Unit 1: Introduction to

Manufacturing
Technology
Outline
• Manufacturing

• Relationship between design,

manufacturing processes and costs

• Environment and energy concerns

1.1 Manufacturing
Definition of Manufacturing

The word was derived from the Latin words manus

(meaning ‘hand’) and facere (meaning ‘to make’). In
Late Latin, these were combined to form the word
manufactus meaning ‘made by hand’ or ‘hand-
made’.
Definition of Manufacturing

In a modern context, the definition of manufacturing

is; the making of products from raw materials using
various processes, equipment, operations and
manpower according to a detailed plan.
Definition of Manufacturing

During manufacturing process, the raw material undergoes

changes to allow it to become a part of a product or
products. Once processed, it should have worth in the
market or a value. Therefore, manufacturing is ‘adding value’
to the material.
Definition of Manufacturing
Manufacturing is generally a complex
activity involving a wide variety of resources
and activities
Classification of industries
Industries can be classified as below:-

1. Primary Industries
Primary industries are usually simple industries involving
processing of raw materials to give input goods to secondary
industries. The value additions in these industries are minimal
and they are usually materials oriented.
Classification of industries
2. Secondary Industries
Secondary industries are complex and diversified which take
input from primary industries and add significant value to it in
different processing stages. The outputs of the secondary
industries are the consumer and capital products.

3. Tertiary Industries
Tertiary Industries are not related to manufacturing processes
but are trade and service providing industries. The scale of
operations of these industries is large and therefore they are
considered as industries.
Types of manufacturing operations
 Types of manufacturing operations

1. Project
A project refers to a process of creating a complex one-of-a-
kind product or service with a set of well-defined tasks. Most
projects are based on customer specification. Projects involve
extensive customization and require highly skilled labours.
Examples of projects are building construction, fabrication of
boiler and movie production.
 Types of manufacturing operations

2. Job Shop
Job shop is characterized by processing small batches of a
large number of different products, most of which require a
different set or sequence of processing steps. General
purpose equipment are used to meet specific customer
orders. Highly skilled labour is required to handle the
processes, as variety and product range are high. Examples
of job shop are printing firm, machine shop and specialized

component manufacturer for aircraft and automotive.

 Types of manufacturing operations
3. Batch Production
Batch production is where production is carried out in discrete parts
at regular intervals. Batch production is employed for stable line
products which are produced in medium volume for customer order
or for inventory. The process has the ability to switch over from one
product to another with relative ease. Though mostly general
purpose machines are used, these are supported by some level of
mechanization and specially design jigs and fixtures. The skill level
of labour is high but not critical. Examples of batch production are
paint production, bakery and electronic chip product ion.

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Types of manufacturing operations
4. Mass Production
In mass production, products are manufactured in large quantities
and uses standardized assembly lines and specialized machines
or high level of automation. Different products can be
manufactured in the same line as long as the sequence of
processes remains the same. Mass production is capital intensive
as setting up the flow line is expensive due to use of specialized
machines. Semi-skilled labours are preferred as they perform
repetitive tasks. Examples of mass production are car assembly
and food processing.
Types of manufacturing operations
Types of manufacturing operations
1.2 Relationship between design,
manufacturing processes and
costs
Design process

Product design is a process that begins with the

recognition of the user’s need and ends with a
manufactured product that is accepted by
customers as being satisfactory in use or service.
The process proceeds from concepts which are
abstracts to a complete product which is concrete.
Design process
Design for Manufacture and
Assembly (DFMA)
Design for Manufacture (DFM) is a method of design for
ease of manufacturing of the collection of parts that will
form the product after assembly.

Design for Assembly (DFA) is the method of design of

the product for ease of assembly.

Now it is collectively known as DFMA.

