MT-221

Manufacturing
Engineering

Lecture : 10

Tuesday, December 31, 2024 Manufacturing Processes 1

Manufacturing Engineering : Defined

• Planning of manufacturing processes for the economic

production of high quality products
– Principal role - to engineer the transition from product
design specification to manufacture of a physical product

– Overall goal - to optimize manufacturing within a particular

organization
 Manufacturing Engineering
Activities
• Process planning
– Deciding most appropriate processes and their sequence
– Determining tooling requirements
– Selecting equipment
– Estimating costs

• Problem solving and continuous improvement and support

to operating departments
• Design For Manufacturability - serve as manufacturability
advisors to product designers
 Process Planning
• Traditionally, process planning is accomplished by manufacturing
engineers who are knowledgeable about the processes used in the
factory and are able to read engineering drawings
• Processes and sequence - the process plan should briefly describe all
processing steps used on the work unit in the order in which they are to
be performed
• Equipment selection - try to develop process plans that utilize existing
plant equipment
– Otherwise, the part must be purchased, or
– New equipment must be installed in the plant
• Tools, dies, molds, fixtures, and gages - design is usually delegated
to the tool design department, and fabrication is accomplished by the tool
room
• Estimating production costs - often accomplished by cost estimators
with help from the process planner
• Cutting tools and conditions for machining operations
 Process Planning for Parts
• The processes needed to manufacture a given part are
determined largely by the material out of which the part is made
and the part design itself
– The material is selected by the product designer based on
functional requirements
– Once the material has been selected, the choice of possible
processes is narrowed considerably
• A typical processing sequence to fabricate a discrete part
consists of:
– A basic process
– One or more secondary processes
– Operations to enhance physical properties
– Finishing operations
 Process Sequence

• Basic process - establishes initial geometry of workpart (a forming process)

– Examples: metal casting, forging, sheet metal rolling (often external)
• In most cases, the starting geometry must be modified or refined by a
series of secondary processes, which transform the basic shape into the
final geometry
– Examples: machining, stamping
• Operations to enhance properties - heat treatment operations
– Treatments to strengthen metal components
– In many cases, parts do not require these property enhancing steps
• Finishing operations - the final operations in the sequence
– Usually provide a coating on the work surface
– Examples: electroplating, painting
 Examples of Typical Process
Sequences

Basic process Secondary Property Finishing

Process(es) Enhancing Operations
Sand casting Machining Heat treating Painting

Rolling sheet Blanking, bending (none) Electroplating

Forging Machining (none) Painting

Extrusion Cut to length Heat treating Anodize

Casting of glass Press, blowing Tempering Chem. etch

 MT-221

Quality Control

Lecture : 14

Tuesday, December 31, 2024 Manufacturing Processes 8

 Quality Control
• What is Quality?
• Process Capability
• Statistical Tolerancing in Product Design
• Taguchi Methods
• Statistical Process Control
 What is Quality?

The dictionary defines it as:

"The degree of excellence which a thing possesses"
or
"The features that make something what it is”
 What is Quality?
• Views of the experts:
– Crosby defines quality as "conformance to requirements"

– Juran summarizes it as "fitness for use" and

"quality is customer satisfaction"

– ASQC defines quality as "the totality of features and

characteristics of a product or service that bear on its
ability to satisfy given needs"
 Two Aspects of Quality in a
Manufactured Product
• Product features - the characteristics of the product that
result from design
– Functional and aesthetic features of the item intended to
appeal to and provide satisfaction to the customer

• Freedom from deficiencies – the product is absent of

defects and out-of-tolerance conditions
– The product does what it is supposed to do within the
limitations of its design features
 Product Cost and Quality
• The inherent cost to make a product is a function of its
design
• Minimizing the product's cost to the lowest possible level
within the limits set by its design is largely a matter of
avoiding defects, tolerance deviations, and other errors
during production
Costs of Quality Deficiencies
• Scrapped parts
• Larger lot sizes for scrap allowances
• Rework, re-inspection, sortation,
• Customer complaints and returns
• Warranty costs and customer allowances
• Lost sales
• Lost good will in the marketplace
Who’s Responsible for Quality?
• Product features are the aspect of quality for which
design is responsible
– Product features determine to a large degree the price that
a company can charge for its products
• Freedom from deficiencies is the quality aspect for which
manufacturing is responsible
– The ability to minimize these deficiencies has an important
influence on the cost of the product
• However, the responsibility for high quality extends well
beyond the design and manufacturing functions in an
organization
 Process Capability
• In any manufacturing operation, variability exists in the
process output
• Manufacturing variations can be divided into two types:
1. Random

2. Assignable
 Random Variations
• Caused by factors such as human variability, variations in
raw materials, machine vibration, and so on
• Random variations typically form a normal statistical
distribution
• When the only variations in the process are random, the
process is said to be in statistical control
• It is when the process deviates from this normal
operating condition that variations of the second type
appear
 Assignable Variations
• An exception from normal operating conditions due to
operator mistakes, defective raw materials, tool failures,
machine malfunctions, and so on
• Something has occurred in the process that is not
accounted for by random variations
• Assignable variations in manufacturing usually betray
themselves by causing the output to deviate from the
normal distribution
• The process is no longer in statistical control
 Process Capability
Defined as  3 standard deviations about the mean output
value (a total of 6 standard deviations)
PC =  3
Where:

PC = process capability;

 = process mean,
which is set at the nominal value of the product
characteristic when bilateral tolerancing is used

 = standard deviation of the process

 Tolerances and Costs
• Conventional wisdom in design engineering is that closer
tolerances mean better performance of the product
• Small regard is given to the cost resulting from
tolerances that are unduly tight relative to process
capability
• As tolerance is reduced, the cost of achieving the
tolerance increases at an accelerating rate
 Specifying Tolerances
• Although design engineering must give primary
consideration to product performance in assigning
tolerances, cost is also a factor
• Any relief that can be given to the manufacturing
departments in the form of wider tolerances without
sacrificing product function is worthwhile
• Approaches that consider process capability in specifying
tolerances:
– Natural tolerance limits
– Statistical tolerancing for assemblies
 Natural Tolerance Limits
• Design tolerances that are equal to process capability
• When design tolerances are set equal to the natural
tolerance limits, then
– 99.73% of the parts will be within tolerance
– 0.27% will be outside the limits

• Any increase in the tolerance range will reduce the

percentage of defective parts
 An Example - What should the
Part Tolerances be?

An assembly consisting of three parts whose overall dimension (La)

has a tolerance of 0.30 mm
 Specifying Tolerances –
Worst Case Design
• In worst case design, the total tolerance is divided
among the parts so that the sum of their individual
tolerances = the assembly tolerance
• Overall assembly length has a tolerance of 0.30 mm
• If assembly tolerance is divided evenly among parts,
then the tolerance of each part = 0.10 mm
• If all of the parts are within tolerance, no combination of
their dimensions will produce an assembly dimension
that is out of tolerance
 Statistical Tolerancing

• A statistical approach can be used for assemblies

(and other additive dimensions), based on the
following relationship:
n
 a =  i
2 2

i =1

Where:
a = standard deviation of the assembly,
i = standard deviation of part i
n = number of components
 Statistical Tolerancing

If tolerances on the individual components are set at some

specified multiple of their respective standard deviations
(e.g., natural tolerance limits, where T = 6 ), and it is
appropriate to set the tolerance on the assembly using the
same multiple, then
n
Ta =  Ti
2

i =1
Where:
Ta = tolerance of the assembly dimension;
Ti = tolerances of the individual component dimensions;
n = number of components
Off-Line and On-Line Quality Control

• Off-line quality control - concerned with design

issues, both product design and process design

– It precedes on-line control

• On-line quality control - concerned with production

operations and customer relations after shipment

– Objective is to manufacture products within the

specifications defined in product design, using
methods and procedures developed in process
design
Control Chart
Underlying Principle in Control Charts

• Variations in any process divide into two types:

– Random variations, which are the only variations present if

the process is in statistical control

– Assignable variations that indicate a departure from

statistical control

• It is the objective of a control chart to identify when the

process has gone out of statistical control, thus signaling that
some corrective action should be taken

• If a sample value falls outside the limits, it is interpreted to

mean that the process is out of control
 Manual Assembly Line

Manual assembly line:

1. Each worker performs a task at his/her workstation.
2. A conveyor moves parts on work carriers from one station to the next.
 Automated Production Line
• Multiple automated workstations connected by a parts
transfer system whose actuation is coordinated with the
stations’ operations
• In the ideal, no human workers are on the line, except
to perform auxiliary functions such as
– Tool changing

– Parts loading and unloading

– Repair and maintenance

 Operations Performed on
Automated Production Lines
• Operations performed by automated stations tend to be
simpler than those performed by humans on manual
lines
• Tasks that are easy to automate consist of:
– Single work elements

– Quick actuating motions

– Straight line feed motions as in machining

 Types of Automated Lines

• Two basic categories:

1. Lines that perform processing operations
• Example: transfer line
2. Lines that perform assembly operations
• Example: automatic assembly machine
 Layouts of Automated Production
Lines
• In-line layout as in a transfer line that performs
machining operations
• Circular around a dial indexing machine
• Carousel – common in automated assembly systems
 Layouts of Automated Production
Lines

A machining transfer line, an important type of automated production line

Layouts of Automated Production
Lines

Configuration of a dial indexing machine

Worktable rotates partially (indexes) at end of each cycle to position
parts at the next station in the sequence
Automated Assembly Systems
• One or more workstations that perform assembly
operations, such as adding components and/or
affixing them to the work unit
• Two basic categories:
1. Single station assembly cells - often organized
around an industrial robot that performs a
sequence of assembly steps
2. Multiple station assembly systems - used for
mass production of small products such as ball
point pens, cigarette lighters, flashlights, and
similar items with relatively few components
Automated Assembly Configurations

Three common configurations of multiple station assembly

systems:
(a) In-line
(b) Rotary
(c) Carousel
 Thank You

Tuesday, December 31, 2024 Manufacturing Processes 39