1. Introduction to Manufacturing Engineering and Technology
Course MAE 3344
Introduction to Manufacturing
Engineering and Technology
Mechanical Engineering Department
Faculty of Engineering,
Assiut University

2. What is Manufacturing?
How do we make these?

3. The Book and Suggested Reading
Manufacturing Engineering and Technology, 3rd Edition by S. Kalpakjain, published by Addison Wesley
Suggested Reading
The New Manufacturing Engineer by M.J. Terminie, published by The Society of Manufacturing Engineers, 1996
Designing for Economical Production by H.E. Trucks, published by the Society of Manufacturing Engineers, 1987
"Handbook of Product Design for Manufacturing," James G. Bralla, Editor, McGraw-Hill, 1986

4. Definition of "Manufacturing"
"Manufacturing" is a process for converting ideas and market or customer needs into artifacts; Includes design, procurement, test, finance, human resources, marketing, etc.
manufacturing is the conversion of raw materials into useful products
Main Focus of This Course

5. Little "m" manufacturing is all about
Creating shapes by various means and assembling these shapes into a useful product
The processes used to transform raw material into finished products
A physical product always has a shape
Function
Aesthetics
These shapes are created by a wide variety of processes
Students must remember that these processes exist only in the context of the larger Manufacturing process

6. People, money, machines and automation
Manufacturing
Customer needs
People, money, machines and automation
Societal pressures, Government regulations, company plans and policies, etc
manufacturing
Raw
material
Products

7. The manufacturing Process
Materials Science, Statics, Dynamics, Thermodynamics, Fluid dynamics
Products
Material
Transformation
Processes
Assembly
Raw Material
Machines and Automation

8. Manufacturing Process Overview
SFF
Finishing
Assembly
Powders
Products
Pressing
Firing/
Sintering
Injection
Molding
Blow
molding
Stamping
Sheet metal
forming
Raw Material
Continuous
Casting/Rolling
Rolling
Machining
Forging/
Press forming
Ingot
casting
Extruding
Molten
Material
Casting
Shapes
Single crystal
pulling
Special
Increasing level of detail

9. Shapes and Production Method
TABLE 1.2 Shapes and Some Common Methods of Production

10. HISTORY OF MANUFACTURING

12. History of Manufacturing (concluded)
TABLE 1.1 Historical development of materials and manufacturing processes.

13. Engineering Materials
FIGURE 1.4 An outline of engineering materials

14. Aluminum Automobile
FIGURE (a) The Audi A8 automobile, an example of advanced materials construction; (b) The aluminum body structure, showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of ALCOA, Inc.

15. Production Methods for a Simple Part
FIGURE 1.6 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.

16. Machining of a Mold Cavity
FIGURE 1.8 Machining a mold cavity for making sunglasses. (a) Computer model of the sunglasses as designed and viewed on the monitor. (b) Machining the die cavity using a computer numerical control milling machine. (c) Final product produced from the mold. Source: Courtesy Mastercam / CNC Software, Inc.

17. Fundamentals of manufacturing - Manufacturing Concepts
The method chosen depends on the material and the shape and properties required
Formability
Machinability
Hardenability
Castability
Compactability
Sinterability
Weldability

18. Why is Manufacturing Important?
Impact on economy
Major wealth creation engines
Gross Domestic Product
jobs
Most decisions made during design are impacted by production/manufacturing processes
Critical Decisions/Trade-offs
function vs cost vs schedule
Choose materials
Choose process(es)
Cost determined by the material and the processes used to create the shape

19. Big "M" - the Process Step Cost of a change
Identify the requirements $0.1
Define one or more concepts,
test them against requirements iterate downselect $1.00
Flesh the chosen few out (details)
test them against requirements iterate down select $10.00
Final design
test against requirements iterate $100.00
Plan for production
select processes identify process steps define process parameters document Acquire material
Produce $
Support

20. Design Steps
FIGURE 1.2 (a) Chart showing varous steps involved in designing and manufacturing a product. Depending on the complexity of the product and the type of materials used, the time span between the original concept and the marketing of a product may range from a few months to many years. (b) Chart showing general product flow, from market analysis to selling the product, and depicting concurrent engineering. Source: After S. Pugh, Total Design. Addison-Wesley, 1991.