Design for Manufacture and
Assembly (DFMA)
The difference between DFM and DFA is DFM is
concerned into reducing the overall part production cost
and concentrates in optimizing the manufacturing
processes by minimizing the complexity in the
manufacturing operations. On the other side DFA is
concerned in reducing the product assembly cost and
concentrates in the optimization of the part/system
assembly by minimizing the number of assembly
operations.
 Design for Manufacture and
Assembly (DFMA)
The similarities of DFM and DFA are both seek to reduce
material, labour and overhead cost or in total the
manufacturing cost. Both methods also shorten the product
development cycle time.
Design for Manufacture and
Assembly (DFMA)
Design for Manufacture and
Assembly (DFMA)

Design changes in motor drive assembly using DFMA

Design for Manufacture and
Assembly (DFMA)

Reduction in assembly cost by using DFMA in design

Design for Manufacture and
Assembly (DFMA)

Reduction in part cost by using DFMA in design

 Design for Manufacture and
Assembly (DFMA)

The guidelines for Design for Manufacture and Assembly are

as follows:-
a.Minimize number of components;
b.Use standard commercially available components;
c.Use common parts across product lines;
d.Design for ease of part fabrication;
e.Design parts with tolerances within the process capability;
 Design for Manufacture and
Assembly (DFMA)

The guidelines for Design for Manufacture and Assembly are

as follows:-
f. Design the product to be fool proof during assembly;
g. Minimize use of flexible components;
h. Design for ease of assembly;
i. Use modular design;
j. Shape parts and products for ease of packaging;
k. Eliminate or reduce adjustments.
Manufacturing process selection
Manufacturing process selection

Manufacturing selection is carried out during the product

design process when the design is being optimized
using the DFMA method. The selection of
manufacturing processes are based on :-
a.Materials used;
b.Complexity of shape of component;
c.Section thickness of the part;
d.Dimensional tolerances and surface roughness;
e. Batch size to be produced.
1.3 Environment and energy
concerns
Industrial Pollution
Any form of pollution that can trace its immediate source
to industrial processes. Below are few of the causes of
industrial pollution that have resulted in environment
degradation.
a.Lack of policies to control pollution;
b.Unplanned industrial growth;
c.Use of outdated technologies;
d.Presence of large number of small scale industries;
e.Inefficient waste disposal;
f.Leaching of resources from our natural world
Industrial Pollution
Common pollutions that are threats to the ecosystem are
as follows:-
a. Water pollution;
Typical causes :-
i)Industrial waste;
ii)Sewage and waste water;
iii)Mining activities;
iv)Marine dumping;
v)Accidental oil leakage;
vi)Chemical fertilizers and pesticides;
Industrial Pollution
Common pollutions that are threats to the ecosystem are
as follows:-
b. Air pollution;
Typical causes :-
i)Burning of fossil fuels;
ii)Agricultural activities;
iii)Exhausts from factories and industries;
iv)Mining operations.
Industrial Pollution
Common pollutions that are threats to the ecosystem are
as follows:-
c. Land pollution;
Typical causes :-
i)Deforestation and soil erosion;
ii)Agricultural activities;
iii)Overcrowded landfills;
iv)Nuclear waste.
Industrial Pollution
Common pollutions that are threats to the ecosystem are
as follows:-
d. Global warming;
Typical causes :-
i)Burning of fossil fuels;
ii)Deforestation;
iii)Farming;
iv)Industrial waste and landfills.
Green manufacturing

Green manufacturing is a method for manufacturing

that minimizes waste and pollution. These goals are
realized through design of ‘green’ products and
‘green’ processes. In Green Manufacturing,
environmental impact of all stages of production is
considered.
Green manufacturing
The objectives of green manufacturing are as below:-

a) Raw ingredients are used as much as possible if the

end product is biodegradable,
b) Hazardous chemical conditioners, chemical anti-bacterial
or chemical preservatives are not used in the products
that might end up at the waste systems (landfills),
c) A cleaner source of energy will be provided to reduce
energy consumption,
Green manufacturing
The objectives of green manufacturing are as below:-

d) Pollutants and wastes are converted into by-products and

promote recycling of the product,
e)Process improvements are carried out to maximize yield
and minimize the waste that is produced.
Green manufacturing
Green manufacturing promises the following benefits:-

