What is manufacturing?

 The word manufacture is derived from two Latin words,

manus (hand) and factus (make); the combination means
made by hand. The English word manufacture is several
centuries old, and ‘‘made by hand’’ accurately described
the manual methods used when the word was first coined.
 The processes to accomplish manufacturing involve a
combination of machinery, tools, power, and labor,
 Technologically, 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 assembly of multiple
parts to make products.
Economically, manufacturing is the transformation
of materials into items of greater value by means
of one or more processing and/or assembly
operations,
 Advanced manufacturing engineering involves the
following concepts
1.Process planning.
2. Process sheets.
3. Route sheets.
4. Cutting tools, machine tools
5. Jigs and Fixtures.
6. Dies and Moulds.
7. Manufacturing Information Generation.
8. CNC part programs.
9. Robot programmers.
10. Flexible Manufacturing Systems (FMS), Group
Technology (GT) and Computer integrated manufacturing
(CIM).
 Industry consists of enterprises and organizations
that produce or supply goods and services.
 Primary industries cultivate and exploit natural
resources, such as agriculture and mining.
 Secondary industries take the outputs of the
primary industries and convert them into consumer
and capital goods. Manufacturing is the principal
activity in this category, but construction and
power utilities are also included.
 Tertiary industries constitute the service sector of
the economy.
Final products made by the manufacturing industries
can be divided into two major classes: consumer
goods and capital goods.
 Consumer goods are products purchased directly
by consumers, such as cars, personal computers,
TVs, tires, and tennis rackets.
 Capital goods are those purchased by companies
to produce goods and/or provide services.
Examples of capital goods include aircraft,
computers, communication equipment, medical
apparatus, trucks and buses, railroad locomotives,
machine tools, and construction equipment.
 A manufacturing process is a designed procedure
that results in physical and/or chemical changes to
a starting work material with the intention of
increasing the value of that material.
 Manufacturing operations can be divided into two
basic types:
(1) processing operations and
(2) assembly operations.
  Based up on the state of the starting material, by
which we have four categories of shaping
processes:
a) solidification processes
b) particulate processing
c) deformation processes
d) material removal processes
 Casting and molding processes start with a work
material heated to a fluid or semifluid state. The
process consists of:
(1) pouring the fluid into a mold cavity and
(2)allowing the fluid to solidify, after which the
solid part is removed from the mold.
 In particulate processing, the starting materials are powders
of metals or ceramics. The common technique involves
pressing and sintering, the powders are first squeezed into a
die cavity under high pressure and then heated to bond the
individual particles together
 In deformation processes, the starting work part is shaped by
the application of forces that exceed the yield strength of the
material. For the material to be formed in this way, it must be
sufficiently ductile to avoid fracture during deformation. To
increase ductility ,the work material is often heated before
forming to a temperature below the melting point. Deformation
processes are associated most closely with metal working and
include operations such as forging and extrusion.
Forging
In forging two halves of a die squeeze the work part,
causing it to assume the shape of the die cavity.
 In extrusion a billet is forced to flow through
a die orifice, thus taking the cross-sectional
shape of the orifice.
 Rolling is a deformation process in which the
thickness of the work is reduced by compressive
forces exerted by two opposing rolls.
 Material removal processes are operations that remove excess
material from the starting work piece so that the resulting
shape is the desired geometry. The most important processes
in this category are machining operations such as:
a) turning,
b)Drilling and
c)milling
 Surface processing operations include
(1) cleaning
Cleaning includes both chemical and mechanical
processes to remove dirt, oil, and other contaminants
from the surface.
(2) surface treatments
Surface treatments include mechanical working such
as shot peening and sand blasting, and physical
processes such as diffusion and ion implantation.
(3) coating and thin film deposition processes
Coating and thin film deposition processes apply a
coating of material to the exterior surface of the work
part. Common coating processes include
electroplating, anodizing of aluminum, organic
coating (call it painting), and porcelain enameling.
 Property-Enhancing Processes The second major type of
part processing is performed to improve mechanical or
physical properties of the work material. These
processes do not alter the shape of the part, except
unintentionally in some cases. The most important
property-enhancing processes involve heat treatments,
which include various annealing and strengthening
processes for metals and glasses. Sintering of powdered
metals and ceramics is also a heat treatment that
strengthens a pressed powder metal work part.
 The second basic type of manufacturing operation
is assembly, in which two or more separate parts
are joined to form a new entity.
 Components of the new entity are connected either
permanently or semi permanently.
 Permanent joining processes include welding,
brazing, soldering, and adhesive bonding. They
form a joint between components that can not be
easily disconnected.
 Certain mechanical assembly methods are available
to fasten two (or more) parts together in a joint
that can be conveniently disassembled. The use of
screws, bolts, and other threaded fasteners are
important traditional methods in this category.
 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 facilities refers to the:
 physical equipment
 the arrangement of equipment in the factory
 the plant layout.
Manufacturing support systems are the procedures used by the
company to manage production and solve the technical and
logistics problems encountered in ordering materials, moving
work through the factory, and ensuring that products meet
quality Production facilities consist of the factory and the
production, material handling, and
other equipment in the factory.
Manufacturing support systems
Manufacturing engineering
planning the manufacturing processes, deciding what
processes should be used to make the parts and assemble
the products, designing and ordering the machine tools.
 Production planning and control
responsible for solving the logistics problem in
manufacturing, ordering materials and purchased parts,
scheduling production, and making sure that the operating
departments have the necessary capacity to meet the
production schedules.
 Quality control
building products that conform to specifications and satisfy
or exceed customer expectations.
 Plant layout is such a systematic and efficient functional arrangement
of various departments, machines, tools, equipment and other
supports services of an industrial organization that 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.
 Advantages of good plant lay out
1. Reduced men and machine hours per unit of production,
2. Effectively and economical utilization of entire floor space of the plant,
3. Work flow is smooth and continuous
4. Work in process inventory is less
5. Production control is better
6. Manufacturing time is less
7. Relatively less floor area is required
8. Material handling is less.
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.
 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.
 Each cell is designed to produce a limited variety of
part configurations; that is, the cell specializes in
the production of a given set of similar parts,
according to the principles of group technology.
 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.
 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 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.
 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 involves production of large number of identical
products (say more than 50000) that 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.