TEC 130Introduction to Manufacturing Processes

Dr. Lou ReifschneiderSection 1 Fall 2011

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Today

Syllabus / Course business Tour Lab Areas Introduction to Manufacturing (ppt)

Lab Manual & Powerpoints available at SAL/TEC_130/… Folder for Syllabus Folder for Lab Manual Folder for Powerpoints

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What is manufacturing?

To make or process a raw material into a finished product, especially by means of a large-scale industrial operation

New American Standard Dictionary

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Primary vs. SecondaryManufacturing

Primary processes convert raw materials into standard stock

bauxite ore aluminum petroleum polyester resin wood lumber

Secondary processes convert standard stock into usable parts

aluminum rod fuel valve polyester resin medical tubing lumber furniture

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Products often made of many parts

Steel sheets and bars Iron & aluminum ingots Plastic resin pellets Uncured rubber Copper wire Nylon thread Glass sheets

CAR

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Secondary Manufacturing Processes

Casting and Molding Forming Separating / Material Removal Conditioning Assembling / Joining Finishing

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Secondary Processes

Casting and Molding processes hold liquid or semi-liquid materials in a mold cavity until the material hardens

Forming processes use a shaping device and pressure to cause a material to take on a new shape and size

Separating processes remove material to produce a desired shape and surface finish

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Secondary Processes

Conditioning processes use heat, chemical reactions, or mechanical means to change the properties of a material

Assembly processes join two or more parts or assemblies through mechanical, thermal, or chemical means

Finishing processes modify the surface of a material to improve appearance or performance

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Manufacturing Work Flow

Custom

Intermittent / Batch

Continuous

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Custom manufacturing

Limited number of products built to customer specifications.

Requires highly skilled labor. Least efficient (but most flexible) form of

manufacturing

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Batch manufacturing

Parts made in lots of 10 – 1,000 General-purpose machinery (table saw,

vertical mill) is used, often run by hand Setup times per part decreases as batches

get larger

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“Continuous” manufacturing

Same product made repeatedly by dedicated machinery (custom built machine – NOT CUSTOM built product)

Automation becomes more cost-effective Some processes still require batch staging Tooling and setup are large initial expenses

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