MANUFACTURING PROCESSES

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Georgiana McDowell
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1 1 MANUFACTURING PROCESSES - AMEM 201 Lecture 1: DR. SOTIRIS L. OMIROU The Manufacturing is a DRIVING FORCE for any economy We are living in an environment that is created and reshaped by manufacturing day by day. Manufacturing is a field which perform all products from cars to aeroplains,, from food to wear, from toys to telecommunications munications means, from medical technic to computers... Manufacturing involves a large variety of processes Here we will deal with manufacturing processes related to machine building, only. 2

2 Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material (raw or semi finished) to make parts or products

2 2 Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a starting material (raw or semi finished) to make parts or products Manufacturing also includes assembly of multiple parts to make products A sequence of operations adds value to the material by changing its shape or properties 3 Motivation (1) A bottle of water Four components (bottle, cap, label, water) - How are each of these manufactured? - What does the equipment cost? 4

3 3 Motivation (2) Stapler Approx. 15 components - How do we select the best material for each component? - How are each of these manufactured? 5 Generaly, the products involve many sub-assemblies and these involve many components (parts). Some pictures will show how complex could be the products/parts. Very complex product. It involves thousands of parts 6

4 4 A subassembly It involves both, Complex parts & Simple parts 7 A subassembly with a small number of components, but very complex almost all 8

5 5 An engine block, a very complex part as shape and surfaces 9 An exploded view for a drive. It involves both simple and complex parts 10

6 6 There are many types of manufacturing processes into the machine building industry: Machining Casting Metal sheet forming Surfaces treating Powder Metalurgy Machine Building Industry Others Forming Assembling Welding 11 People Information Materials Tools & Machines Capital Energy Time Starting Material Manufacturing Process Processed Part Raw Material Product Raw Material Product Cotton Thread Animal Hides Shoes Wood Paper Sand Glass Iron Ore Steel Steel Structures Petroleum Plastic Plastic Patio Chairs 12

7 7 Manufacturing Industries Industry consists of enterprises and organizations that produce or supply goods and services. Industries can be categorized as basic producers, converter, fabricator and service industries. Basic producers cultivate and exploit natural resources and transform these into raw materials e.g. steel producers. Converters take the output of the basic producer and transform these raw materials into various industrial products and some consumer items e.g. producers of sheet-metals and plastics. Fabricators fabricate and assemble final products e.g. manufacturers of automobiles, appliances and garments. 13 Manufacturing Industries Service industry works in parallel with the other three and constitutes the service sector of the economy Basic Producers Converters and Fabricators Service Agriculture Aerospace Appliances Repair/Maintenance Petroleum Automotive Pharmaceuticals Education Fishing Beverages Publishing Hotel Mining Chemicals Textiles Tourism Forestry Electronics Tire and Rubber Transportation 14

8 8 Manufacturing Industries Another classification of manufacturing firms may be by the quantity of the products they make: Job shop production batch production mass production Job Shop Batch Production Mass Production Production quantity Low Medium High Production rate Low Medium High Labor skill level High Medium Low 15 Resources for Manufacturing People Information Materials Tools & Machines Capital Energy Time Starting Material Manufacturing Process Processed Part 16

9 9 People Resources for Manufacturing - Large companies employ a huge workforce because they manufacture several products at the same time - People to put forward the requirement of a new product - Research engineers and design engineers/drafters - Development engineers decide the steps of manufacturing the product - They make a prototype (a test version of the product ) of the new w product before going onto the full scale or mass production - Production engineers implement the plan given by development department - Hundreds of laymen workers work in the production department. These workers may be working on or repairing and maintaining the machines - Skilled and qualified people are required for quality control - Marketing and distribution of the product in the local and international national markets 17 Information Trends in the market Resources for Manufacturing Different type of materials, their costs and quality standards Mechanical drawings of different parts Knowledge of manufacturing processes Companies may launch new research projects in collaboration with universities Materials It is not always a raw material in the natural state, e.g. iron ore, trees, and cotton Steel sheets come from iron ingots made from coal, limestone and iron ore Companies often make a trade-off between the cost and the quality of a material 18

10 10 Resources for Manufacturing Tools and Machines A tool changes the shape of material or fastens it together Hand tools are those that use the power of our hand or arm hammer and pliers A power tool uses a small motor and is usually held in our hands Electric drills Jigs and fixtures facilitate the process of manufacturing devices used to locate and hold work pieces. Machines are usually operated by electric motors bending, cutting, drilling, grinding, and hammering Modern manufacturing processes run under program and feedback control 19 Energy Resources for Manufacturing Energy Mostly in the form of electricity Thermal power electricity from fossil fuels, i.e. coal, oil and natural gas A chemical plant can use its waste heat energy to generate steam co- generation Capital Buy land, build factories, purchase equipment, pay workers, maintain machines, and advertise their products A company may sell shares of stock Capital may also come from a venture capitalist Venture capital is money used to finance the costs of starting a new company Time Productivity is how quickly and cheaply a product is made 20

INTRODUCTION AND OVERVIEW OF MANUFACTURING. Manufacturing is Important. Manufacturing - Technologically Important

INTRODUCTION AND OVERVIEW OF MANUFACTURING 1. What is Manufacturing? 2. Materials in Manufacturing 3. Manufacturing Processes 4. Production Systems 5. Organization of the Book Manufacturing is Important