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Definition of "Manufacturing"

Manufacturing is the process of converting raw materials into finished goods through mechanical, physical, or chemical processes to design, market, and produce goods for sale to customers. It includes the design and production of products, and involves the procurement of raw materials, management of money and human resources, and distribution of products. The manufacturing process converts materials into useful products through material transformation and assembly processes using machines and automation.

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26 views

Definition of "Manufacturing"

Manufacturing is the process of converting raw materials into finished goods through mechanical, physical, or chemical processes to design, market, and produce goods for sale to customers. It includes the design and production of products, and involves the procurement of raw materials, management of money and human resources, and distribution of products. The manufacturing process converts materials into useful products through material transformation and assembly processes using machines and automation.

Uploaded by

lamia97
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Definition of "Manufacturing"

"Manufacturing" is a process for converting ideas


and market or customer needs into artifacts;

Includes design, procurement, test,


finance, human resources, marketing,
etc.
manufacturing is the conversion of raw
materials into useful products
Main Focus of This Course

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Little "m" manufacturing is all about


Creating shapes by various means and assembling
these shapes into a useful product
The processes used to transform raw material into
finished products
A physical product always has a shape
Function
Aesthetics
These shapes are created by a wide variety of
processes
Students must remember that these processes exist
only in the context of the larger Manufacturing
process
ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Manufacturing
Societal pressures, Government regulations,
company plans and policies, etc

Customer
needs

manufacturing

Products

Raw
material

People, money, machines and automation


ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

The manufacturing Process

Products

Material
Transformation
Processes

Assembly

Raw Material

Materials Science, Statics, Dynamics, Thermodynamics, Fluid


dynamics

Machines and Automation

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Shapes and Production Method

TABLE1.2Shapes and Some Common Methods of Production

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Engineering Materials

FIGURE1.4Anoutlineofengineeringmaterials

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Production Methods for a Simple


Part

FIGURE1.6Various methods of making a simple part: (a) casting or powder metallurgy, (b)
forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Fundamentals of manufacturing Manufacturing Concepts


The method chosen depends on the material
and the shape and properties required

Formability
Machinability
Hardenability

ManufacturingEngineeringandTechnology

Castability
Compactability
Sinterability
Weldability

AssiutUniv.Mech.Eng.dept

Lecture1

Why is Manufacturing Important?


Impact on economy

Major wealth creation engines


Gross Domestic Product
jobs

Most decisions made during design are


impacted by production/manufacturing
processes
Critical Decisions/Trade-offs
function vs cost vs schedule
Choose materials
Choose process(es)

Cost determined by the material and the


processes used to create the shape
ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Some functional parameters


affected by production processes
Mechanical properties (Strength, Hardness,
Fatique, Ductility, Resistance to environment)
Tolerances
Surface finish
Resistance to corrosion and abrasion
Electrical properties
Thermal Properties
Appearance/surface finish
ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Commercially Available
Materials
TABLE 40.1
Material
Available as
Aluminum
P, F, B, T, W, S, I
Copper and brass
P, f, B, T, W, s, I
Magnesium
P, B, T, w, S, I
Steels and stainless steels
P, B, T, W, S, I
Precious metals
P, F, B, t, W, I
Zinc
P, F, D, W, I
Plastics
P, f, B, T, w
Elastomers
P, b, T
Ceramics (alumina)
p, B, T, s
Glass
P, B, T, W, s
Graphite
P, B, T, W, s
Note: P, plate or sheet; F, foil; B, bar; T, tubing; W, wire; S,
structural shapes; I, ingots for casting. Lowercase letter
indicates limited availability. Most of these materials are also
available in powder form.
ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Manufacturing Process
Capabilities
Figure 40.3
Manufacturing
process capabilities
for minimum part
dimensions. Source:
J. A. Schey,
Introduction to
Manufacturing
Processes (2d ed.).
McGraw-Hill, 1987.

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Dimensional Tolerance

Figure 40.4 Dimensional tolerance capabilities of various manufacturing processes.


ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Dimensional Tolerance and


Surface Finish
Figure 40.5 Relationship between relative
manufacturing cost and dimensional tolerance.

Figure 40.6 Relative production time, as a function of surface


finish produced by various manufacturing processes. Source:
American Machinist. See also Fig. 25.33.
ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Examples of General
Function/Process Relationships

Cast metals tend to be brittle


Forging adds strength along flow lines
Machining is cost effective for small lot sizes
Casting, forging and extrusion have high
setup costs but low production costs
Heat treatments affect hardness, strength,
corrosion resistance and fatigue properties
Machining results in lots of scrap (the buy to
fly ratio)

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Buy to Fly Ratio


The weight of the purchased raw material
divided by the weight of the final part
Process
Machining
Hot closed die forging
Sheet metal forming
Extrusion
Permanent mold casting
Powder metallurgy

ManufacturingEngineeringandTechnology

Buy to fly ratio


1.1 - 50
1.2-1.5
1.1-1.25
1.1-1.3
1.0-1.2
1.0-1.05

AssiutUniv.Mech.Eng.dept

Lecture1

Critical Fact
You cannot design any hardware without
taking into account the production process
used to make that product
Manufacturing considerations must be
included in the design as early as possible

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

What is Manufacturing Dimensions


Product Creative Characteristics (How new
products differ from previous ones)
Product Size (physical dimension)
Product Complexity/Sophistication
Scale
Material Flow
Degree of Automation
Organization
ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Product Creative Characteristics


How new products differ from previous ones

Selection design (Lego houses)


Configuration design (automobiles)
Parametric design (portable generators)
Redesign (New VCR)
Original design (the original VCR, the Space
Shuttle)

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Product Size (physical dimension)

A individual device on a computer chip


A computer chip
A television
An automobile
A Navy cruiser

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Number of parts/amount of
electronics/intelligence

A nail
A TV
A car or truck
A 777 aircraft
A satellite
Mars sojourner
A CPU chip (5 million
components)

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Scale
Number of people and disciplines involved

Artisan
Garage machine shop
General Motors, Arlington Plant
Boeing Commercial Aircraft
Engineering firms who make bridges, chemical
plants or dams

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Material Flow
How the work is organized on the shop floor

Discrete parts (traditional job shop)


Cellular (New machine shops)
Semicontinuous
Continuous flow (bottle making)
Process (chemical industry and oil refineries)

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Degree of Automation
How much automation exists on the shop floor

Manual
Machine assisted
Computer controlled - islands of automation
Computer integrated manufacturing

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

Company Organization
How the enterprises organize to produce

Traditional
Lean
Agile
Next Generation

ManufacturingEngineeringandTechnology

AssiutUniv.Mech.Eng.dept

Lecture1

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