TEC 130Introduction to Manufacturing Processes

Dr. Lou Reifschneider Section 1 Fall 2011

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Today

Syllabus / Course business Tour Lab Areas Introduction to Manufacturing (ppt) Lab Manual & Powerpoints available at SAL/TEC_130/ Folder

for Syllabus Folder for Lab Manual Folder for Powerpoints2

What is manufacturing?To make or process a raw material into a finished product, especially by means of a large-scale industrial operationNew American Standard Dictionary

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Primary vs. Secondary ManufacturingPrimary processes convert raw materials into standard stockbauxite ore aluminum petroleum polyester resin wood lumber

Secondary processes convert standard stock into usable partsaluminum rod fuel valve polyester resin medical tubing lumber furniture

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Products often made of many parts

Steel sheets and bars Iron & aluminum ingots Plastic resin pellets Uncured rubber Copper wire Nylon thread Glass sheets

CAR

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Secondary Manufacturing Processes

Casting and Molding Forming Separating / Material Removal Conditioning Assembling / Joining Finishing

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Secondary Processes

Casting and Molding processes hold liquid or semi-liquid materials in a mold cavity until the material hardens Forming processes use a shaping device and pressure to cause a material to take on a new shape and size Separating processes remove material to produce a desired shape and surface finish

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Secondary Processes

Conditioning processes use heat, chemical reactions, or mechanical means to change the properties of a material Assembly processes join two or more parts or assemblies through mechanical, thermal, or chemical means Finishing processes modify the surface of a material to improve appearance or performance8

Manufacturing Work Flow

Custom Intermittent / Batch Continuous

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Custom manufacturing

Limited number of products built to customer specifications. Requires highly skilled labor. Least efficient (but most flexible) form of manufacturing10

Batch manufacturing

Parts made in lots of 10 1,000 General-purpose machinery (table saw, vertical mill) is used, often run by hand Setup times per part decreases as batches get larger11

Continuous manufacturing

Same product made repeatedly by dedicated machinery (custom built machine NOT CUSTOM built product) Automation becomes more cost-effective Some processes still require batch staging Tooling and setup are large initial expenses12