Transcript Spring 2005 Design and Manufacturing process

ENM208
DEFINING
MANUFACTURING
ANADOLU
UNIVERSITY
Industrial Eng. Dep.
2006
Saleh AMAITIK
Manufacturing Processes
Defining Manufacturing
The word manufacturing is defined from the Latin
manu factus
made by hand
manu = hand
factus = made
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Manufacturing Processes
Defining Manufacturing
Manufacturing involves making products
from raw materials by means of various
processes, machinery, and operations,
through a well-organized plan for each
activity required.
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Defining Manufacturing
Production
Manufacturing
Manufacturing Engineering is the term used
widely in the United States to describe this area
of industrial activity.
Production Engineering is equivalent term to
manufacturing Engineering in other countries.
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Manufacturing Processes
Manufacturing Systems
The manufacturing System is a collection of
manufacturing processes used to obtain a desired
product(s)
The manufacturing System is the design
arrangement of the manufacturing processes.
or
Control of a manufacturing system applies to overall
control of the whole processes or equipment.
The entire manufacturing system must be controlled
in order to schedule and control production,
inventory levels, product quality and so forth.
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Manufacturing Systems
The manufacturing System takes inputs
produces products for the external customer
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and
Manufacturing Processes
Manufacturing Systems
Manufacturing System may produce
Discrete products
Individual parts (e.g. nails, gears, engine blocks, ……etc.)
Continuous products
May be cut into individual pieces and thus become discrete
parts (e.g. a spool of wire, metal or plastic sheets, tubes ,
……etc.)
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Manufacturing Processes
Production Systems
A production system, or the enterprise, will refer to the
total company and will include with it the
manufacturing system.
The production system includes the manufacturing
system plus all the other functional areas of the plant
for information, design, analysis, and control.
These subsystems are connected by various means to
each other to produce products(s).
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Production Systems
Manufacturing System
(where value is added)
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Production Systems
Production Types
Low-quantity production (1 ~ 100 units/yr)
Job shop, prototyping.
Medium-quantity production (100 ~ 10,000 units/yr)
Batch production & cellular manufacturing.
High-quantity production (> 10,000 units/yr)
Mass production.
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Machine
A specific piece of equipment designed to
accomplish specific processes, often called a
Machine Tool
Examples: Milling machine, punch press, ….
Machine tools linked together to make a
manufacturing system cell
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Job (Station)
A collection of operations done on machines or a
collection of tasks performed by one worker at
one location on the assembly line.
Examples: Machining, inspection, final assembly, ……
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Operation (Process)
A specific action or treatment, often done on a
machine, the collection of which makes up the job
of a worker.
Examples: Drilling, Forming, Welding, assembly, ……
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Manufacturing Processes
Tool
Refers to the implements used to hold, cut,
shape, or deform the work materials.
Examples: Cutting tools in machining.
Jigs and fixtures in work holding.
Punches and dies in metal forming.
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Manufacturing Processes
Design and Manufacturing process
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Manufacturing Processes
Concurrent Engineering
Concurrent engineering is a systematic approach to the integrated,
concurrent design of products and their related processes, including
manufacture and support.
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Design for Manufacturing (DFM)
It is a comprehensive approach to production of
products, ant it integrates the design process with
materials, manufacturing methods, process planning,
assembly, and quality assurance.
Implements design for manufacture requires that
designers have a fundamental understanding of the
characteristics, capabilities, and limitations of
materials, manufacturing processes and related
operations, machinery and equipment.
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Selecting materials for manufacturing
Variety of materials is now available, each having its
own properties, applications, advantages, and
limitations.
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Selecting materials for manufacturing
When selecting materials for products, we consider
Mechanical properties of materials
(Strength, toughness, ductility, hardness, elasticity, fatigues,
creep, ……(
Physical properties of materials
(density, specific heat, thermal expansion and conductivity,
melting point, and electrical and magnetic properties, ……)
Chemical properties of materials
(corrosion, toxicity, flammability, ……)
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Selecting materials for manufacturing
The material properties specified for a product should
be appropriate to the conditions under which the
product is expected to function.
The manufacturing properties of materials determine
whether they can be cast, formed, machined, welded,
and heated-treated with relative ease.
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Selection of manufacturing processes
Many processes are used to produce parts and shapes
and there is usually more than one method of
manufacturing a part from a given material
Classification of manufacturing processes
Machining (turning, drilling, milling, grinding, …….
Forming and shaping (rolling, forging, sheet forming,…..
Casting (expendable mold, permanent mold, ……)
Joining (welding, brazing, soldering, ….)
Finishing (honing, polishing, coating, heat treatment, …
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Characterizing a manufacturing process
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Factors affecting the selection of manufacturing processes
There are many factors which affect the selection of a
suitable manufacturing process for a part. These
factors are:
• Geometry
• Quality
• Quantity
• Material
• Machine or equipment avalibility
• Cost
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Factors affecting the selection of manufacturing processes
Geometry
Cylindrical, conical, and screw threads are mostly
easily produced on a Lathe.
Plane surface, block shapes and slots are generally
produced by shaping, planning or milling.
More complex parts may need to be cast, forged or
shaped before machining.
The shape of a part will decide the process which must
be used to produce that part.
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Factors affecting the selection of manufacturing processes
Quality
Dimensional accuracy (tolerances).
Geometrical accuracy.
Surface finish.
An appropriate manufacturing process should provide
suitable dimensional accuracy, geometrical accuracy,
and surface finish.
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Factors affecting the selection of manufacturing processes
Quantity
The quantity (batch size) determines the
economics of manufacturing process selection.
The cost falls as the batch size increases and more
productive techniques can be employed.
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Manufacturing Processes
Factors affecting the selection of manufacturing processes
Material
The material from which the part is going to be
made
The material specified by the designer influences the
method of manufacturing.
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Factors affecting the selection of manufacturing processes
Machine or equipment availability
Availability of machines and equipment and of
operating experience with the manufacturing
facility
Cost
Operational and manufacturing cost.
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Consequences of improper selection of materials and processes
Numerous examples of product failure can be traced to
Improper selection of material.
Improper selection of manufacturing processes.
Improper control of process variables.
A part is generally considered to have failed when
It stops functioning (e.g. broken shaft, gear, ….)
It does not functioning properly or perform within
required specification limits (e.g. worn bearing, …)
It becomes unreliable or unsafe for further use
(e.g. crack in a shaft, ..)
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Net-shape Manufacturing
Since not all manufacturing operations produce finished parts,
additional operations may be necessary.
Net-shape or near-net-shape manufacturing. The
part is made, in the first operation, as close to the
final desired dimensions, tolerances, surface
finish, and specifications as possible.
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Manufacturing Automation
The major goals of automation in manufacturing facilities are to
integrate various operations so as to improve productivity, to
increase product quality, to minimize cycle times, and to reduce
labor costs
Computers are now used in a very broad range of applications
including:
Control and optimization of manufacturing processes.
Material handling
Automated assembly
Automated inspection and testing of products
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Computer Integrated Manufacturing - CIM
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Computer Integrated Manufacturing - CIM
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Computer application in Manufacturing
The following is an outline of the major applications of computers
in manufacturing.
Computer Numerical Control - CNC
Computer Aided Process Planning - CAPP
Automated and Robotic assembly systems.
Flexible Manufacturing Systems - FMS
Automated handling of materials.
Artificial Intelligence.
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