Transcript Slide 1

ENM208
ÜRETİM NEDİR
ANADOLU
UNIVERSITY
Industrial Eng. Dep.
2006
Saleh AMAITIK
Manufacturing Processes
Üretimin Tanımı
Latince kelimeler olan
manu factus
Ell imal etme
manu = El
factus = Yapmak,imal
etmek
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Manufacturing Processes
Üretimin Tanımı
Üretim,
ürünleri
ham
malzemeden
başlayarak pekçok prosesden,işlemden
tanımı her aşamasının
ve makinelerdenÜretimin
geçiren,
iyi planlandığı bir aktiviteler zinciridir.
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Manufacturing Processes
Üretimin Tanımı
İmalat
Üretim
İmalat Mühendisliği,
tüm dünyada geniş
kullanım alanına sahip ve endüstriyel
aktiviteler alanını içeren bir tanımdır.
Üretim Mühendisliği ise Amerika dışındaki tüm
ülkelerde kullanılan İmalat Mühendisliğine
eşdeğer bir tanımdır. Derslerimizde Üretim
Mühendisliği olarak kullanılacaktır.
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Manufacturing Processes
Üretim Sistemleri
Üretim Sistemi, istenilen ürünleri elde etmek için
kullanılan
üretim
proseslerinin
tamamına
ve
organizasyonuna verilen isimdir.
Üretim Sistemi, üretim proseslerini tasarlamak veya
düzenlemektir.
Üretim Sisteminin kontrolu demek, tüm proseslerin
veya teçhizatın kontrol altında bulunması demektir.
Tüm üretim sistemi, bir program veya plana göre,
üretimin kontrolü, stok seviyesi ve ürünün kalite
seviyesi gibi kavramları kontrol altında tutmak
zorundadır.
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Manufacturing Processes
Üretim Sistemleri
Üretim sistemi, Ürettiği ürünlerin girdilerini
müşterilerinin isteklerinden alır.
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dış
Manufacturing Processes
Üretim Sistemleri
Bir üretim sistemi aşağıdaki ürün tiplerini
üretebilir:
Tekli ürünler
Ayrık-tek parça halindeki ürünler (çivi,vida,dişliler,motor
bloğu vb.)
Sürekli ürünler
Tek parça halinden kesilerk ve böylece tekli ürün halina
getirilenler(Kablo teli,sac veya plastik
plaklar,borular,profiller vbg.)
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Manufacturing Processes
Production Systems
Bir üretim sistemi veya teşebbüs, tüm işletmeyi ve
üretim sistemini kapsayan bir sorumluluk alanına
sahip olacaktır.
Üretim sistemi, Üretim birimine ek olarak tesisin,
işletmenin tüm diğer fonksiyonları ile birlikte, iletişim
,tasarım,analiz ve kontrolunden sorumlu olacaktır.
Bu alt sistemler, üretilen tüm ürünler için çeşitli
anlamlar ifade edeceklerdir.
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Manufacturing Processes
Production Systems
Manufacturing System
(where value is added)
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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
Selecting materials for manufacturing
Variety of materials is now available, each having its
own properties, applications, advantages, and
limitations.
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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
Characterizing a manufacturing process
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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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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Manufacturing Processes
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 Processes
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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Üretim Prosesleri
Bilgisayarla Bütünleşik İmalat - CIM
Manufacturing Processes
Üretimde Bilgisayar Uygulamaları
Üretimde bilgisayar
özetlenebilir.
kullanım
alanları
aşağıdaki
Bilgisayar Destekli Üretim - BDÜ (CNC)
Bilgisayar Destekli Üretim Planlama - BDÜP (CAPP)
Otomasyon ve Robotik Montaj Sistemleri.
Esnek Üretim Sistemleri - EÜS (FMS)
Otomatik Malzeme İletimi.
Yapay Zeka.
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şekilde