INTRODUCTION AND

OVERVIEW OF MANUFACTURING
1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
 Manufacturing is Important
▪ Technologically
▪ Economically
▪ Historically
 Manufacturing - Technologically
Important

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

Manufacturing is one way by which nations

create material wealth
Manufacturing - Historically Important
Throughout history, human cultures that were
better at making things were more
successful
▪ Making better tools meant better crafts &
weapons
▪ Better crafts allowed people to live better
▪ Better weapons allowed them to conquer
other cultures in times of conflict
▪ To a significant degree, the history of
civilization is the history of humans' ability
to make things
 What is Manufacturing?

The word manufacture is derived from two Latin

words manus (hand) and factus (make); the
combination means “made by hand”
 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

 Manufacturing - Economically
Transformation of materials into items of greater
value by means of one or more processing and/
or assembly operations
▪ Manufacturing adds value to the material by
changing its shape or properties, or by combining
it with other materials

Figure 1.1 (b)

Manufacturing
as an economic
process
 Manufacturing Industries
Industry consists of enterprises and
organizations that produce or supply goods
and services
▪ Industries can be classified as:
1. Primary industries - those that cultivate
and exploit natural resources, e.g.,
farming, mining
2. Secondary industries - take the outputs of
primary industries and convert them into
consumer and capital goods -
manufacturing is the principal activity
3. Tertiary industries - service sector
Manufacturing Industries - continued

▪ Secondary industries include manufacturing,

construction, and electric power generation

▪ Manufacturing includes several industries

whose products are not covered in this
course; 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
 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 of
 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

▪ The number of different product types made

each year in a factory can be counted

▪ When the number of product types made in

the factory is high, this indicates high
product variety
P versus Q in Factory Operations

Figure 1.2 P-Q Relationship

 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)
 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

▪ Manufacturing capability includes:

1. Technological processing capability
2. Physical product limitations
3. Production capacity
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
 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

▪ Production, material handling equipment, and

plant size must be planned for products that
lie within a certain size and weight range
 3. Production 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, etc.

▪ Usually measured in terms of output units,

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

▪ Also called plant capacity

 Materials in Manufacturing

Most engineering materials can be classified

into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
▪ Their chemistries are different
▪ Their mechanical and physical properties
are dissimilar

▪ These differences affect the

manufacturing processes that can be used
to produce products from them
 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
 1. Metals
Usually alloys, which are composed of two or
more elements, at least one of which is metallic

▪ Two basic groups:

1. 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)

2. Nonferrous metals - all other metallic

elements and their alloys: aluminum,
copper, magnesium, nickel, silver, tin,
titanium, etc.
 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 (SiO 2)
 3. Polymers
Compound formed of repeating structural units
called mers, whose atoms share electrons to
form very large molecules
▪ 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
 4. Composites
Material consisting of two or more phases that
are processed separately and then bonded
together to achieve properties superior to its
constituents

▪ 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
 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
Figure 1.4 Classification of manufacturing processes
 Processing Operations

Alters a material’s shape, physical properties,

or appearance in order to 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
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
 Solidification Processes
Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
▪ Examples: metal casting, plastic molding
 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
 Deformation Processes
Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
▪ Examples: (a) forging, (b) extrusion
 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
 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
Property‑Enhancing Processes
Performed to improve mechanical or physical
properties of work material

▪ Part shape is not altered

▪ Examples:
▪ Heat treatment of metals and glasses
▪ Sintering of powdered metals and ceramics
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
 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

 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:
▪ Production facilities
▪ Manufacturing support systems
▪ Both categories include people (people
make the systems work)
 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

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
 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
 Medium Production
Two different types of facility, 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
 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
 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
 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
 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 control
Overview of Major Topics

Figure 1.10 Overview of production system.

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. Temperatures are around 1650°C (3000 ° F).
A machining cell consisting of two horizontal machining centers
supplied by an in-line pallet shuttle
A robotic arm performs
unloading and loading
operation in a turning
center using a dual
gripper).
Metal chips fly in a high
speed turning operation
performed on a
computer numerical
control turning center).
Photomicrograph of the cross section of multiple coatings of
titanium nitride and aluminum oxide on a cemented carbide
substrate
A batch of silicon wafers enters a furnace heated to 1000°C
(1800°F) during fabrication of integrated circuits under clean room
conditions
Two welders perform
arc welding on a large
steel pipe section
Automated dispensing of
adhesive onto component
parts prior to assembly
Assembly workers on
an engine assembly line