1. WHAT IS MANUFACTURING? Why do we study manufacturing?

2. What is Manufacturing?  What is the importance of manufacturing in society?  How does manufacturing affect your life?  What is the importance of teamwork when completing a task?

3. “Manufacture”  On a sheet of paper write your definition for the word: “Manufacture”

4. What is your definition of Manufacturing? Class Discussion

5. Definition of Manufacturing  Manufacturing is the transformation of materials into usable products.  Derived from the Latin words manu factus, meaning made by hand.

6. Answer the following questions: What is its purpose? What are its features and functions? What materials were used to make each part? What raw materials were used? How were the raw materials transformed? Class Discussion

7. How a pen is made…  The points - brass.  Stainless steel – all parts on some pens  Brass – the ink cartridge, the body, and the spring  Aluminum – the pen body  Plastic – the body, ink cartridge, cap, point top  All pens are manufactured from various materials. The material composition is what determines the durability and cost to the consumer.

8. The Manufacturing Process  All pens are made slightly different, but the main processes include:  Ink compounding  Metal component formation  Plastic component molding  Piece assembly  Packaging  Labeling  Shipping

9. Making the Ink  Compounders (ink workers) – follow a formula to make batches of ink.  Raw materials are mixed together and can be heated or cooled to speed the mixing process.  Larger quantity raw materials are pumped into the batch tank using computerized controls.  Quality control checks are completed at various points in the mixing process.

10. Stamping and Forming  The balls to the pen are typically supplied by an outside vendor (outsourced).  The point of the pen is manufactured in the following steps: Brass is inserted in stamping machines which cuts small discs. Small discs are softened and poured in a compression chamber. A steel ram presses the brass and a plunger forces it into a die cast mold. The excess metal is scraped off and the die is opened. The pen piece is removed. The pieces are put in a bath to remove oils used during the die process. The ball can then be inserted into the point cavity

11. Molding the Housing  Plastic pieces of the pen are produced by extrusion or injection molding.  Plastic is supplied as granules or powder and fed into a large hopper.  Pen body and ink reservoir – In an extrusion process, a large spiral screw forces the material through a heated chamber making it a thick flowing mass. It is then forced into a die, cooled, and cut.  Caps, ends, and mechanical components – Injection molding is used. Plastic is heated and converted and converted to a liquid that can be forcibly injected into a mold. After it cools and becomes a solid, the die is opened.

12. Ink Filling and Assembly  Assembly takes place after the parts are formed.  The ball point is attached to the ink reservoir.  These pieces are sent on a conveyor to the injectors which fill the ink.  The spring is placed on the barrel of the reservoir.

13. Final Assembly, Packaging, and Shipping  The point and reservoir are placed in the main body of the pen.  The caps and ends are assembled.  Final decorations or coatings are completed.  The pens are packaged  Sales units are put in boxes, stacked on pallets, and shipped to the distributor.

14. Examining a Manufactured Item: The Problem: You are and your team members are engineers with ABC Manufacturing. Your department head has asked you to examine a competitors product. You have 20 minutes to complete your investigation and file your report. Group Activity

15. Working as a Team…  Before you begin, decide how you will work as a team:  Will each of you perform a single task?  Will all of you share in every task?  Will smaller groups perform individual tasks?  Will one person disassemble or assemble while another records?

16. Your Examination…  Write a description of the product and how it is used. What is its approximate cost?  Take apart the item. Identify the parts and materials each is made from. How do you think each part was made? (stamped, molded, etc.)  Note each step you perform and any details that may be important such as how to hold a part. Number each part so they can be reassembled.  Give a step-by-step description of how the item is assembled. You can make a sketch or assembly drawing.

17. Follow Up…  Was working with a team an effective way to work? Do you think you would have accomplished as much working alone?  Were the methods that your team used successful?  How did your team gather and share information? How was information communicated?  What did you contribute to your team? Are you satisfied with what your team did? Would you do anything differently next time?  How would you have assembled your item if there had been 10 of them? 10,000?  How might the study of manufacturing benefit you?

18. Using the internet, find 5 manufactured items during your specified time frame. 1850-1900, 1900-1930, 1940-1950, 1950-1960, 1960-1970, 1980-1990, 1990-2000, 2000-current Create a PowerPoint presentation including the following: (20 pts per invention) Picture of the invention (3pts) Date of invention (2pts) Purpose of invention (5pts) How did it change people’s lives? (10pts) Activity Time – Manufacturing in History