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CHAPTER ONE:
INTRODCUTION TO MANUFACTURING
KNP2013 Manufacturing Technology
Assoc. Prof. Dr Abdullah Hj Yassin
Chapter 1 A.Y Sem 2 2016/2017 1
Contents
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Concepts of Manufacturing
Activities in manufacturing
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Concept of Manufacturing
The word manufacturing from the Latin “manu factus”, meaning made by hand.
In modern sense, manufacturing involves making products from raw materials by means of various processes, machinery, and operations, through a well-organized plan for each activity required.
Manufacturing is a method/technique used to convert input in any form with the use of certain processes into valuable output, going through a series of transition/value-adding processes.
Raw material
Manufacturing End product
Video
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Product’s lifecycle
Source: Wikipedia
Manufacturing is the backbone of any industrialized nation
Manufacturing also involves activities in which the manufactured product is itself used to make other products
Manufactured item has undergoes a number of processes in which pieces of raw material have been turned into a useful product, it has a value, defined as monetary worth or marketable price
Product can be either in the form of physical goods or even in the form of services.
Concept of Manufacturing
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Manufacturing element
Design
Selecting material
Manufacturing Process
In most countries, the income are mainly from manufacturing industries. It is then important for a nation to have a strong manufacturing industries.
Concept of Manufacturing
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Activities
Manufacturing is a complex activities. The activities involve:
Product Design
Machinery and Tooling
Process Planning
Materials
Purchasing
Manufacturing/Fabrication
Production control
Support Service
Marketing
Sales
Shipping
Customer Service
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These activities however must follow several demands and trend:
1) To meet design requirements and product specification and standards
2) Environmentally friendly and economical
3) Quality
4) Flexible to market demands
5) Developments in material, production methods and computer integration
6) The system is view to be a large system
7) The manufacturing must constantly strive for high levels of quality and productivity
Activities
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Activities: Design Process
In order to design a product, one must understand
Functions
Performance
Market also plays an important part and must be
properly analysed
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Traditionally the design and manufacturing are performed sequentially
This means the design takes place first and then manufactured
In effect, the product flow from one department to another
In many cases, this may cause delays and increased of cost
Activities: Design Process –
“Over-the-Wall Engineering”
(a) Chart showing various steps
involved in traditional design and
manufacture of a product.
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Hence, nowadays, concurrent engineering or simultaneous engineering are usually used.
Concurrent engineering is a systematic approach integrating the design and manufacture of products
This approach also consider life cycle - all aspects of product, such as design, development, production, distribution, use, disposal and recycling are considered
(b) Chart showing
general product flow in
concurrent engineering,
from market analysis to
marketing the product.
Activities: Design Process –
Concurrent Engineering
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Certain companies model their product using
software such as Computer Aided Design (CAD),
Computer Aided Engineering (CAE), Computer
Aided Manufacturing
These technology aid in designing the product so
that companies can reduce the manufacturing cost
and avoid over design
Video
Activities: Design Process – Role of
computers in Product Design
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Any finished product, involved one or more than one type of
material.
Material can be obtained in either their original form or artificial
form.
Materials involved in engineering application; alloys, ceramics,
metal and polymers.
More materials is being developed to suit a specific application.
Engineer/Designer has no choice but to know how to choose/select
the best possible alternative for production to achieve their needs.
Activities: Materials Selection
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every product must be able to function.
material selected will determine the characteristic, function and
also costing of the product.
costing involved includes the cost of material and also the cost of
processing the material involved.
Activities: Materials Selection
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Factors that needed to be considered for material selection;
(a). Suitability of material - function of material in finished goods
and processing of the material to produce the product.
(b). Reliability of material - ability/repeatability in producing desired
dimension, surface texture, and tolerances.
(c). Manufacturability of the material - can be formed/casted/welded/
heat-treated/etc.
(d). Processing effect towards the final characteristics of the material
(quality, life, and performance of the products).
(e). Durability of the material - how long the product can last.
Activities: Materials Selection
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(f). Availability of material - ease to obtain & reasonable cost.
(g). Manufacturing cost - reasonable & the best possible methods.
(h). Waste elimination – recycled & avoid illegal disposable.
The above factors should be studied carefully before the best alternative for manufacturing is selected.
It’s not necessarily wise to always go for the cheapest mode, because it might cost you even more in the end.
Activities: Materials Selection
Activities: Materials Selection
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Activities: Materials Selection
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U.S Pennies
1793-1837 100% copper
1837-1857 95% copper, 5% tin & zinc
1857-1863 88% copper, 12% nickel
1864-1962 95% copper, 5% tin & zinc
1943 Steel, plated zinc
1962-1982 95% copper, 5% tin
1982- present 97.5% zinc, plated with copper
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Activities: Selection of
Manufacturing Processes
What are the
manufacturing
processes:
Casting
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What are the
manufacturing processes:
Forming and Shaping –
rolling, forging, drawing,
sheet forming, molding
Activities: Selection of
Manufacturing Processes
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What are the
manufacturing processes:
Forming and Shaping –
drawing, sheet forming
Activities: Selection of
Manufacturing Processes
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What are the
manufacturing
processes:
- Forming and Shaping
–molding
Activities: Selection of
Manufacturing Processes
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What are the
manufacturing
processes:
- Joining – welding,
brazing, soldering,
bonding
Activities: Selection of
Manufacturing Processes
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What are the
manufacturing
processes:
- Machining – turning,
milling, boring,
shaping, grinding
- Finishing – polishing,
surface treatment,
coating, plating
Activities: Selection of
Manufacturing Processes
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The selection of a particular manufacturing process
depends on:
Geometric features – dimensional tolerances, surface
texture required
Flat part & thin cross section – not suitable for casting
Complex part – not suitable for forging
Dimensional tolerances – not suitable for hot-working environment
(distortion, warping, oxidation – elevated temperature)
Workpiece material & its manufacturing properties:
Brittle & hard materials
Cannot be shaped/formed unless at high temperature
Easily machined or cast
Activities: Selection of Manufacturing
Processes
Quiz #1
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Manufacturing does not involved activities in which the manufactured
product is itself used to make other products.
Ans:
Manufacturing consists of two elements: Design & Manufacturing
processes.
Ans: False
In term of time & cost, “Over-the-Wall” approach is better than Concurrent
Engineering.
Ans: False
Selection of materials depend on (1) Geometric (2) characteristics of
material.
Ans: True
False
False
False
True
End of Chapter One26
Chapter 1 A.Y Sem 2 2016/2017
