Manufacturing Process Week 1

2007 John Wiley & Sons, Inc.
M P Groover, Fundamentals of
Modern Manufacturing 3/e
What is Manufacturing?
TAKE A FEW MOMENTS AND INSPECT
VARIOUS OBJECT AROUND YOU
CAN YOU REALIZE THAT ALL THOSE
OBJECTS HAD A DIFFERENT SHAPE?...
Some objects are made of a single part, but most
objects are constructed by the assembly of a
number parts made from variety of materials.
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means made by hand
Made by hand accurately described the
fabrication methods that were used when the
English word manufacture was first coined
around 1567 A.D.
Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human
workers
Manufacturing - Technologically
Application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a starting
material to make parts or products
Manufacturing also includes assembly
Almost always carried out as a sequence of operations
Manufacturing adds value to the material by changing its
shape or properties, or by combining it with other materials
Figure 1.1 (a)
Manufacturing
as a technical
process

Manufacturing - Economically Important

U.S. economy:
Manufacturing is
one way by which
nations create
material wealth
Sector
% of
GNP
Manufacturing
20%
Agriculture, minerals, etc.
5%
Construction & utilities
5%
Service sector retail,

transportation, banking,
communication, education, and
government
70%

Manufacturing Industries
Industry consists of enterprises and
organizations that produce or supply goods and
services
Industries can be classified as:
1. Primary industries - those that cultivate and
exploit natural resources, e.g., farming,
mining
2. Secondary industries - take the outputs of
primary industries and convert them into
consumer and capital goods manufacturing is the principal activity
3. Tertiary industries - service sector
Materials in Manufacturing
Most engineering materials can be classified
into one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
Their chemistries are different
Their mechanical and physical properties
are dissimilar
These differences affect the manufacturing
processes that can be used to produce
products from them
In Addition: Composites
Nonhomogeneous mixtures of the other three
basic types rather than a unique category
Figure 1.3 Venn

diagram of
three basic
material types
plus
composites

Manufacturing Processes
Two basic types:
1. Processing operations - transform a work
material from one state of completion to a
more advanced state
Operations that change the geometry,
properties, or appearance of the starting
material
2. Assembly operations - join two or more
components to create a new entity

Figure 1.4 Classification of manufacturing processes

Processing Operations
Alters a materials shape, physical properties,
or appearance in order to add value
Three categories of processing operations:

1. Shaping operations - alter the geometry
of the starting work material
2. Propertyenhancing operations improve physical properties without
changing shape
3. Surface processing operations - to
clean, treat, coat, or deposit material on
exterior surface of the work

Shaping Processes Four Categories

1.
2.
3.
4.
Solidification processes - starting material

is a heated liquid or semifluid
Particulate processing - starting material
consists of powders
Deformation processes - starting material
is a ductile solid (commonly metal)
Material removal processes - starting
material is a ductile or brittle solid

Solidification Processes
Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
Examples: metal casting, plastic molding

P Groover, Fundamentals of
FigureM1.5
Particulate Processing
Starting materials are powders of metals or
ceramics
Usually involves pressing and sintering, in
which powders are first compressed and then
heated to bond the individual particles
2007 John Figure

Wiley1.6
& Sons, Inc. M P Groover, Fundamentals of
Deformation Processes
Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
Examples: (a) forging, (b) extrusion

M P Groover, Fundamentals of
Figure 1.7
Material Removal Processes

Excess material removed from the starting piece
so what remains is the desired geometry
Examples: machining such as turning, drilling,
and milling; also grinding and nontraditional
processes

P Groover, Fundamentals of
FigureM1.8
Waste in Shaping Processes

Desirable to minimize waste in part shaping
Material removal processes are wasteful in
unit operations, simply by the way they work
Most casting, molding, and particulate
processing operations waste little material
Terminology for minimum waste processes:
Net shape processes - when most of the
starting material is used and no
subsequent machining is required
Near net shape processes - when
minimum amount of machining is required
PropertyEnhancing Processes
Performed to improve mechanical or physical
properties of work material
Part shape is not altered, except
unintentionally
Example: unintentional warping of a heat
treated part
Examples:
Heat treatment of metals and glasses
Sintering of powdered metals and ceramics
Surface Processing Operations
Cleaning - chemical and mechanical

processes to remove dirt, oil, and other
contaminants from the surface
Surface treatments - mechanical working
such as sand blasting, and physical
processes like diffusion
Coating and thin film deposition - coating
exterior surface of the workpart


Modern
Manufacturing
Can
you spot the3/e
hidden face in the coffee beans?
Assembly Operations
Two or more separate parts are joined to form a
new entity
Types of assembly operations:

1. Joining processes create a permanent
joint
Welding, brazing, soldering, and

adhesive bonding
2. Mechanical assembly fastening by
mechanical methods
Threaded fasteners (screws, bolts and

nuts); press fitting, expansion fits
Production Systems
People, equipment, and procedures used for the
combination of materials and processes that
constitute a firm's manufacturing operations
A manufacturing firm must have systems and

procedures to efficiently accomplish its type
of production
Two categories of production systems:

Production facilities
Manufacturing support systems
Both categories include people (people make

the systems work)
Production Facilities
The factory, production equipment, and
material handling systems
Production facilities "touch" the product
Includes the way the equipment is arranged
in the factory the plant layout
Equipment usually organized into logical
groupings, called manufacturing systems
Examples:
Automated production line
Machine cell consisting of an industrial
robot and two machine tools
Facilities versus Product Quantities

A company designs its manufacturing systems
and organizes its factories to serve the
particular mission of each plant
Certain types of production facilities are
recognized as the most appropriate for a
given type of manufacturing:
1. Low production 1 to 100
2. Medium production 100 to 10,000
3. High production 10,000 to >1,000,000
Different facilities are required for each of the
three quantity ranges
P versus Q in Factory Operations
Figure 1.2 P-Q Relationship

Low Production
Job shop is the term used for this type of
production facility
A job shop makes low quantities of
specialized and customized products
Products are typically complex, e.g.,
space capsules, prototype aircraft, special
machinery
Equipment in a job shop is general purpose
Labor force is highly skilled
Designed for maximum flexibility
Medium Production
Two different types of facility, depending on
product variety:
Batch production
Suited to hard product variety
Setups required between batches
Cellular manufacturing
Suited to soft product variety
Worker cells organized to process parts
without setups between different part styles
High Production
Often referred to as mass production

High demand for product
Manufacturing system dedicated to the
production of that product
Two categories of mass production:
1. Quantity production
2. Flow line production

Quantity Production
Mass production of single parts on single
machine or small numbers of machines
Typically involves standard machines equipped
with special tooling
Equipment is dedicated full-time to the
production of one part or product type
Typical layouts used in quantity production are
process layout and cellular layout

Flow Line Production

Multiple machines or workstations arranged in
sequence, e.g., production lines
Product is complex
Requires multiple processing and/or
assembly operations
Work units are physically moved through the
sequence to complete the product
Workstations and equipment are designed
specifically for the product to maximize
efficiency
Types of production system
Figure 1.9

Manufacturing Support Systems

A company must organize itself to design the
processes and equipment, plan and control
production, and satisfy product quality
requirements
Accomplished by manufacturing support
systems people and procedures by which a
company manages its production operations
Typical departments:
1. Manufacturing engineering
2. Production planning and control
3. Quality control
Overview of Major Topics
Figure 1.10 Overview of production system and major

topics
in Fundamentals
Manufacturing.
John
Wiley
& Sons, Inc. of
MModern
P Groover,
Fundamentals
2007
of
A machining cell consisting of two horizontal machining centers

supplied by an in-line pallet shuttle (photo courtesy of Cincinnati
Milacron).

A robotic arm performs

unloading and loading
operation in a turning
center using a dual gripper
(photo courtesy of
Cincinnati Milacron).

2007 John Wiley

& Sons, Inc. M P Groover, Fundamentals of
Did you manage to spot the hidden person?
Dimensions and Tolerances

Factors that determine the performance of a
manufactured product, other than mechanical
and physical properties, include :
Dimensions - linear or angular sizes of a
component specified on the part drawing
Tolerances - allowable variations from the
specified part dimensions that are permitted
in manufacturing

Dimensions (ANSI Y14.5M1982):

A dimension is "a numerical value expressed in
appropriate units of measure and indicated on a
drawing and in other documents along with lines,
symbols, and notes to define the size or
geometric characteristic, or both, of a part or part
feature"
Dimensions on part drawings represent nominal or
basic sizes of the part and its features
The dimension indicates the part size desired by
the designer, if the part could be made with no
errors or variations in the fabrication process
Tolerances (ANSI Y14.5M1982):

A tolerance is "the total amount by which a
specific dimension is permitted to vary. The
tolerance is the difference between the
maximum and minimum limits"
Variations occur in any manufacturing process,
which are manifested as variations in part size
Tolerances are used to define the limits of the
allowed variation

Bilateral Tolerance
Variation is permitted in
both positive and
negative directions from
the nominal dimension
Possible for a bilateral
tolerance to be
unbalanced; for
example, 2.500 +0.010,
-0.005
Figure 1.33 Ways to specify

tolerance limits for a
nominal dimension of 2.500:
(a) bilateral

Unilateral Tolerance
Variation from the
specified dimension is
permitted in only one
direction
Either positive or
negative, but not both
Figure 1.33 Ways to specify
tolerance limits for a
(b) unilateral

