Design for Manufacturing, Assembly, and Reliability · PDF fileo Learning objec:ves o What this module addresses ... 12 Manufacturing ... • The process uses welding wire as feedstock

ManufacturingProcessesU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org www.build4scale.org

DesignforManufacturing,Assembly,andReliabilityModule3CManufacturingProcesses

ManufacturingProcessesU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org

o Choosinganappropriatemanufacturingprocessisperhapsthesinglemostimportantdecisionyouwillmaketoscaleupyourproduc:on

o Manufacturingprocessselec:ondrives:— Costand:metoproduce— Make-or-buydecisions— Capital-investmentdecisions— Productlook,quality,andreliability— Adaptabilitytodesignchanges

Selec%ngtherightmanufacturingprocessisparamounttoyourcompe%%veadvantageinthemarketplace,somakeaninformed

decisionnow!2

Whyisthismoduleimportant?Mo8va8on


o Learningobjec:veso Whatthismoduleaddresseso Introduc:ontomanufacturingprocesseso ProcessaGributeso Manufacturingcostanalysiso Manufacturingprocessselec:ono Addi:onalresources

3

ModuleOutline


o LO1.Iden:fythemanufacturingprocessescapableofproducingnecessarygeometry

o LO2.Recommendappropriatemanufacturingprocessesbasedontechnicalandbusinessneeds

o LO3.Es:matethecapitalandpiececostsassociatedwithalterna:veprocesses

4

LearningObjec8ves


o ThevarioustypesofmanufacturingprocessesandtheirkeyaGributesandcostfactors

o Howtoselectamanufacturingprocessbasedonthedesignrequirements,materialtype,andprocessparameters

o Howproductgeometry(suchasshapeandsize)canlimitthemanufacturing-processselec:ondecision

o Componentandcapitalcostso Anintroduc:onofhowthemanufacturingprocessinfluencesproductdesign

5

WhatThisModuleAddresses


PRODUCTDESIGNOBJECTIVES

MANUFACTURINGREADINESSLEVELSLevels: 109987654321

MfgDevelopmentManufacturingResearch

MfgCapability

Produc:on

MarketResearchDesignResearch

FeasibilityDevelopment

Qualifica:onFieldReadiness

Launch

ManufacturingCapacity

Selec8ngManufacturingProcessesWheredoesthisfitintothedevelopmentcycle?

ConceptandFeasibility Defini8on Productand

ProcessDesignImplementand

ValidateProduc8onandStock

LaunchandClosure

Pre-alpha Alpha Beta Pilot Ramp Scale

PHAS

ES

BUILDS

EngineeringValida0on

DesignValida0on

ProcessValida%on

ConceptValida%on

6


o Manufacturingisabouttransforming(orconver:ng)rawmaterialsintofinishedcomponentsorproducts

Commonmanufacturingprocesses:o Machiningo Pressworkingo Welding/fabrica:ono Cas:ngo Powdermaterialso Layereddeposi:ono Injec:onmoldingo 3DPrin:ng

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Introduc%onManufacturingProcesses

o Extrusion–pipe,sheetstock,tubeso Assembly


Primaryshapingprocesses:o Theseprocessesformtheoverallshapeoftheproduct,orthecomponentsthatwillbejoinedtoformthefinalproduct

Secondaryprocesses:o Themainobjec:veofthisistoprovidethefinalshapesurfacestomeetsomeoftheproductrequirementssuchassurfacefinishing

Assembly/testprocesses:o Assemblyprocessesareusedtojointwoormorecomponents/sub-assembliestoobtainthefinalproductwhiletestprocessesareusedtoinspectdimensionsandfunc:onality

Classifica%onManufacturingProcesses

Adoptedfrom‘’Introduc:ontoManufacturingProcessesandMaterials’’ByRobertCreese8


HierarchyManufacturingProcess

AdaptedfromK.G.SwiGandJ.D.Booker(2013)

SECONDARYPROCESSES

ASSEMBLY/TEST

PROCESSES

EndProduct

JoiningProcessesBol:ng,rive:ng,welding,brazing,soldering,adhesive

bonding

AssemblySystemsComponentfeeding,orienta:on,robo:cs,placement,inser:on

TestProcessesMeasurement,inspec:on,

func:onaltes:ng

BulkHeatTreatmentHardening,tempering,

annealing

MaterialRemovalProcessesTurning,drilling,milling,laser

beammachining

SurfaceTreatmentPla:ng,pain:ng,

anodizing,polishing

RawMaterial

PRIMARYSHAPINGPROCESSES

Cas8ngSand,die,investmentcas:ng

MouldingInjec:on

moulding,blowmoulding

Forming Forging,

presswork,rolling

Powder Powdermetal

sintering

SpecialCompositelay-up

Addi8veManufacturing3Dprin:ng,fused

decomposi:onmodeling,Stereolithography

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Cas%ngandmoldingPrimaryProcesses

Process Descrip8on CommonApplica8on ProcessExample

Cas:ng

•  Moltenmetalispouredintoamoldcavity;uponsolidifica:on,metalconformstotheshapeofthecavity.

•  Mostcas:ngprocessesusepaGernsthatformthecavityofthemoldmadefromwood,plas:cs,ormetals.

Windmilltowerparts,generatorblocks,metalblocksformachining,andothercomplexshapeswithinternalfeatures.

Injec:onMolding

•  Injec:ngorforcingofheatedmoltenplas:cintoacavitymold,whichisintheformoftheproducttobemade.

•  Partisejectedfromthemoldaeeritiscooledandsolidifies.

•  Itcanproducevarie:esofpartdesignsinasinglemoldingopera:on.

Thermoplas:ccomponents,Turbinevanes,mechanicalseals,O-rings,andplas:cboGles.

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ShapingandforgingPrimaryProcesses


RollForming

•  Toformsheetsofuniformcross-sec:on.•  Materialisfedthroughmul:plepairsofformingrollscounteredtoproducethedesiredcrosssec:on.

•  Highmechanicalstrength,dimensionalaccuracy,closertolerances,andgoodsurfacefinish.

Framesofsolarpanel,partsofaircraes,HVAC,railtracks,automobilecomponents,andothergeometricallycomplexshapes.

Forging

•  Controlleddeforma:onofmetalintoaspecificshapebycompressiveforces.

•  Superiortocas:ngbecausethepartsformedhavehighstrength,highresistancetowear,lessporosity.

•  Aluminum,copper,andmagnesiumarepreferredforforging.

Windmillturbinedisksandgearblanks,bearinghousings,seals,fancases.

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Forgingandshaping(cont.)PrimaryProcesses


SheetMetalStamping

•  Stampingpressesandstampingdiesaretoolsusedtoproducesheetmetalparts.Thepressmachineprovidestheforetoclosethestampingdiesthatshapeandcutthesheetmetalintofinishedparts

•  Includesprocessessuchaspunching,blanking,embossing,bending,flangingandcoining.

