Chapter 01: Introduction To Manufacturing

What is Manufacturing?How do we make these?Japan maglev prototype-Top speed 500 km/hPedal-powered Raht Racer- top speed ~100m/h

Value addition processes by which raw materials of low utility and value are converted into high utility and valued products with definite dimensions, forms and finish Definition of ManufacturingValue addition by manufacturing; Mild steel converted into bolt

Impact on economy Major wealth creation engines Gross Domestic Product JobsMost decisions made during design are impacted by production/manufacturing processes Critical Decisions function vs cost vs scheduleChoose materials Choose process(es)Cost determined by the material and the processes used to create the shapeWhy is Manufacturing Important?

Goals in Manufacturingreduction of manufacturing time increase of productivity reduction of manufacturing cost increase in profit

How to improve Profitreducing the overall manufacturing cost, Cm increase in revenue, R by increasing quality and reliability of the products enhancement of saleable production

Broad Classification of Manufacturing ProcessesCasting, foundry, or molding processForming or metalworking processesMachining (material removing) processesJoining and assemblySurface treatments (finishing)Rapid prototypingHeat treating

Joining ProcessesMechanical fasteningSoldering and brazingWeldingPress, shrink, or snap fittingsAdhesive bondingAssembly processes

Surface Treatments Finishing operationsCleaningRemoving burrs left by machiningProviding protective/decorative surfacesPaintingPlatingGalvanizingAnodizing

You cannot design any product without taking into account the production process used to make that product Manufacturing considerations must be included in the design as early as possibleCritical Fact

Trends in ManufacturingTo increase productivity & quality in respect of global competitivenessMaking micro and ultra precision components for the modern electronics, computers and medical applications Green manufacturing (sustainable)3-D printing

*