21. Some functional parameters affected by production processes
Mechanical properties (Strength, Hardness, Fatique, Ductility, Resistance to environment)
Tolerances
Surface finish
Resistance to corrosion and abrasion
Electrical properties
Thermal Properties
Appearance/surface finish

22. Materials Vs Processes
Source:
Kalpakjian
P 1225

23. Commercially Available Materials

24. Approximate Amount of Scrap Produced in Various Manufacturing Processes
BUY to FLY RATIO

25. Advanced Materials
Figure Advanced materials used on the Lockheed C-5A transport aircraft. (FRP: fiber-reinforced plastic)

26. Material Changes From C-5A to C-5B Military Cargo Aircraft

27. Manufacturing Process Capabilities
Figure Manufacturing process capabilities for minimum part dimensions. Source: J. A. Schey, Introduction to Manufacturing Processes (2d ed.). McGraw-Hill, 1987.

28. Dimensional Tolerance
Figure Dimensional tolerance capabilities of various manufacturing processes.

29. Dimensional Tolerance and Surface Finish
Figure 40.5 Relationship between relative manufacturing cost and dimensional tolerance.
Figure Relative production time, as a function of surface finish produced by various manufacturing processes. Source: American Machinist. See also Fig

30. Approximate Ranges of Machinery Base Prices

31. Examples of General Function/Process Relationships
Cast metals tend to be brittle
Forging adds strength along flow lines
Machining is cost effective for small lot sizes
Casting, forging and extrusion have high setup costs but low production costs
Heat treatments affect hardness, strength, corrosion resistance and fatigue properties
Machining results in lots of scrap (the buy to fly ratio)

32. Buy to Fly Ratio
The weight of the purchased raw material divided by the weight of the final part
Process Buy to fly ratio
Machining
Hot closed die forging
Sheet metal forming
Extrusion
Permanent mold casting
Powder metallurgy

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

34. What is Manufacturing - Dimensions
Product Creative Characteristics (How new products differ from previous ones)
Product Size (physical dimension)
Product Complexity/Sophistication
Scale
Material Flow
Degree of Automation
Organization

35. Product Creative Characteristics
How new products differ from previous ones
Selection design (Lego houses)
Configuration design (automobiles)
Parametric design (portable generators)
Redesign (New VCR)
Original design (the original VCR, the Space Shuttle)

36. Product Size (physical dimension)
A individual device on a computer chip
A computer chip
A television
An automobile
A Navy cruiser

37. Number of parts/amount of electronics/intelligence
A nail
A TV
A car or truck
A 777 aircraft
A satellite
Mars sojourner
A CPU chip (5 million components)

38. Scale Number of people and disciplines involved Artisan
Garage machine shop
General Motors, Arlington Plant
Boeing Commercial Aircraft
Engineering firms who make bridges, chemical plants or dams

39. Material Flow How the work is organized on the shop floor
Discrete parts (traditional job shop)
Cellular (New machine shops)
Semicontinuous
Continuous flow (bottle making)
Process (chemical industry and oil refineries)

40. Degree of Automation How much automation exists on the shop floor
Manual
Machine assisted
Computer controlled - islands of automation
Computer integrated manufacturing

41. Company Organization How the enterprises organize to produce
Traditional
Lean
Agile
Next Generation

42. Specific trends - Lean Manufacturing
No waste of any kind
Material waste
No scrap - process right each time
Work-in-Process
Pull material flow (KANBAN system)
Personnel waste
Cross functional teams
Design product so there is only one way to assemble product (poke-a-yoke)
Time Waste
Concurrency in operations where possible

43. Flexible manufacturing
The ability to manufacturing multiple products on a single line

44. Agile Manufacturing
The ability to thrive and prosper in an environment of constant and unanticipated change
Agile Manufacturers must be able to change their business processes in hours to weeks to satisfy new and short lived customer demands
Design cycle times reduced ten fold
Production process changes in minutes

45. Agile, lean and flexible Manufacturing
Lean + Flexible = Agile
Some Lean and Flexible proponents also claim agility
The name is not important -
The trends identified are

46. Summing up Introduction Introductory overview of the larger issues
Who am I?
Statement of course goals
Overall class schedule
Statement of assumptions and policies
Introductory overview of the larger issues
Definitions - "Manufacturing vs manufacturing"
Basic concepts
The importance of Manufacturing
Dimensions of Manufacturing
Future trends in Manufacturing

47. Homework Read General Introduction and Part I in Kalpakjian
Do Questions 1.22, 1.25, 2.32, 2.38, 4.32 in Kalpakjian
These are review questions to test if you have met the prerequisites