Sheetmetalpartsofsimpleandcomplexgeometriescanbeproducedinhighvolume.

Example:Automobilebodyparts,windturbinecasings,rolledsteelsheetsandmanyothers.

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Addi%vemanufacturingPrimaryProcesses


3DPrin:ng(RapidPrototyping)

•  Producespartlayerbylayerfromamaterial(bothpolymerandmetal)basedonthedigitaldata(CAD).

•  Increaseddesignfreedomcomparedtoconven:onalprocessessuchascas:ngandmachining.

•  Nocuingtools,molds,ordiesarerequired.•  Complexpartsproducedinafewhours.

Prototypeformanufacturedobjects,medicalfieldcomponents(e.g.,stents,ar:ficiallimbs,andjoints).

Wire+Arc-AM(WAAM)

•  Theprocessusesweldingwireasfeedstock.•  Itproducesverynearnetshape,withouttheneedforcomplextooling,moulds,dies.

•  WAAMhardwarecurrentlyusesstandard,offtheshelfweldingequipment:weldingpowersource,torchesandwirefeedingsystems.

•  Mo:oncanbeprovidedeitherbyrobo:csystemsorcomputernumericalcontrolledgantries.

•  Suitedformanufacturingofmediumtolargescalecomponents.

•  Foraerospaceindustriescomponentssuchascruciform,s:ffenedpanels,wingribs,etc.

•  It’salsousedinindustriessuchasnuclear,oilandgasforproducingroundshapeendcapsofpressurevessels.

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Addi%vemanufacturing(cont.)PrimaryProcesses


AdhesiveManufacturing

•  Goodalterna:vetowelding,soldering,andbrazing.Effec:veforjoiningdissimilarmetalsubstrateswithdissimilarmel:ngpoints.Doesnotcausedistor:on,discolora:on,orweldworms.

•  Holesneednotbedrilledintothematerialtoaccommodatefasteners.

•  Distributesstressloadevenlyoverabroadarea.

Typicallyusedinapplica:onssuchasthreadlocking;retainingrigid,cylindricalassemblies;andsealingbetweenflanges.

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HeattreatmentSecondaryProcesses


HeatTreatment

•  Anopera:on,orcombina:onofopera:ons,whichinvolvesthehea:ngandcoolingofasolidmetaloralloyforthepurposeofobtainingcertaindesirablecondi:onsorproper:es.

•  Itisusuallydesiredtopreserve,asnearlyaspossible,theform,dimensions,andsurfaceofthepiecebeingtreated.

Itimprovesthehardnessofmetalfortheiruseinapplica:onssuchascertaintypeofbolts,mowerblades,axes,sawblades,drillbits,gardentools,etc.

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MachiningSecondaryProcesses


Turning

•  Workpieceisrotatedaboutitsaxiswhereascuingtoolisfedintoit.

•  Thisshearsawayunwantedmaterialandcreatesthedesiredpart.

•  Turningcanbeperformedonbothexternalaswellasinternalsurfaces.

Tomanufacturerota:ngpartssuchasturbineshae,axles,spindles,gearblanks,pumpdrives,andpinions,etc.

Threading

•  Asingle-pointthreadingtool,typicallywitha60-degreepointednose,movesaxially,alongthesideoftheworkpiece,cuingthreadsintotheoutersurface.

•  Thethreadscanbecuttoaspecifiedlengthandpitchandmayrequiremul:plepassestobeformed.

Applica:oninvolvingthreadssuchasfasteners,connectors,wormdrives,leadscrewofjack,micrometer,pipejointsandhoses.

Milling

•  ItusesrevolvingcuGerstoremovematerialfromaworkpieceadvancinginacertaindirec:onatananglewiththeaxisofthetool.

•  Millingcancreatecomplexshapesaccurately.

Complexshapessuchasbladesofturbines,gearboxcasings,flanges,aircraebodyparts.

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Machining(cont.)SecondaryProcesses


Drilling

•  Tomakestraightcylindricalholesinsolidrigidbodiesand/orenlarge(coaxially)exis:ng(pre-machined)holes.

•  Toolusedintheprocessiscalled“DrillBit”,whichisarotarymul:-pointcuingtool.

Bushing,flanges,collars,andapplica:onswhereitrequiredbulkproduc:onofdrilledmaterialsinvarioussizeandshapelikemetalsheets,plas:c,wood,glassandconcreteconstruc:onapplica:ons.

Grinding

•  Itisanabrasivematerialremovalandsurfacegenera:onprocess.

•  Implementtoshapeandfinishcomponentsmadeofmetalsandothermaterials.

•  ItcanachievebeGersurfacefinishcomparedtoturningormilling.

Anycomponentrequiringsurfacefinishsuchastransmissionshaes,camshaes,bearings,crankshaes,etc.

Reaming

•  Itisusedtoenlargeandtrueahole.•  Toolusedforthisprocessarecalled“Reamers“.•  Areamerisarotarycuingtoolwithoneormorecuingelementsusedforenlargingtosizeandcontourapreviouslyformedhole.

Usedtoproducesmoothandaccurateholes,precisioninstruments,gauges,measurementtools,etc.

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Tapping

•  Aprocessforproducinginternalthreadsusingatool(tap)thathasteethonitsperipherytocutthreadsinapredrilledhole.

•  Acombinedrotaryandaxialrela:vemo:onbetweentapandworkpieceformsthreads.

Widelyusedinmachinetoolindustrytoholdorfastenpartstogether(screws,boltsandnuts),andtotransmitmo:on(theleadscrewmovesthecarriageonanenginelathe.

Boring

•  Processofproducingcircularinternalprofilesonaholemadebydrillingoranotherprocess.

•  Itusessingle-pointcuingtoolcalledaboringbarwhichcanberotated,ortheworkpartcanberotated.

Anycomponentrequiringa:ghtersurfacefinishsuchasthatfortransmissionshae,camshaes,camshaesbearing,endcrankshaes.

CounterSinking

•  Itproducesalargerstepinaholetoallowaboltheadtobeseatedbelowthepartsurface,exceptthatthestepisangulartoallowflat-headscrewstobeseatedbelowthesurface.

•  Acountersinkisanconicalcuingtoolwithangularrelief,havingoneormorefluteswithspecificsizeanglecuingedges.

Usedtorecessaflatheadscrewortochamferholeedges,especiallyinavia:onindustries.

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Broaching

•  Amachiningopera:onthatusesatoothedtoolcalleda“broach”toremovematerial.

•  Broachingcanbeperformedeitherhorizontallyorver:callybyeitherpushingorpullingthebroachesoverorinsidetheworkpiece.

Typicaluseofthisprocessincludescuingkeywaysontheobjectssuchasdriveshaes,gears,pulleys,etc.

