General Introduction to manufacturing

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1 General Introduction to manufacturing What is manufacturing Examples of Manufactured Products Design for Manufacturing

2 What is Manufacturing? Objects around you Watch, car, cell phone One part objects Paper clip Assemblies of different materials Motorcar parts Aircraft parts

3 Every Part made by various processes, we call it Manufacturing* Converting raw materials into products The higher the level of manufacturing the higher the standard of living It is the Backbone of a healthy economy *Engineers are needed for this.

4 What is manufacturing? Involves activities in which manufactured products are used to make other products Like large presses to form sheet metal vehicle body parts Manufacturing involves making products from raw material by various processes, machinery and operations, following a well organized plan for each activity. The word product means something that is produced Production Engineering is also a term used for manufacturing in Europe and Japan

5 Manufacturing is a Complex activity

6 Manufacturing must adhere to the following: Product must meet design parameters and specifications Produced in the most economical manner Quality must be built in along the way of production Production method should be flexible to respond to market changes New development in material, production methods and computer integration must be followed up to ensure the product is produced in the most efficient way

7 Manufacturing organization must constantly strive for higher productivity and optimum use of all its resources, materials, machines, energy, capital, labor and technology Output per employee per hour must be maximized

8 History (Table 1) Read

9 Class example 1

10 Paper clip design What material would you choose?, metal or plastic? How thick must the material be? What mechanical properties must the material have?, stiffness and strength? In what shape must the material be?, should it be round? Is the surface finishing important?, and, if so, what should it be? How would you shape it? Cost consideration, appearance, style, texture, corrosion resistance?

11 During the production process many questions are asked, like: Will material bend without cracking or breaking? Will the cutting process produce smooth edges or a burr? What is the most economical method of manufacturing this part at the desired rate to be competitive in the market?

12 Class example 2: Transistor (note the small dimensions 3-30µm )

13 Class example 3: Incandescent light bulbs

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15 Jet Engines design and manufacturing much more challenging and demanding

16 Design for Manufacturing Design and manufacturing must be intimately interrelated Design and manufacturing should never be separate disciplines or activities Must meet design requirements and specifications. Manufactured economically and with relative ease. Designers must have a fundamental understanding of the characteristics, capabilities, and limitations of materials, manufacturing processes and related operations, machinery and equipment

17 Designer must be able to assess the impact of design modifications on manufacturing process selection, assembly, inspection, tool and dies, and product cost. Computer aided design, manufacturing and process planning techniques use powerful computer programs in the analysis. Expert systems have optimization capabilities Rapid Prototyping