a)Reduce waste to zero; improves the ecology and stop

pollution,
b)A company that practices green manufacturing creates
a great image to the public,
c)A company which could develop a similar, greener
product will certainly have the competitive edge,
Green manufacturing
Green manufacturing promises the following benefits:-

d) Practicing green manufacturing lead to cost

saving,
e) Green manufacturing spins off a lot of research and
development projects for new enhanced technology.
Green manufacturing
The world's energy resources fall into two types:-

a)Non-renewable energy including energy made from fossil

fuels (oil, gas and coal) and nuclear power. It is called non-
renewable as the supplies are considered limited due to a
longer time (millions of years) required for replenishment.
Non-renewable sources supply about 80–90 % of the world's
energy.
Green manufacturing

b)Renewable energy means energy made from the

wind, ocean waves, solar power and biomass. It is called
renewable because, in theory, it will never run out.
Renewable sources currently supply about 10–20 % of the
world's energy.
Green manufacturing
The types of renewable energies are as below:-

a)Solar energy;
b)Hydroelectric energy;
c)Wind energy;
d)Biomass energy;
e)Geothermal energy.
1.4 Safety at workplace
Occupational Health and Safety
(OHS)

OHS legislations’ objective is in the promotion and

maintenance of the highest degree of physical, mental and
social wellbeing of workers in all occupations.

The main contributory factors towards the development of

the OSH legislations are due to the rapid industrial and
agricultural developments that are taking place and the
emergence of new products and manufacturing processes.
Occupational Health and Safety
(OHS)
The positive impact of OHS will be observed in the
reduction of work-related injuries or fatalities.

Only 5-10% of workers in developing countries and 20-

50% of workers in industrial countries (with a few
exceptions) are estimated to have access to adequate
occupational health services. Even in advanced
economies, a large proportion of work sites are not
regularly inspected for occupational health and safety.
 Occupational Health and Safety
(OHS)
According to World Health Organization (WHO), occupational
safety and health can be defined as a multidisciplinary activity
aiming at:
• Protection and promotion of the health of workers by eliminating
occupational factors and conditions hazardous to health and
safety at work;

• Enhancement of physical, mental and social well-being of

workers and support for the development and maintenance of
their working capacity, as well as professional and social
development at work;

• Development and promotion of sustainable work environments

and work organizations.
Hazards and Risks

A hazard is a potential
source of harm or
adverse health effect on
a person or persons.
 Hazards and Risks

Risk the likelihood that a person

may be harmed or suffers
adverse health effects if
exposed to a hazard.

Risk = Likelihood x Impact OR

Risk = Probability x Consequences
Hazards and Risks
The best way to fix a hazard is to get rid of it altogether. If
this is not always possible, employer should try to make
hazards less dangerous by looking at the following options
(in order from most effective to least effective):

• Elimination - Sometimes hazards - equipment,

substances or work practices - can be avoided entirely.
(e.g. Clean high windows from the ground with an
extendable pole cleaner, rather than by climbing a
ladder and risking a fall.)
Hazards and Risks

• Substitution - Sometimes a less hazardous thing, substance or

work practice can be used. (e.g. Use a non-toxic glue instead
of a toxic glue.)

• Isolation - Separate the hazard from people, by marking the

hazardous area, fitting screens or putting up safety barriers.
(e.g. Welding screens can be used to isolate welding
operations from other workers.)
 Hazards and Risks

• Safeguards - Safeguards can be added by modifying tools or

equipment, or fitting guards to machinery. These must never
be removed or disabled by workers using the equipment.

• Instructing workers in the safest way to do something - This

means developing and enforcing safe work procedures.
Students on work experience must be given information and
instruction and must follow agreed procedures to ensure their
safety.
Hazards and Risks

• Using personal protective equipment and clothing (PPE) -

If risks remain after the options have been tried, it may be
necessary to use equipment such as safety glasses,
gloves, helmets and ear muffs. PPE can protect you from
hazards associated with jobs such as handling chemicals
or working in a noisy environment.
Safety Standards

The Occupational Health and Safety Act (OSHA) Standards

have rules that describe the methods employers need to
use to protect employees from hazards. The standard has
been designed to protect employees from a wide range of
hazards.
Safety Standards

