1/10/2024

Chapter 1
General
Introduction
Presented by Dr. Minh Tuan HO
[email protected]

ME2071 – Manufacturing Processes

INTRODUCTION AND
OVERVIEW OF MANUFACTURING

I. What is Manufacturing?
II. Materials in Manufacturing
III. Manufacturing Processes
IV. Production Systems
V. Manufacturing Economics
VI. Recent Developments in Manufacturing

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I. Manufacturing is Important

▪ Making things has been an essential human activity

since before recorded history
▪ Today, the term manufacturing is used for this
activity
▪ Manufacturing is important to the United States and
most other developed and developing nations
▪ Technologically
▪ Economically

Technological Importance

▪ Technology - the application of science to provide

society and its members with those things that are
needed or desired
▪ Technology affects our daily lives, directly and
indirectly, in many ways
▪ Technology provides the products that help our
society and its members live better

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Technological Importance

Technological Importance

▪ What do these products have in common?

▪ They are all manufactured
▪ They would not be available to our society if they
could not be manufactured
▪ Manufacturing is the essential factor that makes
technology possible

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Economic Importance

U.S. Economy
Sector: %GDP
Agriculture and natural resources 5
Construction and public utilities 5
Manufacturing 12
Service industries* 78
100
* includes retail, transportation, banking,
communication, education, and government

What is Manufacturing?

▪ The word manufacture is derived from two Latin

words manus (hand) and factus (make); the
combination means “made by hand”
▪ “Made by hand” described the fabrication methods
that were used when the English word
“manufacture” was first coined around 1567 A.D.
▪ Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers

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Manufacturing - Technological

▪ Application of physical and chemical processes to

alter the geometry, properties, and/or appearance of
a starting material to make parts or products

Manufacturing - Economic

▪ Transformation of materials into items of greater value

by one or more processing and/or assembly operations

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Manufacturing Example:
Artificial Heart Valve

Left: Heart valve Right: Starting titanium billet

Modern Manufacturing

Materials

Processes
Modern
manufacturing
Systems

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II. 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, and their mechanical and
physical properties are different
▪ In addition, there is a fourth category:
4. Composites

Classification of
engineering
materials

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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 and cast iron
2. Nonferrous metals - all other metallic elements
and their alloys:
▪ Aluminum, copper, nickel, silver, tin, 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, and modern ceramics,
such as alumina (Al2O3)
2. Glasses – mostly based on silica (SiO2)

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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 into a rigid structure – cannot reheat
3. Elastomers - shows significant elastic behavior

3. Polymers

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Fiber-Reinforced Polymer (FRP)

4. 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 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

III. 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

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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 - clean, treat,
coat, or deposit material on surface of work

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Four Categories of
Shaping Processes

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
▪ (1) Casting process and (2) casting product

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Particulate Processing

▪ (1) Starting materials are metal or ceramic powders,

which are (2) pressed and (3) sintered

Deformation Processes

▪ Starting workpart is shaped by application of forces

that exceed the yield strength of the material
▪ Examples: (a) forging and (b) extrusion

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Material Removal Processes

▪ Excess material removed from the starting piece so what

remains is the desired geometry
▪ Examples: (a) turning, (b) drilling, and (c) milling

Waste in Shaping Processes

▪ It is desirable to minimize waste in part shaping

▪ Material removal processes are wasteful in the unit
operations, but molding and particulate processing
operations waste little material
▪ Terminology for minimum waste processes:
▪ Net shape processes - little or no waste of the
starting material and no machining is required
▪ Near net shape processes - when minimum
machining is required

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Property-Enhancing Processes

▪ Processes that improve mechanical or physical

properties of work material
▪ Examples:
▪ Heat treatment of metals and glasses
▪ Sintering of powdered metals and ceramics
▪ Part shape is not altered, except unintentionally
▪ Example: unintentional warping of a heat treated
part

Surface Processing Operations

▪ Cleaning - chemical and mechanical processes to

remove dirt, oil, and other surface contaminants
▪ Surface treatments - mechanical working such as
sand blasting, and physical processes like diffusion
▪ Coating and thin film deposition - coating exterior
surface of the workpart
▪ Examples:
▪ Electroplating
▪ Painting

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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, adhesive bonding
2. Mechanical assembly – fastening by mechanical
methods
▪ Threaded fasteners (screws, bolts and nuts);
press fitting, expansion fits

Production Machines and

Tooling
▪ Manufacturing operations are accomplished using
machinery and tooling (and people)
▪ Types of production machines:
▪ Machine tools - power-driven machines used to
operate cutting tools previously operated manually
▪ Other production equipment:
▪ Presses
▪ Forge hammers,
▪ Plastic injection molding machines

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Production Machines and

Tooling

IV. Production Systems

▪ People, equipment, and procedures used for the

materials and processes that constitute a firm's
manufacturing operations
▪ A manufacturing firm must have systems and
procedures to efficiently accomplish its production
▪ Two categories of production systems:
▪ Production facilities
▪ Manufacturing support systems
▪ People make the systems work

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Model of the Production System

Production Facilities

▪ The factory, production equipment, and material

handling systems
▪ Includes the plant layout
▪ Equipment usually organized into logical groupings,
called manufacturing systems
▪ Examples:
▪ Automated production line
▪ Machine cell consisting of three machine tools
▪ Production facilities "touch" the product

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Facilities vs 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
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

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

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Fixed-Position Plant Layout

Medium Production

▪ Two different types of facility, depending on product

variety:
▪ Batch production
▪ Suited to medium and 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

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Process Plant Layout

Cellular Plant Layout

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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

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Flow Line Production

▪ Multiple machines or workstations arranged in

sequence, as in a production line
▪ 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

Product Plant Layout

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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
▪ The people and procedures by which a
company manages its production operations
▪ Typical departments:
▪ Manufacturing engineering, Production
planning and control, Quality control

References

1. M.P. Groover, Fundamentals of Modern Manufacturing

5/e, John Wiley & Sons, 2012
2. S. Kalpakjian, S.R. Schmid, Manufacturing engineering
and technology in SI units 8/e, Pearson, 2021
3. T.D. Sơn, T.A. Sơn, H.T. Hưng, Giáo trình Các Quá
Trình Chế Tạo, NXB ĐHQG Tp. HCM, 2018

Thank you!

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