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EM 470/471: Manufacturing Technology

Unit 1: Lecture 1 – Concept of Manufacturing

1.1 Concept of Manufacturing & Terminologies

Manufacturing defined in 2 ways:
(i)Technological Definition
 Application of physical and chemical processes to alter
geometry, properties, and/or appearance of a raw
material to make parts or products, including assembly.
 Processes involve combination of machinery, tools, power,
and labour (Fig.1)

Fig.1

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(ii) Economic Definition

 Transformation of materials into items of greater value
by means of one or more processing and/or assembly
operations.
 Adding value to material by changing shape or properties, or
by combining with other materials similarly altered (Fig.2).
 eg. conversion of iron ore to steel.

Fig.2

1.2 Economic Importance of Manufacturing

 Material wealth by manufacturing.
 USA: manufacturing = 15% of GDP.
 Modern economies have strong manufacturing bases (or
enough natural resources) to provide strong economies and
high standards of living.

1.3 History of Manufacturing

 2 epochs:
I. Human’s discovery and invention of materials and
processes to make things.
 Casting, forging and grinding—date back 6000 years or more.
 Implements and weapons accomplished more as crafts and
trades.

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II. Development of the systems of production.

 Systems of manufacturing: ways of organizing people and
equipment for efficient production.
 Division of labour—dividing total work into tasks and
specialised workers with only one task.
 Industrial Revolution (circa 1760–1830)
 major impact on production: change from agro-based
economy to industry and manufacturing based.

 Frederick W. Taylor (1856–1915) developed management

science in response to need to plan and control activities of
production workers.

Scientific management includes :

 motion study, aimed at finding best method to perform a
given task;
 time study, to establish work standards for a job;
 extensive use of standards in industry;
 the piece rate system and similar labor incentive plans;
 use of data collection, record keeping, and cost
accounting in factory operations.

 Henry Ford (1863–1947) introduced assembly line and mass

production of complex consumer products.
 Developments resulted in automation of manufacturing.

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1.4 Classification of Industries

 Type of manufacturing depends on kind of product.
 Industry consists of enterprises and organizations that
produce or supply goods and services.
 Industries can be classified as:
- Primary industries cultivate and exploit natural
resources, such as agriculture and mining.
- Secondary industries take outputs of primary
industries and converts them into consumer and capital
goods, eg. manufacturing, construction and utilities.
- Tertiary industries constitute service sector of
economy.

1.5 Manufactured Products

(1) Consumer goods purchased directly by consumers, eg
cars, personal computers, TVs, tires, etc.
(2) Capital goods purchased by companies to produce
goods and/or provide services eg railroad locomotives,
machine tools, construction equipment, etc.
o Without capital goods, the service industries cannot function.

1.6 Production Quantity and Product Variety

 Quantity of products made by factory has important influence
on way its people, facilities, and procedures are organized.
 Annual production quantities classified into (Fig.3):
(1) low production, quantities in the range1to100 units per year;
(2) medium production, from 100 to10,000 units annually;
(3) high production, 10,000 to millions of units.

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Fig.3

 Product variety refers to different product designs or types

that are produced in plant.
 Different products have different shapes and sizes; perform
different functions; are intended for different markets;
 When number of product types is high, this indicates high
product variety.

 Inverse correlation between product variety and production

quantity (Fig.3).
 Manufacturing plants tend to specialize in combination of
production quantity and product variety that lies somewhere
inside the diagonal band in Fig.3.

1.7 Manufacturing Capability

 Manufacturing capability refers to the technical and
physical limitations of a manufacturing firm and each
of its plants.
 Several dimensions of this capability can be identified:
(1) technological processing capability,
(2) physical size and weight of product,
(3) production capacity.

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Technological Processing Capability

 This is the available set of manufacturing processes.
 Technological processing capability is closely related to
material type. Certain manufacturing processes are suited to
certain materials, whereas other processes are suited to
other materials.
 It includes not only physical processes, but also expertise
possessed by plant personnel in these processing
technologies.
 Companies must concentrate on the design and manufacture
of products that are compatible with their technological
processing capability.

Physical Product Limitations

 A plant with a given set of processes is limited in terms of size
and weight of products that can be accommodated.
 Large, heavy products are difficult to move, while smaller
parts and products made in large quantities can be moved by
conveyor or other means.

Production Capacity
 Also called plant capacity, or production capacity, which is
maximum rate of production that a plant can achieve under
assumed operating conditions.
 Operating conditions refer to number of shifts per week, hours
per shift, direct labour manning levels in the plant, etc.

