INTRODUCTION TO MANUFACTURING

PROCESS
 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” accurately 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
 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 - Economically

 Transformation of materials into items of greater value

by one or more processing and/or assembly operations
 Manufacturing - Economically

 When iron ore is converted into steel, value is added.

 When sand is transformed into glass, value is added.
 When petroleum is refined in to plastic, value is
added
 Manufacturing Industries

 Industry consists of enterprises and organizations that

produce or supply goods and services
 Industries can be classified as:
1. Primary industries - cultivate and exploit natural
resources, e.g., agriculture, mining
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and
capital goods
3. Tertiary industries - service sector
Specific Industries in Each
Category
 Manufactured Products

 Final products divide into two major classes:

1. Consumer goods - products purchased directly by
consumers
 Cars, clothes, TVs, tennis rackets
2. Capital goods - those purchased by companies to
produce goods and/or provide services
 Aircraft, computers, communication
equipment, medical apparatus, trucks,
machine tools, construction equipment
 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
 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
 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
 Casting process at left and casting product at right
 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
 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
 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
 Physical vapor deposition
 Painting
 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
Two welders perform
arc welding on a
large steel pipe
section (photo
courtesy of Lincoln
Electric Company).
 Production Systems

 Production systems consist of people, equipment, and

procedures designed for the combination of materials
and processes that constitute a firm’s manufacturing
operations.
 Production systems can be divided into two categories:
(1) production facilities and
(2) manufacturing support systems
 Production Systems

Production facilities refers to the:

 physical equipment
 the arrangement of equipment in the
factory
 the plant layout.
Manufacturing support systems
 planning the manufacturing processes
 Production planning and control
 Quality control
 Various types of plant lay out

 Plant layout is such a systematic and efficient functional

arrangement of various departments, machines, tools,
equipment and other supports services of an industrial
organization
 plant layout will facilitate the smooth processing of the
proposed or undertaken product in the most effective, most
efficient and most economical manner in the minimum
possible time.
 Cont.
Fixed-position layout

If the product is large and heavy, and therefore difficult to move, it

typically remains in a single location during its fabrication or assembly.
Workers and processing equipment are brought to the product, rather
than moving the product to the equipment. This type of layout is
referred to as a fixed-position layout.
 Process layout

 The individual components of the large products are often made in

factories in which the equipment is arranged according to function
or type. This arrangement is called a process layout.
 similar machines, production facilities and manufacturing operations
are grouped together according to their functions.
Cont.
 Product layout

 The workstations and equipment are designed specifically for

the product to maximize efficiency. The layout is called a
product layout, and the work stations are arranged into one
long line, or into a series of connected line segments. The
work is usually moved between stations by mechanized
conveyor.
Cont.
 PRODUCTION PROCESS

 The art of converting raw material into finished goods with

application of different types of tools, equipments, machine
tools, manufacturing set ups and manufacturing processes, is
known as production.
 Generally there are three basic types of production system
1. Job production
2. Batch production
3. Mass production
 Job production

 Job production comprises of an operator or group of

operators to work upon a single job and complete it before
proceeding to the next similar or different job.
 The production requirement in the job production system is
extremely low. It requires fixed type of layout for
developing same products.
 batch production

 Manufacturing of products (less in number say 200 to

800) with variety of similar parts with very little
variation in size and shape is called batch production.
 Mass production

 Mass production involves production of large number of

identical products.
 It needs line layout type of plant layout which is highly
rigid type and involves automation and huge amount of
investment in special purpose machines to increase the
production.