In Malaysia, the Department of Occupational Safety and

Health (DOSH) under the Ministry of Human Resources is
responsible to ensure that the safety, health and welfare of
workers in both public and private sector are upheld.
DOSH is responsible to enforce the Factory and Machinery
Act 1969 and the Occupational Safety and Health Act
1994.
Safety procedures and precautions at
workplace
a. Slips and trips hazards
Precautions to be taken to prevent slip and trip are:-
i) Ensure floor is not wet or contaminated due to
leakage or spillage;
ii) Ensure in case of any contamination, stop
contamination from getting onto the walkways;
iii) Ensure floor is in a good condition and free from
damages. Damage floor may have holes and uneven;
iv) Ensure good housekeeping – no things left on the
walkway and no cables or pipes passing through walkways.
v) Ensure the walkway is well lit.
Safety procedures and precautions at
workplace
a. Slips and trips hazards
Procedures on slips and trips safety:-
i) Clean slippage immediately and prevent anyone from walking
anyone to walk on the floor until it is dry.
ii) Use the correct floor cleaning method and product to prevent
poorly cleaned floor.
iii) Display ‘Wet Floor’ sign when needed.
iv) Use anti slip mat on smooth or polished surfaces; however
precaution need to be taken to ensure the mat does not cause tripping.
v) Carry out periodic inspection for damaged floor and walkway lights
and repairs to be carried out immediately when required.
Safety procedures and precautions at
workplace
a. Slips and trips hazards

vi) Follow strictly the housekeeping practices.

vii)Use covers to cover cables and pipes which are passing
walkways.
viii) Use suitable footwear.
ix) Train staff on slip and trip safety.
Safety procedures and precautions at
workplace
b. Fire hazards
Precautions to be taken to prevent fire are:-
i) Ensure there is no faulty wiring and malfunctioning electrical
equipment.
ii) Ensure equipment that could provide a source of ignition is left in a
safe condition, even when not in use.
iii) Ensure flammable materials are handled, transported, stored and
used properly.
iv) Ensure doors, windows and other openings not required for
ventilation are closed, particularly out of working hours.
v) Ensure all electrical fuses and circuit breakers are of the correct
rating and suitable for the purpose.
Safety procedures and precautions at
workplace
b. Fire hazards

vi) Ensure smoking in hazardous areas is prohibited.

vii) Ensure suitable fire fighting equipment are available (fire
alarm, fire extinguisher, sprinkler system, water hose and fire
blankets)
viii) Ensure work area is clean from rubbish, unused boxes or
plastic bottles or anything that can catch fire easily.
ix) Ensure escape routes are easily identifiable using standard
sign, free from any obstructions and adequately illuminated.
Safety procedures and precautions at
workplace
b. Fire hazards
Procedures to fire safety:-
i) Conduct fire risk assessment on regular interval to report electrical
hazards.
ii) Conduct maintenance on machines and electrical equipment
according to the maintenance schedule.
iii)Train staff on fire prevention and protection and conduct fire drills from
time to time.
iv)Follow strictly the housekeeping practices.
v)Conduct periodic maintenance and testing of fire fighting equipment.
Safety procedures and precautions at
workplace
c. Machinery hazards
Precautions to be taken to prevent machinery related accidents
are:-
i) Ensure guards are used to enclose dangerous parts of the
machine.
ii) Ensure operators are trained before using any machine
and supervisor to monitor all operators when the machines are
being operated.
iii) Ensure loose clothing or jewelry are not worn while
operating machines.
iv) Ensure all machines have adequate lighting.
v) Ensure control switches on machines are marked and
clearly inform the operator their functions.
Safety procedures and precautions at
workplace
c. Machinery hazards
vi) Ensure all machines have emergency stop buttons.
vii) Ensure operators are wearing personal protective equipment
(PPE) such as gloves, safety glasses and safety shoes.
viii) Ensure adequate space for the machine and operator to avoid
cramped conditions or creation of atmospheric or other hazards
(e.g., fire, exposure to excessive heat, radiation, etc.) during
operation.
Safety procedures and precautions at
workplace
c. Machinery hazards

