intrors07by vijay ikhar.ppt
TRANSCRIPT
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Introduction to
Manufacturing
By: Mr. Vijay L. IkharMBA(Operations Mgmt.) B.Sc.( Biotech)
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Introduction to Manufacturing
Observe the objects around you:How did they become what they are?
What important role does manufacturing play in
society?
How do we define manufacturing?
Manufacturing is the ability to make goods and services
to satisfy societal needs
Manufacturing processes are strung together to create amanufacturing system (MS)
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Society & Manufacturing
1930s1920s 1910s
1900s
1990s
1950s
1940s
1960s 1970s1980s
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Types of Goods
Consumer Goods Items which are purchased directly by consumers Consumer electronics
Clothing
Producer Goods Items which are manufactured for other companies to
produce products from
Steel Mills - coil stock
Machine tool builders - Milling Machines Automotive suppliers - Taillight assemblies
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Products
Fabricating - Manufacturing of products from
components, pieces, or sub-assemblies. Separate
discrete items such as machined parts, bolts, nuts
etc. are fabricated. Processing - Manufacturing a product in a
continuous series of operation . Examples include
wire, beverages, chemicals etc.
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Manufacturing a Product
Production systems include People
Money
Equipment
Materials
Supplies
Markets
Management
Manufacturing System
All aspects of commerce
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Manufacturing a Product
The Manufacturing System
Figure 1-4 The functions and
systems of the production
system, which includes (and
services) the manufacturing
system. The functional
departments are connected by
formal and informal informationsystems designed to service the
manufacturing system that
produces the goods.
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Manufacturing a Product
The Manufacturing System
Collection of operations and processes to produce a
desired product or component Design or arrangement of the manufacturing processes
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Roles of People in Mfg.
Manufacturing engineer responsibilities
Select and coordinate specific processes and equipment
Supervise and manage their use
Industrial (Manufacturing) engineer Manufacturing systems layout
Materials engineers
Specify ideal materials Develop new and better materials
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Roles of People in Mfg.
Technicians
QC, machine set-up, machine maintenance, machine
repair, and system integration
Machinist and Tool Makers Producing close tolerance parts and tooling to
specifications
Operators
Running production parts and quality
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Aspects of a Manufacturing System
Mfg. Processes The method (s) used to convert a product from one form to
another- example metal removal. A process typically
involves a sequence of steps or operations.
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Characteristics of Process
Technology Mechanics
Economics or costs
Time Spans
Constraints
Uncertainties and process reliability
Skills
Flexibility
Process capability
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Aspects of a Manufacturing System
Operations Distinct action to produce a desired result or effect
Categories of operations
Materials handling and transport
Processing
Drilling, tapping, turning, milling, injecting
Packaging
Inspecting and testing
Storing
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Aspects of a Manufacturing System
Figure 1-6 The component called a pinion
shaft is manufactured by a sequence of
operations to produce various geometric
surfaces.
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Aspects of a Manufacturing System
Job and station Job is a group of related operations generally done at one station
Station is the location or area where production is done
Treatments operate continuously on a workpiece Heat treating, curing, galvanizing, plating, finishing, chemical cleaning,
painting Tools, tooling and workholders
Lowest mechanism in the production is a tool Used to hold, shape or form the unfinished product
Tooling for measurement and inspection
Rulers, calipers, micrometers, and gages Precision devices are laser optics or vision systems that utilize
electronics to interpret results
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Factory Layouts
Job Shop
Flow Shop
Linked-Cell Shop
Project Shop
Continuous Process
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Factory Layouts
Figure 1-15 Different manufacturing
system designs produce goods at different
production rates.
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Seven Basic Processes
Casting
Forming
Machining
Joining and Assembly
Surface Treatment
Heat Treatment
Other
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Casting
Molten metal fills a cavity in a mold.
Quick method to transform a raw material into a
desired shape.
Two types of casting methods: Expendable mold
Sand casting
Permanent mold
Die casting
Plastic, composite manufacturing, and PM
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Forming & Shearing
Changing materials into a desired shape by: Squeezing
Bending
Shearing
Drawing
Utilizes Materials that have been previously cast
or molded
Performed at cold or hot temperatures cold = room temp to .3 of the melt temperature material
hot = above .3 of the melt temperature of the material
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Metal Removal - Machining
Seven basic processes Shaping
Turning
Drilling
Milling
Sawing
Broaching
Abrasive machining
Non-Traditional
Examples: EDM & Water-Jet
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Joining
Mechanical Fastening
Welding
Adhesive bonding
Assembly
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Surface Treatment
Aesthetic requirements
Painting
Product requirements
Safety Burrs
Surface treatment
chemical plating to resist rust
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Heat Treatment
Altering the mechanical properties of a material.
Strength
Wear resistance
Resistance to penetration
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Other
Inspection
Packaging
Transportation
Waste disposal
Scrap
Chemical by-products
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Product Life Cycle Cost
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Changing World Competition
Globalization has impacted manufacturing
Worldwide competition for global products and their
manufacture
High tech manufacturing for advanced technologyNew manufacturing systems, designs, and management
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New Manufacturing Systems
Toyota Production System
Lean manufacturing system
100% good units flow without interruption
Integrated quality control Responsibility for quality is given to manufacturing
Constant quality improvement
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How Do We Plan For
Manufacturing?
Definition of a need Conceptual design
Review of initial design
Design Prototype
Production plan
Resource specifications
Manufacturing Prototype
Manufacturing
Inspection--quality checks
Packaging - shipping Customer response