Manufacturing Modern manufacturing technologies and processes can produce quality products that enhance the quality of life while having a minimal negative impact on the environment

Manufacturing Manufacturing processes have been changed by improved tools and techniques based on more thorough scientific understanding, increases in the forces that can be applied and the temperatures that can be reached, and the availability of electronic controls that make operations occur more rapidly and consistently

Manufacturing History Prior to the 19 th Century manufacturing referred to hand-made products ◦Artisans were considered the premier manufacturers

Manufacturing History The Industrial Revolution ◦Lasted from roughly 1760 – 1840, and it is technically still going… ◦Machines began to take over hand-made production  Chemical manufacturing  Iron and steel production processes  Water and steam power  Machine tools  Bio-fuels

Manufacturing History Impacts of the Industrial Revolution ◦Average income and population have sustained growth ◦Standard of living increases ◦Economic growth ◦Social classes begin to come closer together

Manufacturing History It is the process that changed!! ◦The key to the Industrial Revolution and continued change is efficiency with regard to waste, cost, and the environment

Focus of Manufacturing Six areas that drive manufacturing ◦Cost ◦Quality ◦Efficiency  Production, waste, environment, resources ◦Delivery  Intermodalism – the use of multiple and appropriate forms or transportation in combinations or individually ◦Safety ◦Morale  Of employees and industry  Customer satisfaction and demand

Manufacturing Fun Fact that Changed Everything In the mid 1900s the Jervis B. Webb Co. patented and created the first electronically coordinated conveyor system It is the algorithm under which a system works that defines and shapes it

An algorithm is a logical arithmetical or computational procedure, that if correctly applied, ensures the solution of a problem. In manufacturing this means the recurring production of a product(s). A Flow Chart is how we represent this in manufacturing

Start/end Process Input/output Decision Arrows Display Parts of a Flow Chart

Start/End Shape is a rounded rectangle Start is required of all flow charts Some flow charts may not have an END

Process Shape is rectangular Process involves the action or the “verb” part of the flowchart Examples include ◦Add 1 ◦Turn the motor on ◦Turn the light off ◦Rotate the part

Input/Output Shape is a parallelogram Indicates that manual operation is needed Examples include ◦Type in the weight ◦Check the balance ◦Time the operation

Decision Shape is a rhombus Outcome is either yes or no Examples include ◦Is this number larger than 10? ◦Does the weight meet specifications? ◦Has the count been reached?

Arrows Arrows indicate the flow of the chart. Arrows are drawn from the output of one block to the input of another. Only one arrow can represent outputs. Multiple arrows may represent inputs.

Example Count from 1 to 9 by odd numbers. Before attempting to draw the flowchart, determine what you want the output to be. What is the first block (always)?

Step 1 The output will be 1, 3, 5, 7, 9. The Start block is always first. START

Step 2 The program begins with the number 1. START INPUT 1

Step 4 Now that there is a number, the program will state the number. START INPUT 1 SAY NUMBER

Step 3 The number 2 will be added to 1 so that the program will continue to count by odd numbers. START INPUT 1 ADD 2 SAY NUMBER

Why is Manufacturing Important Manufacturing accounts for 20% of the US Gross Domestic Product Manufacturing employs 17% of the US work Force ◦When adding in all of the jobs that manufacturing creates, or requires for operation, it accounts for 25% of the total US workforce

What Does Manufacturing Look Like Today (ASRS) Automatic Storage and Retrieval System ◦Moves material vertically or horizontally between storage compartment and transfer station or within a process (AGV) Automated Guided Vehicles ◦Computer-controlled system using pallets to transport work pieces to machine tools and other equipment in a flexible manufacturing system

What Does Manufacturing Look Like Today (AI) Artificial Intelligence ◦Machines learn from experience and begin to problem solve on their own when things go wrong (CIM) Computer Integrated Manufacturing ◦A management philosophy for planning, integration, and implementation of automation

What Does Manufacturing Look Like today (FMS) Flexible Manufacturing Systems ◦Systems that can adapt and change quickly and efficiently as design specifications are altered  These systems have increased productivity by an average of 50% overall  This type of system was adopted/adapted from Japanese systems built off of Kaizen ◦ Kaizen – Japanese word for improvment

What Does Manufacturing Look Like Today (JIT) Just-in-Time Manufacturing ◦A manufacturing system directed towards eliminating waste. A management system where all aspects of the system depend heavily on one another for efficient operation  This system is capable of producing mixed products as changes can occur rapidly  Utilizes and trains workers for multiple functions

What Does Manufacturing Look Like Today (TPS) Toyota Production System ◦Specifically applied to automotive manufacturing. Is a very specific manufacturing system centered around CIM, JIT, and Lean Manufacturing Processes ◦Is one of the most efficient mass production systems

What Does Manufacturing Look Like Today Lean Manufacturing ◦Systematic elimination of waste ◦Entire system must participate and work together to produce effectively Rapid Prototyping ◦Prototyping made directly from a computer model  Technologies involved ◦ Stereolithography, 3D Printing, Selective Laser Sintering, Fused Deposition Modeling

Manufacturing Processes Primary Manufacturing Processes ◦Turning raw materials into useable goods  These materials can be renewable or exhaustible Secondary Manufacturing Processes ◦Create Products through the use of primary manufacturing end materials

The Processes Inputs Processes Outputs Feedback

Processes Separating ◦Involves the removal of material to expose another ◦Also referred to as the subtractive process

Processes Forming ◦Uses varying forces to cause a material to permanently take a shape ◦Changes material properties

Processes Finishing ◦May be completed before or after final assembly ◦Used primarily to protect a product from various conditions ◦Also used to enhance a product’s apperance

Processes Finishing / Cleaning ◦Techniques  Alkaline Cleaning  Electrolitic Cleaning  Solvent Cleaning  Vapor Degreasing  Acid Cleaning  Abrasive Blasting  Abrasive Wheels

Processes Finishing ◦Other possible Finishing Techniques  Coating  Deburring  Conditioning

Production Companies Manufacturing Enterprises ◦A complex system centered around a shared mission to satisfy customer need in a manner in relation to a given product or service, or set of products or services.  Professional employment ranges through all aspects of educational background ◦ Management ◦ Design ◦ Finance ◦ Production ◦ Marketing ◦ Distribution ◦ Etc. etc. etc…