Manufacturing Technology

Transcription

1 Manufacturing Technology What is manufacturing technology? A manufacturing technology is a system of people, machines, and materials that mass-produce goods for the market. Automation is manufacturing using machines or robots. Provide some examples of technologies that are manufactured. Paper plates, plastic forks, pencils, erasers, ceramic mugs, futon mattresses, toothbrushes, cell phones, computers, cars, chairs

2 Manufacturing Technology Batch vs. Assembly Line What is batch production? Batch production makes standard (common) parts or components in large quantities. Batch production comes before assembly line production. E.g., product many windows, tires, steering wheels in the same process What is an assembly line production? Assembly line production assembles parts at a steady rate, including batchproduced standard parts. Depends on batch production of interchangeable parts and specialization of workers.

3 Manufacturing Technology Assembly Line Why did the assembly line revolutionize manufacturing? Allows for continuous production Allows for economy of scale products can be made faster in large quantities and cheaper Labor is cheaper workers only need to know how to make their part and not the entire product What is an continuous production? Products are made at a steady rate (uninterrupted). Before continuous production in assembly lines, a craftsman had to finish an entire product before starting another one.

4 Manufacturing Technology Just-In-Time Production What is the difference between continuous production and Just-In- Time (JIT) manufacturing? Continuous production means making products without interruption. Such a process can create a large and expensive inventory of product, which may not sell. Just-In-Time (JIT) manufacturing is producing products only when they are needed. Such a process eliminates a large inventory and cuts costs.

5 Manufacturing Technology What are interchangeable parts in manufacturing? Interchangeable parts are made to standard (common) specifications. These made assembly line production possible. The same part can fit and be used in many different products. Why did interchangeable parts revolutionize manufacturing? Parts could be made in large batches to save costs, and then sent to multiple manufacturers. Parts could be replaced easier and cheaper (save costs) they are more available. Allow more products to be produced faster. Before interchangeable part, a single craftsman made all the parts and assembled them.

6 Manufacturing Technology What is economy of scale? Economy more economical, cheaper Scale large quantities Economy of scale is saving costs because you are making products in large quantities. How does producing large quantities of a product at the same time save money (economy of scale)? Materials cost less because of discounts when buying in bulk Labor costs less because workers do one specific job (specialization) less skilled Factory and Machinery (capital) is cheaper because the costs are spread out over a large number of products Total profit is greater because more products are sold.

7 Manufacturing Technology What are unintended consequences of a technology? Unintended consequences are effects of a product s use in society that designers failed to foresee. Unintended consequences are usually discovered after a product is widely used. Unintended consequences can be positive or negative. What are some examples of positive and negative unintended consequences? Cars Positive: People could travel more easily; ambulances could reach more patients in time; food and other products could be distributed to more areas regularly Negative: Car crashes are leading cause of death; Urban sprawl cities spread out into suburbs; increased air pollution; increased CO2 emissions

8 Manufacturing Technology How can engineering minimize negative unintended consequences? Engineers should form a team during design with experts in different fields to explore how the product may impact: Environment Health Culture Values How can consumers help to minimize negative unintended consequences? Consumers should learn as much as possible about a new technology before purchasing. Consumer can refuse to keep buying a product if it has a negative impact on our society.

9 Manufacturing Technology How did Henry Ford revolutionized automobile manufacturing? Early cars were expensive because each car was made from start to finish by a single skilled factory works. It took a very long time. What is the difference between durable and non-durable goods? How did Henry Ford revolutionized automobile manufacturing by inventing the assembly line process, which depended on having batch-produced parts and workers who specialized in one task. Durable good are made to last a long time. Example: Cars, hand tools, ovens, furniture Non-durable goods are made to be disposable and last for only a short time. Example: disposable phones, paper plates, plastic utensils, pencils, paper, soap

10 Manufacturing Technology What is a system? What are system inputs? Inputs include everything that enters the system. Example: money, materials, information, tools, training, machinery

11 Manufacturing Technology - Systems What are system processes? Processes change the inputs into the desired products and other output using an orderly step-by-step procedure. Example: For baking cookies, the processes are verbs a) mixing ingredients, b) shaping the cookie dough, c) baking What is system feedback? Feedback is information collected during a process to catch problems and make corrections. Example: Feedback can detect temperature changes and send a signal to raise or lower the temperature to keep it constant.

12 Manufacturing Technology - Systems What are system outputs? Outputs include everything the process produces: a) Desired product b) Waste, pollutants Example: Manufacturing circuit boards also produces fumes that irritate eyes and skin. What is a system goal? Goal is whatever a manufacturing system is meant to create in the most efficient, healthy way possible. Example: Chocolate chip cookies, circuit boards, sensors wit least waste and pollution.

13 Manufacturing Technology - Systems What are system optimization? To optimize something means to make it better to meet certain constraints. Optimizing a manufacturing system means redesigning it to make faster, less wasteful, and less damaging to people and the environment. What is a waste management system? Waste is produced during manufacturing and when the product is disposed: Waste removal Waste treatment Recycling Incineration (burning) of trash Landfills

14 Manufacturing Technology Life Cycle Analysis, CAM What is life cycle analysis? What is CAM system? Life cycle analysis is thinking about what happens to the product - from the stage of raw materials to the time the product is disposed: a) Label each step and its impact on the environment production, selling, use, waste disposal b) How will the product be disposed of (burnt, put in landfill, recycled)? c) How could the design be changed to have the least negative impact.? A CAM system is a Computer-Aided Manufacturing system. A CAM system takes a CAD file of the design and designs an efficient manufacturing process to make a physical product using the factory machines.

15 Manufacturing Technology - Materials What are raw materials? Raw materials are natural resources of the Earth: Trees Animals Plants Metals Oil, coal, natural gas What are renewable raw materials? Renewable materials can be replaced in a relatively short time e.g., one or more times within our lifetime. Examples: Trees Animals Plants

16 Manufacturing Technology - Materials What are composite materials, synthetic materials, and natural materials? Provide 2 examples of each. Composite materials made of 2 or more different materials. The combination has better properties than the substances alone. Examples: Concrete sand, cement, ground rock Fiberglass glass and plastic Any metal alloy Asphalt Synthetic materials created by chemists. Example: plastics Natural materials Examples: cotton, wool, wood

17 Manufacturing Technology - Materials What are NON-renewable raw materials? NON-Renewable materials take a very long time to replenish, or cannot be replenished at all. Examples: Petroleum Natural gas Coal Metals What is the role of primary processing in manufacturing? Primary = first Primary processing is the first step in manufacturing. Primary processing extracts raw materials, and makes them usable for manufacturing the products (secondary processing).

18 Manufacturing Technology Primary Processing List examples of primary processing. What does it means to say that systems are embedded in other systems or all systems are interrelated. Mining and refining metals (removing impurities from mined or recycled pieces). Rolling metal into sheets or bricks. Harvest trees and produce plywood, particle board, or two-by-fours. Glass mills transform sand into glass. Textile mills transform raw cotton to fabric. embedded = inside interrelated = inter between = connected Each system is a part of another, larger system. This idea is related to life-cycle analysis of a product: some systems extract and process raw materials, which lead to manufacturing, which lead to distribution, use, and waste disposal.

19 Manufacturing Technology System Example Describe an automobile manufacturing assembly line system in terms of inputs, outputs, processes, feedback, and goals. Inputs: metal, glass, fabricated car parts Outputs: finished cars, exhaust, waste Materials Processes: forming the body, welding, bolting parts in place, testing Feedback: number of cars produced per hour would feed back into the system to either increase or decrease production Goals: Produce high-quality automobiles that everybody wants to buy.

20 Manufacturing Technology System Example Conduct a life cycle analysis of an automobile. Consider production, use, and outputs. Inputs: Production: steel, tires, glass, workers, factories, money, upholstery, energy to run the factory Use: gasoline, motor oil, knowledge, highways, roads Outputs: cars, industrial wastes such as leftover material, air pollution, millions of cars on the road, junk cars in wrecking yards, partially recycled and partially in landfills The automobile has had unintended consequences on the environment. Understanding systems can lead both to a better product and to fewer unintended consequences.

21 Manufacturing Technology 7 Manufacturing Processes List and briefly describe the 7 manufacturing processes. 1. Separating: cutting or machining to remove unwanted materials 2. Forming: shaping metals or hard materials with force 3. Assembling (or combining): putting parts of a product together 4. Molding (plastic) and casting (metal): pouring a liquefied material into a mold, allowing it to solidify in the shape of the mold, then removing the solidified material from the mold 5. Conditioning: any process that uses chemicals, high temperatures, or force to change the properties of a material 6. Finishing: any final treatment to the surface of the product to make it more attractive to a consumer 7. Quality control: tests on samples from the production line to ensure highquality products

22 Manufacturing Technology 7 Manufacturing Processes List and briefly describe the 7 manufacturing processes of a New Balance shoe. 1. Separating: use cutting dies to cut fabric for the shoes 2. Forming: Using a press to make cutting dies for the fabric 3. Assembling (or combining): Sewing shoes together 4. Molding (plastic) and casting (metal): Pouring rubber into molds and allowing it harden into shoe soles 5. Conditioning: Heating the shoes to change the chemical properties. This makes fabric stick better to the rubber soles. 6. Finishing: Shoes are cleaned, laced and boxed 7. Quality control: Spot check shoes for any flaws. If flaws are found, check the entire batch.

23 Manufacturing Technology 7 Manufacturing Processes List and briefly describe the 7 manufacturing processes of wooden birdhouses. 1. Separating: Wood must be cut to size. 2. Forming: Any metal parts will most likely be created using forming. 3. Molding (plastic) and casting (metal): Any ceramic or plastic attachments on the birdhouses will be created using molding or casting processes. 4. Assembling (or combining): Wood will be nailed together 5. Conditioning: Birdhouses will be sanded and painted with primer. 6. Finishing: Birdhouses will be painted with paint. 7. Quality control: Birdhouses will be spot-checked to ensure that they are free of flaws.

24 Manufacturing Technology 7 Manufacturing Processes List and briefly describe the 7 manufacturing processes of ceramic coffee mugs. 1. Separating: Separate raw materials to get pure clay and quartz sand. 2. Forming: Metal or plastic tops for the mugs are produced in various forming machines. 3. Molding (plastic) and casting (metal): The clay is poured into a mold and allowed to harden. 4. Conditioning: Soft clay mugs are fired at a high temperature to make them stronger. 5. Finishing: A glaze is sprayed on the mugs so that they will hold liquids and to make them look nices. The mugs are then fired a second time to melt and harden the glaze. 6. Assembling (or combining): Tops are put on top of the mugs, and they are packaged for shipment. 7. Quality control: Sample mugs are inspected for imperfections and tested to be sure they hold hot liquids.