1. Manufacturing Operations
Manufacturing: application of physical and chemical processes to alter the geometry, material properties, and/or appearance of a given starting material to make parts or products also includes joining of multiple parts to make assembled products
Manufacturing as a technological process
Manufacturing
process
Machinery
Tools
Power
Labor
Starting
material
Completed part
or product
Scrap
and/or
waste
Manufacturing is almost always carried out as a sequence of operations Each successive operation brings the material closer to the desired final state
IE321 Industrial Production Systems – Fall 2017

2. Manufacturing Operations
Manufacturing: transformation of materials into items of greater value by by means of one or more processing and/or assembly operations
Manufacturing as an economic process
Manufacturing
process
Material in processing
Value added
Starting
material
Completed part
or product
Manufacturing adds value to the material by changing its shape or properties or by combining it with other materials that have been similarly altered
IE321 Industrial Production Systems – Fall 2017

3. Manufacturing Operations
Economic Point-of-View
The material has been made more valuable through the manufacturing operations performed on it
Example: When iron ore is converted to into steel, value is added
Example: When petroleum is refined into plastic, value is added When plastic is molded into the complex geometry of a patio chair, it is even made more valuable
IE321 Industrial Production Systems – Fall 2017

4. History of Manufacturing
processes to shape wood and metal
ore
metal
wood working forming
firing
grinding
polishing
spinning
weaving
dyeing
wood
clay
Stone
Age
8000−3000BC
stone
textiles
cloth
gold
Bronze
Age
hammering
smelting
casting
3500−1500BC
copper silver
Iron
Age
heating
quenching
tempering
1000BC
iron
IE321 Industrial Production Systems – Fall 2017

5. History of Manufacturing
Industrial Revolution (England)
an economy based on agriculture & handicraft
an economy of industry & manufacturing
transformed to
Steam Engine (power) and Machine Tools
Spinning jenny, power loom and other textile machinery increased textile productivity
Factory system: a new way of organizing large numbers of production workers based on the division of labor
boring machine (started with water wheel powered machines)
bore cylinders on the steam engine
machine tool technology boring milling turning shaping drilling planning
Drilling & sawing of wood predates machine tools
IE321 Industrial Production Systems – Fall 2017

6. History of Manufacturing
Assembly Methods binding with twine and rope soldering riveting forge welding nailing adhesive bonding
Ships, weapons, tools, farm implements, machinery, chariots and carts, furniture, garments
Nuts, bolts, screws required the development of machine tools screw cutting lathe 1800s fusion welding s
Interchangable Parts Manufacture traditional method: custom-fabricate each part of a product hand fit together (filing) (guns, muskets) each product is unique manufacturing time considerably long
Components made accurately enough to permit parts assembly without fitting (1800s)
Collection of special machines, fixtures, gages, etc
Mass Production emerging
IE321 Industrial Production Systems – Fall 2017

7. History of Manufacturing
Mid&late 1800s expansion of railroads, steam-powered ships, and other machines growing need for iron and steel and for new methods of producing steel also sewing machine, bicycle, and automobile mass production, assembly lines, electrification of factories
Growing need for mass production in the US population 76 million population 106 million The assembly line turned out to be an important technology
Scientific Management motion study − determine best method to perform a task time study − establish work standards extensive use of standards in industry price rate system and similar labor incentive systems use of data collection, record keeping, cost accounting
1881 electrification began electric motors being used as power source electricity had taken over 20th century automation
IE321 Industrial Production Systems – Fall 2017

8. Manufacturing Industries
Industry consists of enterprises and organizations that produce and/or supply goods and/or services
Primary Industries are those that cultivate and exploit natural resources
Secondary Industries convert the outputs of the primary industries into products. Manufacturing is the primary activity but also includes construction and power utilities
Tertiary Industries constitutes the service sector of the economy
IE321 Industrial Production Systems – Fall 2017

9. Manufacturing Industries
Primary
Secondary
Tertiary
Agriculture
Forestry
Fishing
Live stock
Quarries
Mining
Petroleum
Aerospace
Apparel
Automotive
Basic Metals
Building Materials
Chemicals
Computers
Construction
Consumer Appliances
Electronics
Fabricated Metals
Heavy Machinery
Paper
Petroleum Refining
Pharmaceuticals
Plastics (shaping)
Textiles
Tire and Rubber
Wood and Furniture
Banking
Communications
Education
Entertainment
Financial Services
Government
Healthcare and Medical
Hotel
Information
Insurance
Legal
Real Estate
Repair & Maintenance
Restaurant
Retail Trade
Tourism
Wholesale Trade
Secondary industries are our main interest in this course.
IE321 Industrial Production Systems – Fall 2017

10. Manufacturing Industries
Process Industries
Discrete Parts/Products Industries
chemicals
pharmaceuticals
petroleum
basic metals
food
beverages
electric power generation
automobiles
aircrafts
appliances
computers
machinery
component parts
packaged goods
discrete units
IE321 Industrial Production Systems – Fall 2017

11. Manufacturing Industries
input is continuous
output is continuous
Process
continuous production
Process
Industries
input in batches
output in batches
Process
batch production
batch
input in discrete units
output in discrete units
Process
continuous production
Manufacturing
Industries
input in batches
output in batches
Process
batch production
batch
batch
IE321 Industrial Production Systems – Fall 2017

12. Manufacturing Industries
Continuous Production
production equipment is used exclusively for the given product
output of the product is uninterrupted
liquid, gas, powder
no breaks or changeovers, 100% dedication
Batch Production
finite amounts or quantities (certain amount)
interruption in production between batches
b/c only a finite amount of mtrl can be accomodated
b/c differences between the parts or products made in batches
batch production in process industries:
the whole batch is processed at once in a vat or container
batch production in manufacturing industries:
one or multiple parts at a time
IE321 Industrial Production Systems – Fall 2017