Honing•  Anabrasivemachiningprocesswherehoningtools(honings:cks)arepressedagainsttherota:ngworkpiecetoobtainrequiredmaterialremoval.

Improvesthedimensionalaccuracyofinternalsurfacesofcylindricalpartssuchasboreofautomobilegearbox.

Burnishing

•  Itisaprocessofpolishingandworkhardeningusedforametallicsurface.

•  Itsmoothensandhardensthesurface,crea:ngafinishwhichlastslonger.

Usedmainlyinclockmakingandwatchmakingindustries.Partssuchasbearingsurfaces,pivots,and,pivotholesarefewexamples.

Super-finishing

•  Asnamesuggests,it’safinematerialremovalprocess.

•  Itinvolvesverylowsurfaceroughnessvaluesoftheorderof0.012-0.025µm.

•  Itinvolvesrela:velylargergrainedstoneremovingdesiredstock.

Par:cularlyusedforgivinghighsurfacefinishestoballbearingspartssuchasraces,etc.


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Machining(cont.)

SecondaryProcesses


Shaping

•  Toolisreciproca:nghorizontallyandtheworkpieceisfedintothecuingtool.

•  Toolusedforshapingiscalledshaper.•  Feedanddepthofcutareprovidedbymovingtheworkpiece.

Usedformachiningflatsurfacesonsmallsizedjobs.

Workpieceisheldonafixedbedtobeusuallyrectangularinshape.

Plaining

•  Workpieceisreciproca:ngandthetoolisfedin.•  Producesflatsurfacesindifferentplanes.•  Muchlargerandmoreruggedwithlongerlengthandheavycutscomparedtoshapingmachines.

Usedifthesizeofthejobrequiringlongerandfasterstroke,e.g.largestampdiesandplas:cinjec:onmolds.

Otherusescontainsanytaskwherelargeblockofmetalshavetobesquared.

Sloing

•  Toolisreciproca:ngver:callyandtheworkpieceisfedintothecuingtool.

•  Canbeconsideredasver:calshapingmachines.•  Lengthandposi:onofstrokecanbeadjusted.

Usedtomachineinternalsurfaces(flat,formedgroovesandcylindrical).

Workpieceisheldonafixedbedtobeusuallycircularinshape.

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ElectricalDischargeMachining(EDM)

•  Removesmetalbymeansofelectricsparkerosion.•  Electricsparkisusedasacuingtooltocut(erode)theworkpiece.

•  Pulsa:ng(on/off)electricchargeofhigh-frequencycurrentissuppliedthroughtheelectrodetotheworkpiece.

•  Removingvery:nypiecesofmetalfromtheworkpieceatacontrolledrate.

ThemostcommonuseofEDMisindiemaking.Itcanproduceverysmallandaccuratepartsaswellaslargeitemslikeautomo:vestampingdiesandaircraebodycomponents.

21


TypesofgrindingSecondaryProcesses


SurfaceGrinding

•  Itisusedforgrindingplainflatsurfaces.•  Eitherperipheryofthegrindingwheel(horizontally)ortheflatfaceofthewheel(ver:cally)isusedtoperformthisopera:on.

Usedforgrindingofspecialcontouredsurfacesandhashighmetalremovalrates.

CylindricalGrinding

Therearetwosubtypes:•  Externalorcenter-type:similartoturningopera:on,work-pieceisrotatedbetweencentersandthegrindingwheelisfedagainstit.

•  Internal:similartoboringopera:on,work-pieceisheldinchuck(rotatedataveryhighspeed)againsttherota:nggrinder.

External:crankshaes,axles,spindles,rollsforrollingmills.Internal:togrindrota:onalpartssuchasthehardenedinsidesurfacesofbearingracesandbushingsurfaces.

CenterlessGrinding

•  Workpieceisnotheldbetweencenters.•  Workpieceissupportedbyarestbladeandfedthroughbetweenthetwowheels.

•  Some:mes,twosupportrollsareusedinsteadofrestbladetomaintaintheposi:onofthework.

Usedforgrindingexternalandinternalcylindricalsurfaces.Thisisspecificallyusedtogroundbarstockandchromedbarstock.

Source:FundamentalsofModernManufacturingMaterials,Processes,andSystems–Groover,MikellP.,JohnWiley&Sons,2010,4thedi:on,PP.616-617

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JoiningAssemblyProcesses


Welding

•  Itisamaterialsjoiningprocesswhereintwoormorepartsarecoalescedattheircontac:ngsurfacesbyasuitableapplica:onofheatand/orpressure.

•  Mostoftheweldingprocessesareaccomplishedbyheatalone,withnopressureapplied;othersbyacombina:onofheatandpressure;ands:llothersbypressurealone,withnoexternalheatsupplied.

Commonapplica:onincludes(butnotlimitedto)construc:on,suchasbuildingsandbridges,pressurevessels,boilers,piping,andstoragetanks,shipbuilding,aircrae,aerospace,andautomo:veandrailroad.

Brazing

•  Ajoiningprocesswhereinafillermetalismeltedanddistributedbycapillaryac:onbetweenthefayingsurfacesofthemetalpartsbeingjoined.

•  Nomel:ngofthebasemetalsoccursinbrazing;onlythefillermelts.

Itcanbeusedtojoinanymetalsincludingdissimilarmetals.

Itcanbeusedinapplica:onwhereweldingcannotbeperformed,e.g.thinwallplates

PressureWelding

•  Externalpressureisappliedtoproduceweldedjointseitherattemperaturesbelowthemel:ngpoint,whichissolidstatewelding,oratatemperatureabovethemel:ngpoint,whichisfusionstatewelding.

Usedformetalsthatarehighlyduc:leorwhoseduc:lityincreaseswithincreasingtemperatures.

Applica:onsincludejoiningsheets,wires,andelectriccomponents.

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Joining(cont.)AssemblyProcesses


SpinWelding

•  Itusesheatgeneratedbyrota:onalfric:onatthejointlinetoweldthermoplas:cpartswithrota:onallysymmetricjoints.

•  Thespinweldingmachineappliespressureaxiallywhilerota:ngonepartagainstitssta:onarymate,andtheresul:ngfric:ongeneratesheatthatmeltsthepartstogether.

Mostefficientmethodofjoiningcircularpartsthatrequirehighqualitypermanentjoints.

Note:Onlyapplicableforthermoplas:cparts.

ElectricResistanceWelding

•  Itincludesthespot,seam,andprojec:onweldingprocesses.

•  Spotweldingoccurswhentheworkissqueezedbetweentwocopperelectrodeswhichhaveanelectriccurrentflowingbetweenthem.

•  Inseamwelding,theelectrodesareintheformofopposingwheelswhicheffectacon:nuousfusedjointorseam.

•  Inprojec:onwelding,fusionoccursatpredeterminedloca:onscharacterizedbyembossments,projec:ons,orjointintersec:ons.

