INTRODUCTION AND OVERVIEW OF MANUFACTURING Materials in Manufacturing Design Manufacturing Processes Production Systems What is Manufacturing? Technologically Economically Historically John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Materials in Manufacturing Metals Ceramics Polymers Venn diagram John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Composites Material consisting of two or more phases phases processed separately bonded together properties superior to its constituents Phases homogeneous mass of material particles or fibers Properties depend on components direction of fibres John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Metals, Ceramics, Polymers & Composites ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Manufacturing - Technologically Physical and chemical processes Alter geometry Alter properties Alter appearance Machining and assembly operations Manufacturing as a technical process John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Manufacturing - Economically Transformation of materials Create items of greater value Manufacturing adds value changing its shape or properties combining it with other materials Manufacturing as an economic process John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Metal chips fly in a high speed turning operation performed on a computer numerical control turning center (photo courtesy of Cincinnati Milacron). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Life Cycle Assessment John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Two welders perform arc welding on a large steel pipe section (photo courtesy of Lincoln Electric Company). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Manufacturing Industries Primary industries cultivate and exploit natural resources farming mining Secondary industries use outputs of primary industries convert them into consumer and capital goods manufacturing is the principal activity Tertiary industries service sector John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Steelmaking involves charging of a basic oxygen furnace, in which molten pig iron produced in a blast furnace is poured into the BOF. Temperatures are around 1650°C (3000 ° F). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

A robotic arm performs unloading and loading operation in a turning center using a dual gripper (photo courtesy of Cincinnati Milacron). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

A batch of silicon wafers enters a furnace heated to 1000°C (1800°F) during fabrication of integrated circuits under clean room conditions (photo courtesy of Intel Corporation). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Assembly workers on an engine assembly line (photo courtesy of Ford Motor Company). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Production Quantity Q & Variety P Production range Annual Quantity Q Low production 1 to 100 units Medium production 100 to 10,000 units High production 10,000 to millions of Production Variety P Soft product variety Hard product variety John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

P versus Q in Factory Operations P-Q Relationship John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

A machining cell consisting of two horizontal machining centers supplied by an in-line pallet shuttle (photo courtesy of Cincinnati Milacron). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Manufacturing Capability Manufacturing plant processes and systems people transform materials into products materials, processes and systems Manufacturing capability Technological processing capability Physical product limitations Production capacity John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Video John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Manufacturing Processes John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Solidification Processes Starting material is heated Transform it into a liquid or plastic state metal casting plastic molding John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Particulate Processing Starting materials are powders metal powder ceramic powder sintering powder pressing John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Deformation Processes Starting workpart is shaped application of forces exceed the yield strength forging extrusion John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Material Removal Processes Excess material removed transform to desired geometry Example includes machining grinding and nontraditional processes turning drilling milling John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Photomicrograph of the cross section of multiple coatings of titanium nitride and aluminum oxide on a cemented carbide substrate (photo courtesy of Kennametal Inc.). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Assembly operations on the Boeing 777 (photo courtesy of Boeing Commercial Airplane Co.). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Automated dispensing of adhesive onto component parts prior to assembly (photo courtesy of EFD, Inc.). John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Production Facilities fixed position layout fixed position layout cellular layout product layout John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing

Overview of Production Systems John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing