BMCG 2312

MANUFACTURING PROCESS
 WHAT IS
MANUFACTURING?
 WHAT IS MANUFACTURING

Machinery
Tooling

Power
Labor
TECHNICAL PROCESS
Conversion of raw
material into products Product
by using machines, Raw materials Manufacturing
tooling, power,BMCG
labour 2312 Process Profit
etc. according to a
detailed plan.
MANUFACTURING PROCESS

Raw Material(s)

1) Technology – 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 products.
Manufacturing also includes the assembly of multiple parts to make products.
WHAT IS MANUFACTURING

ECONOMIC PROCESS Manufacturing

Process
2) Economic –
Value
manufacturing is the Raw Material(s) added Products
transformation of materials
into items of greater value by
means one or more Starting Material in Processed
processing involve. material processing material
Therefore, manufacturing is
“added value” to the
material.
WHAT WILL YOU LEARN?

Raw Material(s) Process(es) Products

STEEL SUBTRACTIVE PROCESSES

TYPE OF PROCESSES
MANUFACTURING FORMING AND SHAPING CONTINOUS PROCESS
OPERATION AND
LAYOUT NET SHAPE PROCESS
ADDITIVE PROCESS
QUALITY AND METROLOGY JOINING PROCESS

SUSTAINABLE MANUFACTURING
 HOW MANUFACTURING STARTS

DEVELOPMENT
PRODUCT
INPUT FROM COMMENTS
CUSTOMERS INPUT FROM FROM
SUPPLIERS CUSTOMER

PROJECT PROJECT PRODUCT PRODUCT PROJECT

PROPOSAL PLANNING
DESIGN
MANUFACTURE LAUNCH CLOSE
 PLANNING
TEAM

PRODUCT
DESIGN TEAM
ENGINEERING/
PRODUCTION
TEAM
 CONCURRENT ENGINEERING

CUSTOMERS PLANNING ENGINEERING/PRODUCTIO N

New feature SUPPLIERS

Quantity to produce
Destination market Does the design can fit the
Production location current equipment
Product life Need new machine?
Similar competitor model

Translate planning design

Into manufacturable
Design

HOW DISCUSSION TAKE PLACE?

WHY CONCURRENT ENGINEERING IS IMPORTANT?
 SEQUENTIAL/OVER THE WALL ENGINEERING

PLANNING TEAM PRODUCT DESIGN ENGINEERING/

TEAM PRODUCTION
TEAM
 HOW TO SELECT THE RIGHT PROCESSES
DESIGN EXTERNAL REGULATIONS
• Size and shape of the final MATERIAL
• Environment and
product and raw material • Material to be used (type and basic
• safety
• Geometry complexity properties)
• parts with thin cross-sections • Castability/ weldability/Machinability
QUANTITY
cannot be cast properly; • Number of parts or products
complex parts cannot be required and
formed easily. • desired production rate
QUALITY
COST • Dimensional accuracy
• Economics (cost) of tooling, (tolerances) required
capital,scrap rate etc • Surface finish required -additional MACHINES AND TOOLS
• Operational and Cost operations: grinding, polishing • Availability of machines and
considerations: (better finish but more equipment
• Design and cost of tooling expensive!) • Flexibility to change the design at
any time
TIME FRAME
Lead time required to Additional reading
begin production https://writepass.com/journal/2016/08/factors-that-affect-selection-of-manufacturing-process-de
at-apple-inc/
 HOW MANUFACTURING ARE CALSSIFIED

 bulk deformation process -forming and shaping (F&S)

 F&S (Sheet Metal)
 Casting
 Machining
 F&S (Polymer)
 Joining
PROCESS AVAILABLE

 Casting
 forming and shaping (F&S) (bulk deformation process)
 F&S (Polymer)
 F&S (Sheet Metal)
 Machining
 Joining
as the dimensions may change.
Metal forming is a general term for a large OTHERS CLASSIFICATION
group, that includes a wide variety of
manufacturing processes. Metal forming
processes are characteristic in that the metal
being processed is plastically deformed to
shape it into a desired geometry. In order to
plastically deform a metal, a force must be
applied that will exceed the yield strength of
the material.
Metal forming processes can be classified
under two major groups. Bulk deformation
processes and sheet metal working processes.
Bulk deformation is characteristic in that the
work formed has a low surface area to
volume ratio. In sheet metal working, the
metal being processed will have a high surface
area to volume ratio.