Thisisawidelyusedweldingmethodtojoinanycarbonsteelparts.

Theseweldingmethodsarewidelyusedinautomobilefinalassemblyplantstoweldthecarbodies.

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Manufacturingprocesseshavemanya_ributes:o Toleranceo Surfaceroughnesso Massrangeo Sizerangeo Economicbatchsizeo Capitalcostso Produc:onrate

25

BasicsProcessA_ributes


o Onlyspecificmaterialscanbeshapedorformedbyspecificprocesses

o Specificdesignscanbeachievedwithspecificprocessesandmaterials

o Process-aGributetablesprovidedetailedinforma:onontheabove-men:onedaGributes,therebyhelpingdecisionmakersinchoosingtherightmanufacturingprocessesfortheirdesignandmaterialrequirements

26

Basics(cont.)ProcessA_ributes


27

MachiningProcessA_ributes

A_ributesofMachiningProcesses

Process Material SizeRange

Tolerance(mm)

SurfaceFinish(µm)

CostsEOQ Produc:onrate

perhourLabor Equipment Tooling

Turning

Allexceptsome

ceramics

<φ3000mm ±0.05 0.025-25 High Low Medium 1+ 1-50

Milling

Allexceptsome

ceramics

<1000mm2 ±0.1 0.2-25 Medium-

high Medium Medium-high 1+ 1-100

Drilling

Allexceptsome

ceramics

<φ250mm ±0.05 0.8-12.5 Low-

medium Low Low-medium 1+ 10-500

Grinding Allmetals

<φ0.5mm-2m6mlong

±0.005 0.025-6.3 Low-high Medium Medium-high 1+ 1-100

Threading Allmetals

0.1m–0.8m ±0.05 0.2-25 Low-high Low-high Medium 1+ 1-50


28

Machining(cont.)ProcessA_ributes

A_ributesofMachiningProcesses

Process Material SizeRange

Tolerance(mm)

SurfaceFinish(µm)

CostsEOQ Produc:onrate

perhourLabor Equipment Tooling

Broaching Allmetals

25mm–3mlong ±0.005 0.4-6.3 Low-high High Low-

Medium 1+ 1-400

Honing

Allincludingsome

ceramicsand

plas:cs

Ø6-750mm

12mlong±0.005 0.025-1.6 Medium Low-high Medium 1+ 10-1000

Lapping Allhardmaterials 500mm ±0.005 0.012-0.8 Low-high Low-high Medium 1+ 10-3000

Shaping Allmetals 2mlong ±0.05 0.4-25.0

Medium-high

Low Medium-high 1+ 1-50

Planning Allmetals 25mlong ±0.05 0.4-25.0

Medium-high

Low

Medium-high

1+ 1-50


29

ShapingandforgingProcessA_ributes

A_ributesofShaping/FormingProcesses

Process Material Weight(kg)/size

Tolerance(mm)

SurfaceFinish(µm)

CostsEOQ

Produc:onrateperhourLabor Equipment Tooling

ShapeRolling MostMetals 10-1000 ±0.5 0.8-25 Low-

mediumMedium-high

Medium-high 50000m 20-500m/hr

Shapedrawing

SteelorAland/orCualloys

10-1000 ±0.1 0.2-0.8 Low-medium

Medium-high Medium 1000m 10-2000m/

hr

Coldforgingand

extrusionMostmetals 0.001-50 ±0.1 0.4-3.2 Low-

mediumMedium-high High 1000 10-10000

Hotextrusion Mostmetals 1-5000 ±0.1 1.0-25.0 Medium High Medium 1-10 10-100

Hotforging(opendie) Mostmetals 0.1-200000 ±0.5 1.0-25.0 High Medium Low 1-100 1-50


30

Shapingandforging(cont.)ProcessA_ributes

A_ributesofShaping/FormingProcesses

Process Material Weight(kg)/size

Tolerance(mm)

SurfaceFinish(µm)

CostsEOQ Produc:on

rateperhourLabor Equipment Tooling

Hotforging(impression) Mostmetals 0.01-100 ±0.5 1.0-25.0 Medium High Medium 100-1000 10-300

Bending SteelorAland/orCualloys Any ±0.2 0.2-0.8 Low-

medium Medium Medium 100-10000 100-100000

DeepDrawing

SteelorAland/orCualloys Any ±0.1 0.2-0.8 Low-

mediumMedium-high High >1000 10-10000

Vacuumforming Thermoplas:cs 20m2 ±0.25 Good Low-

mediumLow-

MediumLow-

Medium 10-1000 50-350

Blowmolding Thermoplas:cs 3m2 ±0.5 Good Low Medium-high

Medium-high 1000-1x106 100-2500

Contactmolding

Glassreinforcedfibers,

thermoseingliquidresins

0.01–500m2 ±0.03-20 Good High Low Low 1-500 1-10


31

Cas%ngProcessA_ributes

A_ributesofCas8ngProcesses

Process Material Weight(kg) Tolerance(mm)

SurfaceFinish(µm)

CostsEOQ Produc:on


Sandcas:ng Any,butsteeldifficult 0.05-Nolimit ±0.5 3.2-25 Low-

medium Low Low <100 1-60

Shellcas:ng

Mostmetalsexcept(Pb,Zn,Mg,:tanium

alloys,refractoryandzirconiumalloys)

0.05-100 ±0.2 0.8-6.3 Low-medium

Medium-high

Low-medium >100 5-200

Plastercas:ng

Non-ferrousmetals(Al,Mg,

Zn,Cu)0.025-25 ±0.05 0.8-3.2 High Medium Low-

medium 10-100 1-10

Investmentcas:ng Anymetal 0.005-100 ±0.05 0.4-3.2 High Low-

mediumMedium-high 10-1000 1000

Diecas:ngNon-ferrous

metals(Al,Mg,Zn,Cu)

0.05-300 ±0.05 0.4-3.2 Low-medium High High 500-1000 5-200

Centrifugalcas:ng

Anymetalandsomeceramics 1-5000 ±0.2 1.6-12.5 Low-

mediumMedium-high Medium <1000 50


32

Cas%ng(cont.)ProcessA_ributes

A_ributesofCas8ngProcesses

Process Material Weight(kg) Tolerance(mm)

SurfaceFinish(µm)

CostsEOQ Produc:on


Injec:onmolding

Mostthermoplas:cs,

somethermosets,

compositesandelastomers

6-25 ±0.05-8.0 0.2-0.8 Low Medium-high High >10000 60-360

Reac:oninjec:onmolding

Mostthermoplas:cs,

somethermosets,


6-25 ±0.05-8.0 0.2-0.8 Low Medium-high High >1000 60-360

Compressionmolding

Mostthermoplas:cs,

somethermosets,


0.05-15 ±0.05-9.0 0.2-0.8 Low Medium-high High >1000 5-200


A_ributesofAddi8veManufacturing

Process Material PartDimensions PartComplexity

DimensionalAccuracy

Deposi:onRate Build-UpOn

SurfaceRoughness

(µm)

LayerThickness

LMD(LaserMetalDeposi:on)

Largematerialsdiversity

Limitedbythehandlingsystem Limited ≥0.1mm 3–10

mm3/s

3Dsurfaceandon

exis:ngparts

60-100

≥0.03–1mm

SLM(Selec:veLaser

Mel:ng)

Limitedandlowermaterials

diversity

Limitedbytheprocesschamber(φ250mm,height:

160mm)

Nearlyunlimited

≥0.1mm 1–3mm3/

s

Flatsurfaceandflatperforms

30-50

≥0.03–0.1mm

33

Addi%vemanufacturingProcessA_ributes

Source:Introduc:ontoAddi:veManufacturingTechnology–Aguidefordesignengineers,EuropeanPowderMetallurgyAssocia:on,2015,1stedi:on,pp.14.


Costes8ma8onsarecri8calfor:o Determiningwhethertomakeaninvestmenttoproduceaproductorpart,ortobuyitfromavendor(outsourcingdecision)

o Decidingifacompanyshouldprovideaquoteonaproductforsaletoanothercompany

o Alsocalledamake-versus-buyanalysis

34

BasicsManufacturingCostEs8ma8on


o Establishthebidprice,specifica:ons,quality,andengineeringrequirementsofaproductforaquota:onorcontract

o Verifyquota:onssubmiGedbysuppliers–typicallythreequotesifpossible

o Ascertainwhetheraproposedproductcanbemanufacturedandmarketedprofitably

o Providedataformake-versus-buydecisions

35

PurposeManufacturingCostEs8ma8on


o Helpdeterminethemosteconomicalmethod,process,andmaterialformanufacturingaproduct

o Provideatemporarystandardforproduc:onefficiencyandguideopera:ngcostsatthebeginningofaproject

o Supportevalua:onofdesignproposalso Comparedifferentconceptsofproductdesignsandmanufacturingprocesses

36

Purpose(cont.)ManufacturingCostEs8ma8on


Variablecosts:o Materials:rawmaterials,anyotherprocessconsumableso Energy:torunthemachineso Labor:directlaborthatgoesintoyourprocessFixedcosts:o Mainmachineandaddi:onalequipment:themainmachine(s)foryourprocess

o Tooling:thededicatedtoolingorfixturesthatarerequiredforyourprocess

o Building:thecostofthespacethathousesyouropera:onso Maintenance:thecostofkeepingequipmentrunning

37

SamplelistManufacturingCostDrivers


FixedCosts:(cont.)o Fixedoverhead:non-process-specificopera:ngcosts(e.g.,management,administra:on)

Produc8onmanagement:o Plantsupervisoro Plantadministratoro Plantengineero Qualitycontrolo Produc:oncontrol

38

Samplelist(cont.)OverheadCostDrivers

Otherunitsandadministrators:o Laboratoryo Healthandwork-safetydepartments

o Maintenanceo Plantsecurity


o Totalcost(TC)=Totalfixedcost(FC)+Totalvariablecost(VC)o Averagecosts:

o Averagecostistheper-unitcostofacomponent(thisisagoodmetrictocomparebetweendifferentprocessop:ons)

SeeModule3Aforamoredetailedcostanalysis

39

BasicsTotalCostCalcula8ons

Fixed costQuantity

FCAFCQ

= =

Variable costQuantity

VCAVCQ

= =

Total costQuantity

TCATCQ

= =


o Plas:cboGlesareproductsinwideuseonadailybasis—Let’sanalyzethecostsinvolvedintheirmanufacturingprocess

o Theproduc:onprocessinvolvesthefollowingsteps:

40

Example–Plas%cboWlesCostAnalysis

Injec:onMolding

StretchBlow

Molding


Allcalcula8onsfromhereonarebasedonthefollowingassump8ons:o Monthlyrentofproduc:onfacility=$8,000o Monthlyproduc:oncapacity=400,000boGleso Averagelife:meofmachines=10yearso Averagelife:meoftools=2yearso Produc:onperiod=1montho Produc:onquan:ty=400,000unitsNote:Averagelife:messource:NevadaDept.ofTaxa:on,PersonalPropertyManual2011–2012.Actualmachinelife:mesarelessthanstatedaboveduetocon:nuoustechnologicaladvancements

41

Example– Plas%cboWles(cont.)

Ini8alDataCollec8on


Injec8onMoldMachine:o TotalCost(TC)=$13,000o Salva:onCost=$1,000o DepreciableCost=TC–Salva:oncost=$12,000o ExpectedLife:me=10yearso MonthlyDeprecia:onPercent=100%ofitsvalue/numberofmonthsinlife(inthiscase10yearsX12monthsor120months.

Calcula%on:100%/120months=0.8334%deprecia:onpermontho MonthlyDeprecia:onValue=Deprecia:onCostsxDeprecia:onPercent

Calcula%on:$12,000x0.0834%=$10042


Deprecia8onCostCalcula8ons


Injec8onMolds:o TotalCost(TC)=$8,000o Salva:oncost=$200o DepreciableCosts=TC–Salva:oncost=$7,800o ExpectedLife:me=2yearso MonthlyDeprecia:onPercent=100%ofitsvalue/numberofmonthsinlife(inthiscase2yearsX12monthsor24months.


Calcula%on:$7,800x4.167%=$32543




BlowMoldingMachine:o TotalCost(TC)=$34,000o Salva:oncost=$4,000o DepreciableCosts=TC–Salva:oncost=$30,000o ExpectedLife:me=10yearso MonthlyDeprecia:onPercent=100%ofitsvalue/numberofmonthsinlife(inthiscase2yearsX12monthsor24months.


Calcula%on:$30,000x0.834%=$25044

Example–Plas%cboWles(cont.)



BlowMoldingMolds:o TotalCost(TC)=$4,000o Salva:oncost=$280o DepreciableCosts=TC–Salva:oncost=$3,720o ExpectedLife:me=2yearso MonthlyDeprecia:onPercent=100%ofitsvalue/numberofmonthsinlife(inthiscase2yearsX12monthsor24months.