Limit Dimensions
Permissible variation in
a part feature size
consists of the
maximum and
minimum dimensions
allowed
Figure 1.33 Ways to

specify tolerance limits for a
(c) limit dimensions

Tolerances and Manufacturing

Processes
Some manufacturing processes are inherently
more accurate than others
Examples:
Most machining processes are quite
accurate, capable of tolerances = 0.05 mm
( 0.002 in.) or better
Sand castings are generally inaccurate, and
tolerances of 10 to 20 times those used for
machined parts must be specified

Franklin Featherstone is sometimes referred to as the Father of

Refrigerated Freight, because of his efforts in publicising the benefits of
this form of transport
How many f letter you counted in the sentence?

Design & Manufacturing a

Product:
a Product
There Defining
are two general
types of products:
Physical Goods
Services
Goods
which are easily understood

because the buyer can see and often
experience their benefits prior to
buying
Actions
that companies offer to

customers for the purpose of
transaction

Stage-Gate Product
Development Process
Idea
Generation
Concept
Development
Idea Screening
Business
Analysis
Product
Design
Prototype
Development
Management
Review
Management
Review
Test Market
Commercialization
Management
Review
Once the decision to develop a new product is made, the actual product development
process
begins
2007
John Wiley & Sons, Inc. M P Groover, Fundamentals of
Characteristics of Successful Product

Development
Product quality
How good is the product resulting from the
development effort?
Product cost
What is the manufacturing cost of the product?
Development time
How quickly did the team complete the product
development effort?
Development cost
How much did the firm have to spend to develop
the product?
Development capability
Are the team & the firm better able to develop
future products as a result of their experience with
a prod. dev. project?

Who design & develop products?
Manufacturing
Engineer
Marketing
professional
Industrial
designer
Team
leade
r
Purchasing
specialist
Electronics
designer
2007 John Wiley & Sons,Mechanical

Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e designer
Design
In general we can analyze design in four phases : Conceptual design

Detailed design
Manufacturing
Distribution, servicing, disposal etc
What is the most important design phase?
Which one of these stages effects the success of a new product?

Importance of Design Stage

Life-cycle cost committed
100
Total Cost (%)
80
Cost incurred
60
Product LifeCycle
Includes
Design Phase
40
20
Ease of change
0
Concept
ual
Design
Detaile
d
Design
Prototy
pe
Manufacturin
g
Manufacturing
Phase
Product
usage
phase
Disposal
phase
Distribution,
service, and
disposal
Design phase determines the most of the cost

associate with delivering a product
2007
John Wiley
Fundamentals
Typically,
80% &ofSons,
the Inc.
costMofPaGroover,
product
is fixed atof
Modern
Manufacturing
the design
stage 3/e
The Product Design Process

Customer Requirements,
Customer Needs
Future Directions
Problem
Identification
Preliminary Ideas
Refinement
Process
Refinement
Process
NO
Criteria
Satisfied
Analysis and
Decision Process
Implementation
YES

Products in Various Stages of Life Cycle

Products in Various Stages of Life Cycle



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2007 John Wiley & Sons, Inc.

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Manufacturing - Economically Important

Agriculture, minerals, etc.

Construction & utilities

Service sector retail,

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 1.3 Venn

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 1.4 Classification of manufacturing processes

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Three categories of processing operations:

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Shaping Processes Four Categories

Solidification processes - starting material

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley & Sons, Inc.

2007 John Figure

2007 John Wiley & Sons, Inc.

Material Removal Processes

2007 John Wiley & Sons, Inc.

Waste in Shaping Processes

Surface Processing Operations

Cleaning - chemical and mechanical

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Types of assembly operations:

Welding, brazing, soldering, and

Threaded fasteners (screws, bolts and

A manufacturing firm must have systems and

Two categories of production systems:

Both categories include people (people make

Facilities versus Product Quantities

P versus Q in Factory Operations

Figure 1.2 P-Q Relationship

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Often referred to as mass production

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Flow Line Production

Types of production system

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Manufacturing Support Systems

Overview of Major Topics

Figure 1.10 Overview of production system and major

A machining cell consisting of two horizontal machining centers

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

A robotic arm performs

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley

Dimensions and Tolerances

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Dimensions (ANSI Y14.5M1982):

Tolerances (ANSI Y14.5M1982):

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 1.33 Ways to specify

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Figure 1.33 Ways to

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Tolerances and Manufacturing

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Franklin Featherstone is sometimes referred to as the Father of