13. Manufacturing Industries
Examples of Final Products from Secondary Industries
Aerospace
Automotive
Computers
Consumer appliances
Electronics
Equipment
Fabricated metals
Glass and ceramics
Heavy machinery
Plastics (shaping)
Tire and rubber
Commercial and military aircrafts
Cars, trucks, buses, motorcycles
Mainframe and personal computers
Large and small household appliance
TVs, VCRs, DVD players, audio equipment
Industrial machinery, railroad equipment
Machined parts, metal stampings, tools
Glass products, ceramic tools, pottery
Machine tools, construction equipment
Plastic moldings, extrusions
Tires, shoe soles, tennis balls
These are industries whose products are likely to be produced by the production systems discussed in this course.
IE321 Industrial Production Systems – Fall 2017

14. Manufacturing Industries
Consumer Goods products purchased directly by consumers
such as cars, personal computers, TVs, tires, toys, and tennis rackets
Capital Goods products purchased by other companies to produce goods and supply services
such as commercial aircraft, mainframe computers, machine tools,
railroad equipment, construction machinery
Materials, Components and Supplies main input for the companies that make the final products
such as sheet metal, bar stock, metal stampings, machined parts, plastic moldings and extrusions, cutting tools, dies, molds, lubricants
IE321 Industrial Production Systems – Fall 2017

15. Manufacturing Operations
Factory Activities
1. Processing and Assembly Operations shaping, property-enhancing, surface joining multiple parts
2. Material Handling and Storage moving, storing, retrieval
3. Inspection and Test compliance to specifications, functionality testing, quality control
4. Coordination and Control regulation of operations at various scopes and time scales of the plant
activities that “touch” the product – that use the product as an input
value added activities – activities that cannot be avoided
IE321 Industrial Production Systems – Fall 2017

16. Processing and Assembly Operations
1.1. Processing Operations
transform a work material from one state of completion to a more
advanced state that is closer to the final desired part or product
adds value by changing the geometry, properties, or appearance of
the starting material. Processing a workpart by altering its
to add value
shape physical properties appearance
using forms of energy
mechanical thermal electrical chemical
before, during & after each cycle
controlling the machines
overseing operations
loading & unloading parts
human energy
IE321 Industrial Production Systems – Fall 2017

17. Processing Operations
Shaping Operations
Operations are performed in a particular sequence to achieve geometry
and/or condition defined by the design specification.
Solidification Processes
starting material: heated liquid or semifluid is poured or forced to flow into a mold cavity where it cools and solidifies, taking a solid shape that is the same as the cavity
casting (metals) molding (plastics and glasses)
Particulate Processing
starting material: in powder form, processed in a die (cavity) at high temperatures and under high pressure sintering (high temperature below the melting point) powder metallurgy (metals, ceramics)
IE321 Industrial Production Systems – Fall 2017

18. Processing Operations
Shaping Operations
Deforming Processes
starting material: ductile metal, apply stress that exceeds the metal’s yield strength, to increase the ductility metal is often heated forging
extrusion (metals, plastics)
rolling (sheet, bars, beams)
drawing, forming, bending (sheet metal processes)
IE321 Industrial Production Systems – Fall 2017

19. Processing Operations
Shaping Operations
Material Removal Processes
starting material: solid (metal, ductile or brittle), excess material is removed from the starting workpiece so that the resulting part has the desired geometry
machining operations
turning
drilling
milling
grinding
lasers
electron beams
chemical erosion
electric discharge
electrochemical energy
using cutting tools that are harder and
stronger than the work metal
abrasive grinding wheel
IE321 Industrial Production Systems – Fall 2017

20. Processing Operations
Property-Enhancing Operations
heat treatments (strengthening/toughening)
Surface Processing Operations
cleaning (chemical, mechanical) dirt, oil, contaminants
surface treatments (mechanical: shot peening, sand blasting, etc) (physical: diffusion, ion implantation, etc)
coating (electroplating, anodizing, organic coating, etc)
thin film deposition (physical vapor deposition, oxidation, chemical vapor deposition, etc)
IE321 Industrial Production Systems – Fall 2017

21. Assembly Operations 1.2. Assembly Operations
join two or more components to create a new quantity, which is called an assembly, subassembly, or some other term that refers to the specific joining process
welding brazing soldering adhesive bonding
threaded fastners (screws, bolts & nuts) rivets press fittings expansion fittings
IE321 Industrial Production Systems – Fall 2017

22. Material Handling and Storage
2. Material Handling and Storage moving and storing materials between processing and/or assembly operations is usually required
in some cases: moving and storage takes more than prosses
in some cases: majority of the labor cost is in handling, moving, storing materials
Time on
machine
Moving and waiting
Time in
factory 5%
95%
30%
70%
Time on
machine
Cutting
Loading, positioning
gaging, etc
IE321 Industrial Production Systems – Fall 2017

23. Inspection and Test
3. Inspection and Test Inspection and testing are quality control activities
inspection: to determine whether the manufactured part meets the established standards and specifications (dimensions, apperance, tolerances, etc)
testing: functional specifications of the final product rather than
the individual parts
IE321 Industrial Production Systems – Fall 2017

24. Coordination and Control
regulation of individual processing and assembly operations and management
of plant level activities
planning of activities at various scopes of the plant at various time scales of the time horizon in order to coordinate (divide-and-conquer)
sense, react, and replan in order to control (correct)
process level control achieving certain performance objectives by properly manipulating the inputs and other parameters of the process
plant level control effective use of labor, maintenance of the equipment, moving materials in the factory, controlling inventory, shipping products of good quality on schedule, keeping plant operating costs at a minimum possible level
IE321 Industrial Production Systems – Fall 2017