INTRODUCTION TO MANUFACTURING Howard Kimmel Kimmel@adm.njit.edu Levelle Burr-Alexander Burr-alexander@adm.njit.edu John Carpinelli Carpinelli@adm.njit.edu Center for Pre-College Programs

Any artifact or product in our society is the result of various design and manufacturing operations High performance materials Petroleum and petrochemical technologies Health technologies Household appliances Toys Air conditioning and Refrigeration Communications Devices; e.g., Telephone Computers Agricultural Mechanization and Food Products Radio and Television Airplane Automobile

All these artifacts and products were designed, and redesigned a number of times - Different cell phone (or iphone) models every few months with more features, different features. Computers are continually upgraded with more power and features at lower costs. At this time, with energy concerns as a top priority, there are redesigned and more efficient automobiles on the market. All of these products/product changes are due to the activities in engineering design and manufacturing operations.

Manufacturing generally applies to industrial production, in which raw materials are transformed into finished goodson a large scale. Manufactured products may be used for manufacturing other more complex products. E.g., The manufacture of electronic components that supply the manufacturing of items such as cell phones, computers and televisions Design process techniques continue to evolve and result in the production of more flexible, efficient and inexpensive products.

Manufacturing Involves the production of goods. Is the use of technology to make things that people need or want. The process may use tools and machines to produce goods for the consuming public. Includes all intermediate processes required for the production and integration of a product's components. Includes quality control as an integral part of the process by having control over all materials and products (co-products, by-products and end-products) throughout the entire process, from design to production and distribution. Also produces waste products and pollution both undesirable and not needed. Manufacturing operations provides everything we use, and eat, and utilizes many engineering disciplines, including, mechanical, chemical industrial, electrical, and materials science.

Manufacturing – The Beginnings The definition of manufacturing originated with artifacts made by hand. The first manufacturing probably occurred in the stone-age where people made tools, weapons, clothing, pottery, etc, to meet their needs for survival. From individual production of small amounts of consumer-made products, the manufacturing process has evolved to factories that mass-produce large quantities of products for the needs of the consumers. In between, there were distinct periods from the early development of tools and materials (such as the Iron Age in which iron and steel were used as the primary materials for tools) through the Industrial Revolution, in which the process of continuous manufacturing leading to mass production operations was developed.

Manufacturing is more than what occurs in the factory Manufacturing is more than what occurs in the factory. It starts with the engineers who design and develop objects which are perceived as needed but do not occur in the natural world or where needed. It is the purpose and function of the engineer not only to design products, but to keep improving upon their design.

IMPROVING COMMUNICATIONS

The products of today contain many improvements over those first created by early engineers. Engineers: Design things that meet the needs of people, the community, and society. Analyze existing objects for improvements. Re-think and re-engineer existing objects. Manufacturers must respond to feedback from consumers and distributors in ways that affect quality and quantity of their products. They must be able to define and measure customer quality specifications at critical steps in the process and maintain the quality of the processes and products in order to satisfy the expectations of your customers.

Various factors must be considered in the design of a product Various factors must be considered in the design of a product. They include: Personal interests of the engineer Company interests Needs of the community Economics and the marketplace Politics Social and environmental issues Aesthetics Ethics Raw materials - Availability and quality

The engineering design is also a critical process The engineering design is also a critical process. The process includes the following steps Identification of the Problem Analysis of the Problem – Design Constraints Research the Problem – Information Gathering Brainstorm Alternative Design Solutions Modeling “Best” Solution Testing and Evaluating Model/Prototype Refine and Retest Model/Prototype Communicate Final Design The process allows the engineer to investigate, create, plan, make, test, improve, and evaluate solutions to a problem, such as the production of an artifact.

In this module, lessons and resources are provided that illustrate manufacturing operations, and the process of examining a product, or the process of reverse engineering, to study its components, understand how it is produced, and consider how the product can be modified to better meet the needs of the consumer. Pharmaceutical Industry. Manufacture of Chocolate Chip Cookies. Baking Soda. Re-engineering of a Cellphone.