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Kalpakjian, Manufacturing Processes for Engineering Materials © 1997 Addison Wesley Page 1-1
CHAPTER 1
Introduction
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Kalpakjian, Manufacturing Processes for Engineering Materials © 1997 Addison Wesley Page 1-2
What is manufacturing?
- Manufacturing:In its broadest sense, the process of converting raw materials into products, consisting of the design and making of goods, using various production methods and techniques
- Automobile has about 15,000 parts,C-5A transport plane more than 4 M parts
Boeing 747-400 6M parts.
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- Origin: Manu factus (made by hand) in Latin
- Manufacture was initially used in 1567 andmanufacturing appeared in 1683
- Manufacturing in U.S.A. andProduction Engineering in E.U. and Japan
- Discrete products or Continuous products
- Value addedness
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- Meet design requirements and specifications
- Produced by the most economical ways
- Quality
- Flexibility of the processes
- Require new materials, production methods, and computer integration
- Reviewed as a large system
- Strive for higher Productivity
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The design process and concurrent engineering
Design process:
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- Concurrent engineering is a systematic approach integrating the design and manufacture of products with the view of optimizing all elements involved in the life cycle of the product.
- Direct engineering utilizes a database representing the engineering logic used in the design of each part of a product. If a design modification is made on a part. DE will determine the manufacturing consequences of that change.
- CAD, CAE, CAM, and Rapid prototyping
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Design for manufacture and assembly
- DFM is a comprehensive approach to production of goods and integrates the design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance.
- DFA and DFD – 3-D conceptual designs and solid models.
- Design for manufacture and assembly.
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Selecting materials
- Ferrous materials (carbon steels, etc)
- Nonferrous materials (aluminium, magnesium, copper, titanium alloys, etc.)
- Plastics (thermoplastics, thermoset, and elastomers)
- Ceramics, glass ceramics, glasses, graphite, diamond
- Composite materials (reinforced plastics, metal-matrix and ceramic-matrix composites, and honeycomb structures)
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- Properties of materials
- Cost and availability
- Appearance, service life, and recycling
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Selecting manufacturing processes
- Casting
- Forming and shaping
- Machining
- Joining
- Finishing
Dimensional and surface finish considerations.
Operational and manufacturing cost considerations.
Consequences of improperly selecting materials and
processes.
Net-shape manufacturing.
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Computer-integrated manufacturing
- Machine control systems: NC, CNC,AC, automated handling of materials,industrial robots
- Computer technology: CIMCAD, CAM, CAPP, GT, FMS, JIT, AI,Expert System, Neural Network,Shared manufacturing
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Quality assurance and total quality management
- Quality must be built into a product – from design stage through all subsequent stage of manufacture and assembly. Control the processes and not products.
- Total quality management (TQM) and quality assurance
- Statistical process control (SPC)
- Experimental design
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Global competitiveness and manufacturing costs
- The design should be as simple as possible to manufacture, assemble, and recycle.
- Materials should be chosen for the appropriate manufacturing characteristics.
- Dimensional accuracy and surface finish specified should be as broad as permissible.
- Because they can add significantly to cost, secondary and finishing processing of parts should be avoided or minimized.
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Lean production and agile manufacturing
- Lean production or lean manufacturing involves a major assessment of each of a company’s activities.
- Agile manufacturing ensures flexibility in the manufacturing enterprise so it can quickly respond to changes in product demand and customer needs.
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Environmentally conscious design and manufacturing
- Reducing waste of materials at their source by refinements in product design and reducing the amounts of materials used.
- Conducting R&D in environmentally safeproducts and manufacturing technologies.
- Reducing the use of a hazardous materials in products and processes.
- Ensuring proper handling and disposal of all waste.
- Making improvements in recycling, waste treatment, and reuse of materials.
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Product liability
- The aspects that deal with product safety and the resource a customer has if and when a product is defective.
- Protection strategy for legal and technical aspects for the consequence of using a product that has malfunctioned, causing bodily injury, or even death, and financial loss to a person or organization.
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Organization for manufacture
- View the people in the organization as important assets.
- Emphasize the important and need for teamwork and involvement in problem solving and decision-making processes in all aspects of operations.
- Encourage product innovation and improvements in productivity.
- Encourage efforts for continuous improvement in quality
- Increase flexibility of operation for faster response to product demands in both the domestic and global marketplace
- Ultimately and most importantly, focus on customer satisfaction