Calcula%on:$3,720x4.167%=$15545




FixedCostType TotalCost(A)

%ApplicableforThisJob(B)

NetFixedCostforThisJob(A*B/100)

EquipmentInjec:onmoldingMachine $100 60% $60

StretchBlowMoldingMachine $250 100% $250

EquipmentSubtotal $310Tooling

Injec:onMolds $325 100% $325 BlowMoldingDies $155 100% $155

ToolingSubtotal $480 $480 Building $8,000 20% $1,600

Maintenance $3,000 20% $600

ManagementandAdministra:veOverheads

$4,000 20% $800

TotalFixedCostforThisjob $3,790

Note:Thebuildingmaybeusedtohouseothermanufacturingprocessesandofficeuses,therefore,can’tbecharged100%justforthisjob.Sameconceptmaybeapplicabletoothercostcategoriesaswell. 46

Example– Plas%cboWles(cont.)CostAnalysis


VariableCostType PerUnitCost(A)

Quan8tyProduced(B)

NetVariableCostforThisJob(A*B)

Material

RawMaterials $0.03 40,000 $1,200

Consumables $0.06 40,000 $2,400

MaterialsSubtotal $3,600

Labor $0.10 40,000 $4,000

Energy $0.05 40,000 $2,000

TotalVariableCost $0.24 $9,600

Example– Plas%cboWles(cont.)CostAnalysis

47


o Marginalcost(MC)istheincreaseinTCthatarisesfromanextraunitofproduc:on

o MChelpsanswerthefollowingques:on:Howmuchdoesitcosttoproduceanaddi:onalunitofoutput?

48


MarginalCosts

MarginalCost(MC)=ChangeinTotalCost(TC)

Changeinproduc8onquan8ty


Example– Plas%cboWles(cont.)MCcalcula8onsarebasedonthefollowingassump8ons(anychangesintheseassump8onswouldrequirenewcalcula8ons):o Produc:oncapacityofmachinesforcurrentu:liza:onrate(60%ofinjec:onmoldingmachineand100%ofblowmoldingmachine)is40,000units/month

o FCremainsthesameun:lthe40,000units/monthbecauseitiswithinthecurrentcapacity—  Ifproduc:onquan:tyismorethanthecurrentcapacity,newmachinesneedtobepurchased,whichwouldrequireaccoun:ngforthataddi:onalinvestmentinyourFC

o Thenewlyboughtmachinesandtheirtoolingwouldbeused100%forthisproductonly

o TheperunitrateforVCremainsthesameregardlessofproductquan:ty 49

MarginalCosts


o ThecalculatedTCfor40,000boGles/monthwas$13,390(row1)o Whenthisquan:tyisincreasedfrom40,000to45,000units,itrequirespurchasingnewmachines;therefore,MCincreases

o However,whenchangeisfrom45,000to80,000units,theaddi:onalFCisoffsetwiththeaddi:onalproduc:onvolume(TheMCthenreducesevenfurtherto$0.11/unit)

Note:TheFCcalcula:ontableformorethan40,000produc:onunitsisprovidedattheendofthismodule

Quan8ty FC VVC TC AverageTC MC

40,000 $3,790 $9,600 $13,390 $0.33 $0.24

45,000 $4,620* $10,800 $15,420 $0.35 $0.41

80,000 $4,620* $19,200 $23,820 $0.30 $0.11

50


MarginalCosts


o Thebreak-evenpointistheminimumquan:tyrequiredtomakeaprofitfrommanufacturing

o Itisthepointatwhichtheburdenoffixedcosts(FC)ismadeequaltotheprofitmadefromsellingaproduct

Formula8on:o TotalRevenue=sellingpricextotalquan:tysoldo TC=totalFC+totalVCAtthebreak-evenpoint:o TotalRevenue=TCo SPxQ=FC+VCxQo Q=FC/(SP-VC)

51

BasicsBreak-EvenAnalysis


o Thebreak-evenpointistheminimumquan:tyrequiredtomakeaprofitfrommanufacturing

o Itisthepointatwhichtheburdenoffixedcosts(FC)ismadeequaltotheprofitmadefromsellingaproduct

Formula8on:o TotalRevenue=sellingpricextotalquan:tysoldo TotalCost(TC)=totalFixedCost(FC)+totalVariableCost(VC)AttheBreak-Even(BE)point:o TotalRevenue=TCo BEiswhenSalePrice(SP)xQuan:ty(Q)=FC+VCxQo BreakEvenQuan:tate=FC/(SP-VC)

52

BasicsBreak-EvenAnalysis


Quan8ty FC($) VC($) TC($) TotalRevenue($) Profit($)

0 $3,790 $0 $3,790 $0 $-3,790

1,000 $3,790 $240 $4,030 $500 $-3,520

10,000 $3,790 $2,400 $6,190 $5,000 $-1,190

20,000 $3,790 $4,800 $8,590 $10,000 $1,410

30,000 $3,790 $7,200 $10,990 $15,000 $4,010 53

ExampleBreak-EvenAnalysis

o IfSP=$0.50,o TotalRevenue=SPxQ=$0.50xQ

o Break-EvenPoint=0.5xQ=3,790+0.24xQQ=3,790/(0.5–0.24)Q≈14577

o TC=FC+VCxQ=3,790+0.24xQ


Selec8ngthebestmanufacturingprocessforagivencomponentdependsonseveralfactorssuchasthefollowing:o Materialselec:ono Finalshapeandappearanceo Desiredtoleranceandsurfacefinisho Designrequirementso Toolingcosto Productmarketprice(ifitisacommodityproduct)o Safetyandenvironmentalconcerns

54

ManufacturingProcessSelec8on


55

FlowchartManufacturingProcessSelec8on

Product design specifica1ons (Engineering drawings, parts lists, any

specific customer requirements)

Manufacturing requirements (Surface finish, tolerance, special treatments, tooling)

Analyze processing factors from material selected, manufacturing requirements and geometry

to iden1fy poten1al manufacturing process class (e.g. machining, cas1ng, forming, etc.)

List of suitable processes

More than one suitable process?

Financial analysis (Piece cost, capital

cost, breakeven analysis)

Select the final process

Geometry (Shape, size,

weight, features, threads)

Material specifica1ons

(Material type, grade, proper1es)

Select the available process

Review process aKributes tables to iden1fy a specific set of processes within the poten1al process class (e.g. turning, milling, hot

forging, etc.)

Yes No


o Understandcustomer(ordesign)requirements— Conductmaterialsanalysis— Conductcomponentgeometryanalysis(shape,size,featureslikethreading,holes,etc.)