Bulk Deformation

Rolling: Rolling is a metal forming process

that deforms the work by the use of rolls.
Rolling processes include flat rolling, shape
rolling, ring rolling, thread rolling, gear rolling,
Manufacturing is the procedure by which materials are
transformed into desired shapes. Materials are
first formed into preliminary shapes, and then refined into
Shaping fall is the category
more precise shapes, after which the final
of Machining. Material removal from the
shaping and finishing operations are performed
part is required in this process which is a
major difference from forming. The
In the shaping process, a component or product can be removal of material is achieved by use of
created from a solid, granular, a sharp tool called machine tool.
particle state, or liquid state, meaning the state of the work Reciprocal movement of the tool, either
material in the shaping phase. horizontally or vertically over the work
piece causes the material removal.
Classification of technological shaping processes may be
based on many different criteria, depending on
the purpose of the processes. In general, shaping process
can be classified into two main categories: primary
and secondary shaping processes. The primary shaping
processes form the overall shape of the
product or the component that will, with other parts make
up the final product’s shape. The purpose of
secondary processes is to provide the final, precisely
shaped surfaces that will meet product requirements,
 OTHERS CLASSIFICATION

 Forming and shaping (general)

 Additive
 Net Shape
 Subtractive
 Continuous
 TYPE OF INDUSTRIES

Industries can be classified as:

 Take the outputs of the
primary industries and
Those that CULTIVATE CONVERT them into
AND EXPLOIT natural consumer and
resources; capital goods.

•Aerospace
Constitute with
•Automotive SERVICE SECTOR of
•Agriculture
PRIMARY INDUSTRY

•Banking
•Forestry •Beverages the economy.
•Communications

SECONDARY
INDUSTRY

TERTIARY INDUSTRY
•Fishing •Building materials
•Education
•Livestock •Chemicals
•Entertainment
•Quarries •Computers
•Financial services
•Mining •Consumer appliances
•Health and medical
•Petroleum •Electronics
•Government
•Equipment
•Hotel
•Food processing
•Insurance
•Glass, ceramic
•Restaurant
•Paper
•Retail trade
•Pharmaceuticals
•Tourism
•Plastics (shaping)
•Transportation
•Textiles
•Real estate
•Tire and rubber
•Wood and furniture
WHICH INDUSTRIES SPOON AND FORK INVOLVE WITH ?
 11
Manufacturing system can be defined
as a transformation system in which a The system can be divided into two
product or service is created by categories;
working upon a set of inputs. Inputs
Intermittent and Continuous
are usually in the form of men, system
machine, money, materials etc.
Production systems are usually Intermittent
PROJECT
classified on the basis of the following: BATCH
JOBSHOP

Product quantity Continuous

MASS
Product variety
RELATIONSHIP BETWEEN PRODUCT QUANTITY AND PRODUCT VARIETY

Above 10,000 units

Mass 100 to 10,000 units

QUANTITY/VOLUME
High Batch 10 to 100 units
Product

Job shop 1 to 10 units

Medium
Project

Low

Product VARIETY

Production quantity: number of unit produced annually of a particular product type.

Product variety: different product designs or types that are produced in the plant.
• Product position-remains
stationary during the
manufacturing process – size,
weight, location of the product.
• Materials, people, machinery are
brought to the product or product
site.
• Based on customer specifications
• Example: bridge, building
construction, aircraft, ships,
locomotive.
2) JOB SHOP
A job shop is a type of manufacturing process in which
small batches of a variety of custom products are made. In the
job shop process flow, most of the products produced
Volume- Low require a unique set-up and sequencing of process steps.

Variety-high (called lot size)

Product-custom made
Layout-different machine with similar
functional or processing capabilities are
grouped together as department
Labour-high skill to operate a variety of
equipment
Example: production of space vehicles,
reactor vessels, turbines, aircraft
components
Product Variety-High
Same facility used to manufacture different items
Machine layout-Functional layout (based on
function to be performed)
Production style-batches (group)- a one time
production’
Useful for seasonal item/difficult to forecast the
demand
Example: Hand tools, bakery, paint

Batch Production Examples:

Baked goods Flat-pack furniture
Clothing Jet engine production
Computer software Machine tool manufacturing
Die- or mold-making Material coating
Electrical goods Newspapers/magazines
Advantages Disadvantages
• Reduce initial capital • Requires very careful production
outlay – due to a single planning & control – next batches;
production line when, types.
• can be used to several • When switching to another batches –
products – machines can takes time (“down time”) – can cause
be used more effectively, loss of output (low yield).
materials can be bought • Create inventory/stock – increases
in bulk, workers can costs such as inventory cost, cost
specialize in that task. because of damage to stock.
The example production line (shown below) is that of an engineering company, manufacturing small steel
products such as hinges and locks. They manufacture batches of five hundred at a time. The workers are
unskilled and semi skilled. As each task is completed the item being manufactured is passed down the
production line to the next worker, until it is complete.
• AKA flow production, repetitive flow production,
series production
• Producing goods in large quantities at low cost
per unit and in short period of time
• Machinery (eg robots, machine press) that is
needed to set up the line are expensive
• Fewer labour cost and faster rate of production
• Machines are arranged in a flow line layout
• Workpiece is transferred automatically form one
machine to another (eg conveyor system)
• Example of the product; light bulbs, refrigerator,
tv set
Mass production often involves the assembly of a number of
sub-assemblies of individual components. Parts may be bought
from other companies.
The concepts of mass production are
applied to various kinds of products,
• from fluids and particulates handled
in bulk (such as food, fuel, chemical
and mined mineral)
• to discrete solid parts (such as
fasteners)
• to assemblies of such parts (such as
household appliances and
automobiles)
A job process is one-off, whereas a batch process groups a
number of items together and processes them at once. For
example, a lot of people read email as soon as it comes
into their inbox (job processing) whereas waiting a few
hours and reading a group of emails together (batch
processing) can be more efficient. The same can be true of
administrative functions such as budget approvals and
timesheeting.

https://strategicppm.wordpress.com/2010/01/20/batch-vs-job-
processes-becoming-more-efficient/
MANUFACTURING PLANT LAYOUT

Plant layout refers to an

optimum arrangement of
facilities including
personnel, operating
equipment, storage space,
material handling
equipment and all other
supporting services along
with the design of best
Goal of Plant Layout
structure to contain all To maximize the profit by arrangement of
these facilities in order to all the plant facilities to the best advantage
of total manufacturing of the product.
maximize the profit.
https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
PLANT LAYOUT

Objectives
• Utilise space, machine and labour efficiently
• Provide for employee convenience, safety and comfort.
• Minimize investment in equipment.
• Minimize overall production time.
• Eliminate bottleneck
• Facilitate the manufacturing process.
• Minimize materials handling and cost.
• Flexibility of manufacturing operations and arrangements.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
Principles of Plant Layout

Principle of integration: A good layout is one that integrates Principle of cubic space utilization: The good
men, materials, machines and supporting services and others in layout is one that utilizes both horizontal and vertical
order to get the optimum utilization of resources and space. It is not only enough if only the floor space is
maximum effectiveness. utilized optimally but the third dimension, i.e., the
height is also to be utilized effectively.
Principle of minimum distance: This principle is concerned
with the minimum travel (or movement) of man and materials. Principle of flow: A good layout is one that makes the
The facilities should be arranged such that, the total distance materials to move in forward direction towards the
travelled by the men and materials should be minimum and as completion stage, i.e., there should not be any
far as possible straight line movement should be preferred. backtracking.

Principle of maximum flexibility: The good layout is

Principle of safety, security and one that can be altered without much cost and time,
satisfaction: A good layout is one that gives i.e., future requirements should be taken into account
due consideration to workers safety and while designing the present layout.
satisfaction and safeguards the plant and
machinery against fire, theft, etc.
Principle of minimum handling: A good
layout is one that reduces the material
handling to the minimum
 TYPE OF LAYOUT

Fixed position layoutProject

Product Layout (Flow Line)Mass Pro
Process Layout(Functional)batch/jobshop
Cellular LayoutMixed of Product and Process

http://slideplayer.com/slide/3715352/
 TYPE OF LAYOUT

PRODUCT LAYOUT CELLULAR LAYOUT

A
B
B
C A

PROCESS LAYOUT FIXED POSITION LAYOUT

A
A
B

roject
 TYPE OF LAYOUT

Type of Product Process Cellular Project

Layout
Description Sequential Functional Group machines Machine will be
arrangement of grouping of into cell brought in
machines machines/areas

Type of Continuous, Mass Intermittent job Intermittent , One off

process production, shop and batch Mini product
assembly production layout

Product Standardised, Varied, make to Varied, make to Varied, make to

make to stock order order order

Storage Small Large Small Nil

 1.FIXED POSITION LAYOUT

• This is also called the project type of layout. Advantages

• the material, or major components remain in a fixed The major advantages of this type of layout are:
location and tools, machinery, men and other materials 1.Helps in job enlargement and upgrades the skills of the
are brought to this location. operators.
• suitable when one or a few pieces of identical heavy 2.The workers identify themselves with a product in which
products are to be manufactured and when the they take interest and pride in doing the job.
assembly consists of large number of heavy parts, the 3.Greater flexibility with this type of layout.
cost of transportation of these parts is very high. 4.Layout capital investment is lower.
 2. PROCESS (FUNCTIONAL) LAYOUT
• CHARACTERISTICS
All machines performing similar type of operations are
PROCESS LAYOUT
grouped at one location in the process layout according
to their functions e.g., all lathes, milling machines, etc.
are grouped in the shop will be clustered in like groups.
• The flow paths of material through the facilities from A
one functional area to another vary from product to B
product. Usually the paths are long and there will be
possibility of backtracking.
• Process layout is recommended for batch
production.
• Process layout is normally used when the
production volume is not sufficient to justify
a product layout.
• Typically, job shops employ process
layouts due to the variety of products
manufactured and their low production
volumes.
 2.PROCESS LAYOUT (CONTINUE)