Procedures for machinery safety:-

i) Conduct inspection and maintenance on machines
according to the machinery safety checklist.
ii) Conduct risk assessment on regular interval to
identify machine hazards.
iii)Follow strictly the housekeeping practices.
iv)Machine safety operating procedures (pre-operational and
operational safety checks) should be placed on machines in a
position easily viewed by operators.
v)Staff trained on the machinery and operation safety on
regular period.
Safety procedures and precautions at
workplace
d. Noise hazard

Precautions to be taken to prevent hearing loss due to loud

noise:-
i) Ensure hearing protection devices (HDP) such as
earmuffs and ear plugs are worn during work.
ii) Ensure noise source is enclosed or isolated.
iii) Ensure low noise tools and machineries are used.
iv) Ensure machines are lubricated.
v) Ensure dampers are used to reduce machine
vibrations.
vi) Ensure a quiet place is provided for workers to rest.
Safety procedures and precautions at
workplace
d. Noise hazard

Procedures for noise safety:-

i) Conduct noise assessment at workplace at regular intervals
to identify noise hazards and workers whom are being
affected.
ii) Conduct inspection and maintenance on machines according
to the machinery safety checklist.
iii) Conduct training that ensures the workers are aware of the
hazard from excessive noise exposures and how to properly
use the protective equipment that has been provided.
iv) Conduct audiometric testing on workers every one or two
years.
Safety procedures and precautions at
workplace
e. Manual lifting and handling hazard

Precautions to be taken to prevent injury due to manual lifting and

handling:-
i) Ensure use of lifting aid such as a pallet truck, electric and
hand powered hoist or a conveyer.
ii) Ensure repetitive handling is avoided.
iii) Ensure warm up cold muscles with gentle stretches before
engaging in any manual work.
iv) Ensure cool down after heavy work with gentle, sustained
stretches.
v) Lift and carry heavy loads correctly by keeping the load
close to the body and lifting with the thigh muscles.
Safety procedures and precautions at
workplace
e. Manual lifting and handling hazard

vi) Pushing a load (using body weight to assist) will be less

stressful on body than pulling a load.
vii) Ensure back is not bent or twisted while carrying load.
viii) Ensure obstructions are removed to free movement and floor
is clean and not slippery.
Safety procedures and precautions at
workplace
e. Manual lifting and handling hazard

Procedures for manual handling and lifting safety:-

i) Conduct checks regularly to monitor use of manual handling at
workplace.
ii) Conduct training on manual handling and correct lifting/back
care.
Safety procedures and precautions at
workplace
f. Electricity hazard
Precautions to be taken to prevent electrical related accidents:-
i) Ensure lower voltage is used wherever possible.
ii) Ensure equipment is fitted with correct rated fuse.
iii) Ensure damaged section of the cable is replaced completely and
not repaired used insulating tapes
iv) Ensure electrical equipment is suitable for its working
environment.
v) Ensure electrical equipment used in flammable/explosive
atmospheres should be designed not to produce sparks.
Safety procedures and precautions at
workplace
f. Electricity hazard
vi) Ensure enough socket-outlets are provided for equipment in use.
vii) Ensure damaged, unsafe electrical equipment or cords are removed
from the workplace
viii) Power cables to machines must be insulated and protected from
damage, eg sheathed and armoured or installed in conduit.
ix) Ensure tools and power sockets are switched off before plugging in
or unplugging.
x) Ensure repairs to electrical equipment or installations are carried out
after the equipment or installation has been suitably isolated.
xi) Ensure safety signs, safety symbols or accident prevention tags are
used to warn others about electrical hazards which may endanger
them.
Safety procedures and precautions at
workplace
f. Electricity hazard
Procedures for electrical safety:-
i) Conduct Electrical Hazard Analysis (EHA) to identify electrical
hazards.
ii) Provide training for staff in proper operation and maintenance of
equipment to prevent electrical contact injuries.
iii) Conduct inspection and maintenance on electrical equipment
according to the equipment safety checklist.