— Processparametersormanufacturinginforma:onanalysis(tolerance,surfacefinish,volumeneeded,etc.)

o Analyzecri:calprocessingfactors— Determinecri:calprocessingfactorsbasedoncomponentgeometry,materialsselec:on,andmanufacturinginforma:on

o ReviewprocessaGributes— ComparethecandidateprocesseswithrespecttoprocessingfactorsbyusingprocessaGributestables

o Iden:fyasuitableprocess— Financialanalysis:compareaveragecostperunitforvariousprocessop:ons

56

KeystepsManufacturingProcessSelec8on


57

PartgeometryManufacturingOp8ons

Shape/Features Produc8onMethod

Flatsurfaces Rolling,planning,broaching,milling,shaping,grinding

Partswithcavi:es Endmilling.Electrical-dischargemachining,electrochemicalmachining,ultrasonicmachining,cast-incavity

Partswithsharpfeatures Permanent-moldcas:ng,machining,grinding,fabrica:ng

Thinhollowshapes Slushcas:ng,electroforming,fabrica:ng

Shapingoftubularparts Rubberforming,expandingwithhydraulicpressure,explosiveforming,spinning

Curvatureonthinsheets Stretchforming,peenforming,fabrica:ng

Openingsinthinsheets Blanking,chemicalblanking,photochemicalblanking

Reducingcross-sec:ons Drawing,extruding,shaving,turning,centerlessgrinding

ProducingSquareedges Fineblanking,machining,shaving,beltgrinding

Producingsmallholes Laser,electrical-dischargemachining,electrochemicalmachining

Producingsurfacetextures Knurling,wirebrushing,grinding,beltgrinding,shotblas:ng,etching

Detailedsurfacefeatures Coining,investmentcas:ng,permanentmoldcas:ng

Threadedparts Threadcuing,threadrolling,threadgrinding,chasing

Verylargeparts Cas:ng,Forging,fabrica:ng

Verysmallparts Investmentcas:ng,machining

Partswithholes,and/orthreads Drilling,Reaming,Boring,Tapping,Countersinking

Source:AdaptedfromSwieandBooker(2015)


58

Casestudy–BaseplateassemblyforelectricmotorSchema8c


59

Casestudy– Baseplateassemblyforelectricmotor(cont.)

EngineeringDrawing


60

ExampleEngineeringDrawing

o Anengineeringdrawingshouldaccuratelystatethegeometricfeaturesofaproductoritscomponents.

o Thegoalistoclearlydefinerequirementsinaccordancewithconven:onsforlayoutnomenclature,size,etc.toenableitsproduc:on.

o Thiscaninclude(notlimitedto):— Billofmaterial— Generalnotes— Materialspecifica:ons— Drawingoriginandversion— Mul:pleview— Holespecifica:ons

Enlargedonnextpage


61

Example– Interpre%ngtheblueprintEngineeringDrawing


62

Casestudy– Baseplateassemblyforelectricmotor(cont.)

EngineeringSpecifica8ons

PartNumber PartName Descrip8on

Dimensions(mm)

(LxBXH)

Tolerance

SurfaceFinish(µm)

Quan8ty

AnySpecial

Features?

UCP211-AST PILLOWBLOCKBEARING

AST-METRICSERIES 219x60x125 8–28µm 0.8 1 N.A.

3GAA103001-BSE

ELECTRICMOTOR

ABB-M2AA100L61.5KW

351x200x237 ±0.5mm 0.8 1

N.A.

91292A241 SOCKETHEADSCREWS MCMASTER-CARR

M16x2mmThread,45mmlong

-- -- 2 N.A.

91292A274 SOCKETHEADSCREWS MCMASTER-CARR

M20x2.5mmThread,45mmlong

-- -- 4 N.A.

7493250BEARING

MOUNTINGPAD

MACHINEDANDFABRICATED

312.5x100x312.5 ±0.015mm 0.8 1

2HoleswithØ16dia

20mmdeep

7493251 BASEFRAME MACHINEDANDFABRICATED 400x300x50 ±0.25mm 0.8–

12.5 1 N.A.

7493252 MOTORSHAFT MACHINEDANDFABRICATED

Ø55diam770length ±0.015mm 0.8 1

N.A.


1.  Understanddesignrequirements2.  Analyzecri:calprocessingfactors3.  Reviewrelevantprocess-aGributestables4.  Iden:fysuitableprocesses

63

Step-by-step–Howtoselectasuitableop%onManufacturingProcessSelec8on


o Therearethreepartsthatneedtobemachinedorfabricated,whichincludebearingmoun:ngpad,baseframe,andmotorshae

o Componentmaterials:alllow-carbonsteelo Componentshapes:

— Moun:ngpadandbaseframehaveflatsurfaceswithrectangularshapes— Motorshaehasroundsurface

o Specialmanufacturingfeatures:twoholesonbearingmoun:ngpad

o Manufacturingrequirements:— Designtolerancesrangefrom8–28micrometers,andsurfacefinishisalsointherangeof8–12.5micrometersforallpartsincludingholes

— Motorshaeneedstobehardenedtowithstandthetorsionalstress64

Step1-UnderstanddesignrequirementsManufacturingProcessSelec8on


Basedonthegeometry,material,andmanufacturingrequirementsmen8onedinStep1,theini8alprocessrequiredmustsa8sfythefollowingcriteria:o Besuitabletomachinelow-carbonsteelo Beabletoproduceaflatsurfaceandrectangularshapeso Beabletoproducearoundsurfacewithadiameterof55mmo Beabletomeetthegeneraldimensionaltoleranceof+/-8micrometers(µm)

o Beabletomeetthesurfacefinishrequirementsof12.5µmo Beabletoproduceholeswiththeabove-men:onedtoleranceof+/-8µm

65

Step2-Analyzecri%calprocessingfactors



Basedonthegeometry,material,andmanufacturingrequirementsmen8onedinStep1,theini8alprocessrequiredmustsa8sfythefollowingcriteria:(cont.)o Beabletoeconomicallyproduceinbatchesof100(assumed)(Itisalsoassumedthattheshapeoftherawmaterialwillbeflat)

o Beabletomeetthespecificdimensionalandgeometrictolerancesstatedonthedrawing

o Beabletoimprovethehardnessofmotorshae

Basedontheserequirements,theini%alcandidateprocessesarebroachingormillingforflatsurfaceofmoun%ngpadandbaseframe,turningforthemotorshaG,anddrillingaholeonthe

moun%ngpad66

Step2-Analyzecri%calprocessingfactors(cont.)



67

Step3-Reviewrelevantprocess-aWributestables


o ReviewingthemachiningprocessaGributestables(S27-28;seerelevantrowsbelow),allfourprocessescanmeetgeneraltoleranceandsurface-finishrequirements

Note:Althoughbroachingandmillingcanproduceflatsurfaces,theirproduc:onratesandcoststructuresaredifferent(Broachinghasahigherproduc:onrateandcanachieve:ghtertolerancesthanmilling,butitisalsomoreexpensivethanthemillingopera:on)

Process Material SizeRange Tolerance(mm)

SurfaceFinish(µm)

CostsEOQ Produc:on


Turning Allexceptsomeceramics <φ3000mm ±0.05 0.025-25 High Low Medium 1+ 1-50

Milling Allexceptsomeceramics <1000mm2 ±0.1 0.2-25 Medium-high Medium Medium-high 1+ 1-100

Drilling Allexceptsomeceramics <φ250mm ±0.05 0.8-12.5 Low-medium Low Low-medium 1+ 10-500

Broaching Allmetals 25mm–3mlong ±0.005 0.4-6.3 Low-high High Low-Medium 1+ 1-400

Grinding Allmetals<φ0.5mm-

2m6mlong

±0.005 0.025-6.3 Low-high Medium Medium-high 1+ 1-100


Basedonthereviewoftheprocess-a_ributestable,thefollowingprocessesarerecommendedforthegivenjobs:o Bearingmoun:ngpad:Millingforflatsurface,drillingforholeo Baseframe:Millingforflatsurfaceo Motorshae:Turningfordiameterorroundsurface,surfacehardeningandgrindingtomeetthehardnessandtolerancerequirementsrespec:vely.

