general purpose

• Labor force is highly

skilled

• Designed for maximum

flexibility

48 Chapter1- Part2
 Medium Production
Two different types of facilities, depending on
product variety:

Batch production
 Suited to hard product variety
 Setups required between batches

Cellular manufacturing
 Suited to soft product variety
 Worker cells organized to process
parts without setups between different
part styles

49 Chapter1- Part2
 High Production
 Often referred to as mass production
 High demand for product
 Manufacturing system dedicated to the
production of that product

 Two categories of mass production:

1. Quantity production
2. Flow line production

50 Chapter1- Part2
 Quantity Production
Mass production of single parts on single
machine or small numbers of machines
 Typically involves standard machines equipped
with special tooling

 Equipment is dedicated full-time to the

production of one part or product type

 Typical layouts used in quantity production are

process layout and cellular layout

51 Chapter1- Part2
 Flow Line Production
Multiple machines or workstations arranged in
sequence, e.g., production lines
 Product is complex
 Requires multiple processing and/or
assembly operations
 Work units are physically moved through the
sequence to complete the product
 Workstations and equipment are designed
specifically for the product to maximize
efficiency

52 Chapter1- Part2
2- Manufacturing Support Systems

A company must organize itself

 to design the processes and equipment,
 plan and control production, and
 satisfy product quality requirements
Accomplished by manufacturing support systems - people
and procedures by which a company manages its
production operations

Typical departments:
1. Manufacturing
engineering
2. Production planning
and control
3. Quality
53
control Chapter1- Part2
 Overview of Major Topics

Figure 1.10 Overview of production system and major topics in

Fundamentals of Modern Manufacturing.

54 Chapter1- Part2
A spectacular scene in steelmaking is charging of a basic oxygen furnace,
in which molten pig iron produced in a blast furnace is poured into the BOF
(Basic Oxygen Furnace). Temperatures are around 1650°C (3000 ° F).

55 Chapter1- Part2
A machining cell consisting of two horizontal machining centers
supplied by an in-line pallet shuttle (photo courtesy of Cincinnati Milacron).

56 Chapter1- Part2
A robotic arm performs
unloading and loading
operation in a turning
center using a dual gripper
(photo courtesy of Cincinnati
Milacron).

57 Chapter1- Part2
Metal chips fly in a high
speed turning operation
performed on a computer
numerical control turning
center (photo courtesy of
Cincinnati Milacron).

58 Chapter1- Part2
Photomicrograph of the cross section of multiple coatings of
titanium nitride and aluminum oxide on a cemented carbide
substrate (photo courtesy of Kennametal Inc.).

59 Chapter1- Part2
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).

60 Chapter1- Part2
Two welders perform arc
welding on a large steel
pipe section (photo
courtesy of Lincoln Electric
Company).

61 Chapter1- Part2
Automated dispensing of
adhesive onto component
parts prior to assembly
(photo courtesy of EFD, Inc.).

62 Chapter1- Part2
Assembly workers on an
engine assembly line
(photo courtesy of Ford Motor
Company).

63 Chapter1- Part2
Assembly operations
on the Boeing 777
(photo courtesy of Boeing
Commercial Airplane Co.).

64 Chapter1- Part2