1. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 MANUFACTURING PROCESSES I IE 351 Lecture 2 -- Manufacturing

2. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 What is Manufacturing? How do we make these?

3. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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

4. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Manufacturing Customer needs People, money, machines and automation Societal pressures, Government regulations, company plans and policies, etc manufacturing Raw material Products

5. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Little "m" manufacturing is all about Creating shapes by various means and assembling these shapes into a useful product A physical product always has a shape –Function –Aesthetics These shapes are created by a wide variety of processes

6. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Material Transformation Processes Raw Material Assembly Products Machines and Automation Materials Science, Statics, Dynamics, Thermodynamics, Fluid dynamics The manufacturing Process

7. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces. Production Methods for a Simple Part

8. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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

9. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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

10. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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

11. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Commercially Available Materials

12. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Manufacturing Process Capabilities Figure 40.3 Manufacturing process capabilities for minimum part dimensions. Source: J. A. Schey, Introduction to Manufacturing Processes (2d ed.). McGraw-Hill, 1987.

13. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Dimensional Tolerance Figure 40.4 Dimensional tolerance capabilities of various manufacturing processes.

14. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Dimensional Tolerance and Surface Finish Figure 40.5 Relationship between relative manufacturing cost and dimensional tolerance. Figure 40.6 Relative production time, as a function of surface finish produced by various manufacturing processes. Source: American Machinist. See also Fig. 25.33.

15. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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)

16. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Buy to Fly Ratio The weight of the purchased raw material divided by the weight of the final part ProcessBuy to fly ratio Machining1.1 - 50 Hot closed die forging1.2-1.5 Sheet metal forming1.1-1.25 Extrusion1.1-1.3 Permanent mold casting1.0-1.2 Powder metallurgy1.0-1.05

17. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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

18. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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

19. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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)

20. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Product Size (physical dimension) A individual device on a computer chip A computer chip A television An automobile A Navy cruiser

21. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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)

22. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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

23. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 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)

24. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Degree of Automation How much automation exists on the shop floor –Manual –Machine assisted –Computer controlled - islands of automation –Computer integrated manufacturing

25. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2 Company Organization How the enterprises organize to produce –Traditional –Lean –Agile –Next Generation

26. Manufacturing Processes IE 351 KSU.-Industrial. Eng. dept Lecture-2