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1.8 Manufacturing Processes

 A designed procedure that results in physical and/or
chemical changes to a starting work material with the
intention of increasing value of material.
 Usually carried out as a unit operation, a single step in
sequence of steps required to transform starting material into
final product.
 Manufacturing operations are divided into two basic types
(Fig.4):
(i) processing operations
(ii) assembly operations.
 A processing operation transforms a work material from
one state of completion to a more advanced state, closer to
final desired product and adds value by changing geometry,
properties, or appearance of starting material.
 An assembly operation joins two or more components to
create a new entity (eg welding).

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PROCESSING OPERATIONS
o Use energy to alter workpart’s shape, physical properties, or
appearance to add value to material.
o The forms of energy include mechanical, thermal, electrical,
and chemical. The energy is applied in a controlled way by
means of machinery and tooling.
o A model of a processing operation includes:
- Material is fed into the process, energy is applied by the
machinery and tooling to transform the material, and the
completed workpart exits the process.
- It is an important objective in manufacturing to reduce
waste in any form.

 Three categories of processing operations are distinguished:

(1) shaping operations,
(2) property-enhancing operations, and
(3) surface processing operations.

 Shaping operations alter geometry of starting work material by

various methods such as casting, forging, and machining.

 Property-enhancing operations add value to material by

improving its physical properties without changing its shape,
eg heat treatment.
 Surface processing operations are performed to clean, treat,
coat, or deposit material onto the exterior surface of the work,
eg. plating and painting.

Shaping Processes
 Apply heat, mechanical force, or combination to effect a
change in geometry of work material.
 Shaping operations are:
(1) solidification processes, in which starting material is a
heated liquid or semifluid that cools and solidifies to form the
part geometry;

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Shaping Processes
(2) particulate processing: starting material is a powder which
is formed and heated into desired geometry;
(3) deformation processes: starting material is a ductile solid
(commonly metal) deformed to shape the part; and
(4) material removal processes, starting material is a solid
(ductile or brittle), from which material is removed so that
resulting part has desired geometry.

Solidification processes
 Starting material is heated to transform into a liquid or highly
plastic (semifluid) state.
 All materials can be processed in this way, eg metals,
ceramic glasses and plastics.
 Most processes that operate this way are called casting (for
metals) or moulding (for plastics).

Fig.5

Particulate processing
 Starting materials are powders of metals or ceramics.

 Common technique involves pressing and sintering, in which

the powders are first squeezed into a die cavity under high
pressure and then heated to bond individual particles
together.

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Deformation processes
 Starting workpart is shaped by application of forces that
exceed yield strength of material.
 Material must be sufficiently ductile to avoid fracture during
deformation.
 To increase ductility, work material is heated before forming
to temperature below melting point, eg. forging, extrusion,
etc.

Fig.7

Material removal processes

 Remove excess material from starting workpiece to get
desired geometry, eg. turning, drilling, milling and grinding.
 Applied to solid metals, performed using cutting tools that are
harder and stronger than work metal.
 Nontraditional processes use lasers, electron beams, chemical
erosion, electric discharges, and electrochemical means.
 Material removal processes (e.g., machining) produce a lot of
waste.

Fig.8

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Property-Enhancing Processes
 Performed to improve mechanical or
physical properties of work material.
 They do not alter shape of part, eg heat
treatment

Surface Processing
These include:
 Cleaning includes both chemical and mechanical processes
to remove dirt, oil, and other contaminants from the surface.
 Surface treatments include shot peening and sand blasting,
diffusion and ion implantation.
 Coating and thin film deposition processes apply a coating of
material to exterior surface of workpart, eg. electroplating,
anodizing, organic coating or painting and porcelain
enameling, physical vapor deposition and chemical vapor
deposition to form extremely thin coatings of various
substances.

ASSEMBLY OPERATIONS
 Two or more separate parts are joined to form new entity,
connected either permanently or semi permanently.
 Permanent joining processes include welding, brazing,
soldering, and adhesive bonding.
 Mechanical assembly methods involve fastening two (or more)
parts together in a joint that can be disassembled with screws,
bolts, and other threaded fasteners.
 More permanent mechanical connections include rivets, press
fitting, and expansion fits.
 Special joining and fastening methods are used in assembly of
electronic products for assembly of components such as
integrated circuit packages to printed circuit boards to produce
complex circuits.

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References:

 Groover, M.P., (2010), Fundamentals of Modern

Manufacturing: materials, Processes & Systems, 4th Edition,
John Wiley.

 Kalpakjian, S. & Schmid, S., (2009), Manufacturing

Engineering and Technology, 6th Edition, Pearson.

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