Note:Althoughbroachingoffersagreaterproduc:onrateandcanproduce:ghtertolerance,thedesiredproduc:onquan:tycanbeachievedalongwiththerequiredtoleranceandsurface-finishspecifica:onswithlowerinvestments.Therefore,millingisrecommendedoverbroachingforproducingtheflatsurfaces.However,iftherearemoreop:onswithlessobviouschoices,onecancalculatetheaverageTCfortheop:onusingthemethodsdescribedpreviouslytodeterminethelowestcostop:on.

68

Step4-Iden%fysuitableprocesses



o TurninghGps://v.ecdn.net/01/07/59/25/700_F_107592507_IsVzgls5saZIPa1AeP6EuM3yWQLEx5N5_ST.mp4

o MillinghGps://v.ecdn.net/01/34/51/13/700_F_134511365_G546DqFEsvnob4P5lGUbBkLdrSgNjNWp_ST.mp4

o DrillinghGps://v.ecdn.net/01/27/58/86/700_F_127588642_XTAt07UoBr1tvEuhD6lRE5WqhAkwXExu_ST.mp4

o GrindinghGps://v.ecdn.net/00/36/97/31/700_F_36973197_XNCHEwNjD1WtIhTYRLr0PD�wd2CGvqd_ST.mp4

o 3Dprin:nghGps://v.ecdn.net/01/44/42/33/700_F_144423391_TXIBLUFKu2fN2mfuRRAtkonzN8HCdlGw_ST.mp4

69

Resources


o Cas:nghGps://www.youtube.com/watch?v=LmjAQGvSrF0

o RollforminghGps://www.youtube.com/watch?v=uGEYZHriKZk

o Injec:onmoldinghGps://www.youtube.com/watch?v=b1U9W4iNDiQ

o ForginghGps://www.youtube.com/watch?v=hSUp-e7zu0g

o ThreadinghGps://www.youtube.com/watch?v=9IvWuXjCVbg

o ReaminghGps://v.ecdn.net/00/79/23/02/700_F_79230212_xsxgXmVD3ORY5eL0igojeUhqpYb5OloC_ST.mp4

o BoringhGps://v.ecdn.net/01/07/57/45/700_F_107574502_9ADKfORVouLtVKOLtV3V62rTDDsFlXhl_ST.mp4

o DrillingboringreaminghGps://www.youtube.com/watch?v=ZGU1zP7KPbY

70

(cont.)

Resources


o CountersinkinghGps://www.youtube.com/watch?v=kLbX8ISF5UA

o ElectricaldischargemachininghGps://www.youtube.com/watch?v=kSIFiWSRpBw

o SheetmetalstampinghGps://www.youtube.com/watch?v=Fid1r3tG538

o Wire+arcAmhGps://youtu.be/_WrhWf9XLHM

o ShapinghGps://youtu.be/Omsyy-RiaqU

o PlaninghGps://www.youtube.com/watch?v=W8-_9ziKiao

o SloinghGps://www.youtube.com/watch?v=hE2aKmINlU4

71

(cont.)Resources


Fixedcostforproduc%onover40000unitsAppendix–Slide51Follow-Up

72

FixedCostType TotalCost(A) %ApplicableforThisJob(B)

NetFixedCostforThisJob(A*B/100)

EquipmentInjec:onMoldingMachine1 $100 60% $60

StretchBlowMoldingMachine1 $250 100% $250

Injec:onmoldingMachine2 $100 100% $100

StretchBlowMoldingMachine2 $250 100% $250

EquipmentSubtotal $660Tooling

Injec:onMolds1 $325 100% $325

BlowMoldingDies1 $155 100% $155

Injec:onMolds2 $325 100% $325

BlowMoldingDies2 $155 100% $155

ToolingSubtotal

Building $8,000 20% $1,600 Maintenance $3,000 20% $600

ManagementandAdministra:veOverheads

$4,000 20% $800

TotalFixedCostforThisjob $4,620

Glossary

Module 3C

Engineering Validation measures and analyzes the process, audits and calibrates equipment and creates a document trail that shows the process leads to a consistent result to ensure the highest quality products are produced. (Repeat from 2C)

Design Validation is testing aimed at ensuring that a product or system fulfills the defined user

needs and specified requirements, under specified operating conditions. (Repeat from 2B)

Development is the systematic use of scientific and technical knowledge to meet specific

objectives or requirements. (Repeat from 2B)

Manufacturing Development or Engineering & Manufacturing and Development (EMD)phase is

where a system is developed and designed before going into production. (Repeat from 2B)

Molding Process is the process of manufacturing by shaping liquid or pliable raw material using

a rigid frame called a mold or matrix.

Make-Versus-Buy Analysis calculates the benefits between manufacturing a product in-

house or purchasing it from an external supplier.

Total Cost (TC) describes the total economic cost of production and is made up of variable

costs, which vary according to the quantity of a good produced and include inputs such as labor

and raw materials, plus fixed costs, which are independent of the quantity of a good produced

and include inputs (capital) that cannot be varied in the short term, such as buildings and

machinery. (Repeat from 3A)

Total Fixed Cost (FC) are business expenses that are not dependent on the level of goods or

services produced by the business. (Repeat from 3A)

Total Variable Cost (VC) is costs that change in proportion to the good or service that a

business produces. (Repeat from 3A)

Marginal Cost (MC) is the change in the opportunity cost that arises when the quantity

produced is incremented by one unit, that is, it is the cost of producing one more unit of a

good.

Break-Even (BE) Point is the point at which total cost and total revenue are equal. (Repeat from

3A)

http://www.getreskilled.com/what-is-a-validation-engineer/

http://www.businessdictionary.com/definition/design-validation.html

http://www.businessdictionary.com/definition/development.html

http://acqnotes.com/acqnote/acquisitions/emd-phase

https://en.wikipedia.org/wiki/Molding_(process)

https://www.investopedia.com/terms/m/make-or-buy-decision.asp

https://en.wikipedia.org/wiki/Total_cost

https://en.wikipedia.org/wiki/Fixed_cost

https://en.wikipedia.org/wiki/Variable_cost

https://en.wikipedia.org/wiki/Marginal_cost

https://en.wikipedia.org/wiki/Break-even_(economics)#Construction

Design for Manufacturing, Assembly, and Reliability · PDF fileo Learning objec:ves o What this module addresses ... 12 Manufacturing ... • The process uses welding wire as feedstock

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