Advantages Limitations
1.In process layout machines are better utilized 1.Backtracking and long movements may
and fewer machines are required. occur in the handling of materials thus,
2.Flexibility of equipment and personnel is reducing material handling efficiency.
possible in process layout. 2.Material handling cannot be mechanized
3.Lower investment on account of which adds to cost.
comparatively less number of machines and 3.Process time is prolonged which reduce
lower cost of general purpose machines. the inventory turnover and increases the in-
4.Higher utilization of production facilities. process inventory.
5.A high degree of flexibility with regards to 4.Lowered productivity due to number of
work distribution to machineries and workers. set-ups.
6.The diversity of tasks and variety of job 5.Throughput (time gap between in and out
makes the job challenging and interesting. in the process) time is longer.
7.Supervisors will become highly 6.Space and capital are tied up
knowledgeable about the functions under their
department.
by work-in-process.
https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/classification-of-layout-
9481.html
 3.PRODUCT LAYOUT
PRODUCT LAYOUT
When Applicable
• When volume of production of a A
product is high such that a B
separate production line to C
manufacture it can be justified. Product A L L M D
• In a strict product layout,
Product B L M M D
machines are not shared by
different products. Product C L G G D
• Therefore, the production
volume must be sufficient to
achieve satisfactory utilization
of the equipment.
https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/classification-of-layout-
9481.html
 3.PRODUCT LAYOUT (CONTINUE)

A typical product layout

CHARACTERISTICS
• Machines and equipment are positioned along a flow line according to the
processing sequence of the product.
• Several flow lines may come together to feed the final assembly line.
• Product passes from workstation to another workstation along the flow line.
• Special purpose machines are used which perform the required function
quickly and reliably.
• High level of machine and manpower utilization
• Need to categorize operations to ensure equal processing time at all work
stations (line balancing).
https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/classification-of-layout-
9481.html
 3.PRODUCT LAYOUT (CONTINUE)
Advantages Limitations
1.The flow of product will be smooth and logical in 1.A breakdown of one machine in a product line
flow lines. may cause stoppages of machines in the
2.In-process inventory is less. downstream of the line.
3.Throughput time is less. 2.A change in product design may require major
4.Minimum material handling cost due to alterations in the layout.
mechanised handling systems and straight flow (e.g. 3.The line output is decided by the bottleneck
conveyor) machine.
5.Simplified production, planning and control 4.Comparatively high investment in equipments is
systems are possible. required.
6.Less space is occupied by work transit and for 5.Lack of flexibility. A change in product may
temporary storage. require the facility modification.
7.Perfect line balancing which eliminates bottlenecks
and idle capacity.
8.Manufacturing cycle is short due to uninterrupted
flow of materials.
9.Small amount of work-in-process inventory.
10.Unskilled workers can learn and manage the
production.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/classification-of-layout-
9481.html
 4.CELLULLAR LAYOUT
CELLULAR LAYOUT
• Combination of the product layout and process
layout THUS combines the advantages of both
layout systems. A
• In process layout, the objective is to minimize the
total cost of materials handling. Because of the
nature of the layout, the cost of equipment will be
the minimum in this type of layout.
• In product layout, the cost of materials handling
will be at the absolute minimum. But the cost of
equipment would not be at the minimum if the
equipment are not fully utilized.
 4.CELLULLAR LAYOUT (continue)
CHARACTERISTICS
• Plant divided into groups or cells in a
small unit (individual cell), consisting of
one to several workstations.
• A w/station can contains either one
machine (known as a single machine cell),
or several machines (known as a group
machine cell) with each machine
performing a different operation on the
part.
• Cells can process a complete family of • The flow among the equipment in the cells can vary
parts – need to form families of products depending on the composition of parts within the part
family.
• The machines at w/stations can be modified, retooled,
and regroup for different product lines within the same
family of parts.
 Relate to quantity &
Plant layout variety of product

Type of
Nature of manufac Tech
work operation
involved
Classificati Definition
Definition on
Intro to Econ
Industry
Manufac
classification
Select
People
process
Example involve
Factors to
consider
Roles