Manufacturing Processes for Engineering

Kalpakjian, Manufacturing Processes for Engineering Materials © 1997 Addison Wesley Page 1-1

CHAPTER 1

Introduction

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What is manufacturing?

- Manufacturing:In its broadest sense, the process of converting raw materials into products, consisting of the design and making of goods, using various production methods and techniques

- Automobile has about 15,000 parts,C-5A transport plane more than 4 M parts

Boeing 747-400 6M parts.

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- Origin: Manu factus (made by hand) in Latin

- Manufacture was initially used in 1567 andmanufacturing appeared in 1683

- Manufacturing in U.S.A. andProduction Engineering in E.U. and Japan

- Discrete products or Continuous products

- Value addedness

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- Meet design requirements and specifications

- Produced by the most economical ways

- Quality

- Flexibility of the processes

- Require new materials, production methods, and computer integration

- Reviewed as a large system

- Strive for higher Productivity

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The design process and concurrent engineering

Design process:

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- Concurrent engineering is a systematic approach integrating the design and manufacture of products with the view of optimizing all elements involved in the life cycle of the product.

- Direct engineering utilizes a database representing the engineering logic used in the design of each part of a product. If a design modification is made on a part. DE will determine the manufacturing consequences of that change.

- CAD, CAE, CAM, and Rapid prototyping

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Design for manufacture and assembly

- DFM is a comprehensive approach to production of goods and integrates the design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance.

- DFA and DFD – 3-D conceptual designs and solid models.

- Design for manufacture and assembly.

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Selecting materials

- Ferrous materials (carbon steels, etc)

- Nonferrous materials (aluminium, magnesium, copper, titanium alloys, etc.)

- Plastics (thermoplastics, thermoset, and elastomers)

- Ceramics, glass ceramics, glasses, graphite, diamond

- Composite materials (reinforced plastics, metal-matrix and ceramic-matrix composites, and honeycomb structures)

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- Properties of materials

- Cost and availability

- Appearance, service life, and recycling

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Selecting manufacturing processes

- Casting

- Forming and shaping

- Machining

- Joining

- Finishing

Dimensional and surface finish considerations.

Operational and manufacturing cost considerations.

Consequences of improperly selecting materials and

processes.

Net-shape manufacturing.

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Computer-integrated manufacturing

- Machine control systems: NC, CNC,AC, automated handling of materials,industrial robots

- Computer technology: CIMCAD, CAM, CAPP, GT, FMS, JIT, AI,Expert System, Neural Network,Shared manufacturing

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Quality assurance and total quality management

- Quality must be built into a product – from design stage through all subsequent stage of manufacture and assembly. Control the processes and not products.

- Total quality management (TQM) and quality assurance

- Statistical process control (SPC)

- Experimental design

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Global competitiveness and manufacturing costs

- The design should be as simple as possible to manufacture, assemble, and recycle.

- Materials should be chosen for the appropriate manufacturing characteristics.

- Dimensional accuracy and surface finish specified should be as broad as permissible.

- Because they can add significantly to cost, secondary and finishing processing of parts should be avoided or minimized.

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Lean production and agile manufacturing

- Lean production or lean manufacturing involves a major assessment of each of a company’s activities.

- Agile manufacturing ensures flexibility in the manufacturing enterprise so it can quickly respond to changes in product demand and customer needs.

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Environmentally conscious design and manufacturing

- Reducing waste of materials at their source by refinements in product design and reducing the amounts of materials used.

- Conducting R&D in environmentally safeproducts and manufacturing technologies.

- Reducing the use of a hazardous materials in products and processes.

- Ensuring proper handling and disposal of all waste.

- Making improvements in recycling, waste treatment, and reuse of materials.

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Product liability

- The aspects that deal with product safety and the resource a customer has if and when a product is defective.

- Protection strategy for legal and technical aspects for the consequence of using a product that has malfunctioned, causing bodily injury, or even death, and financial loss to a person or organization.

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Organization for manufacture

- View the people in the organization as important assets.

- Emphasize the important and need for teamwork and involvement in problem solving and decision-making processes in all aspects of operations.

- Encourage product innovation and improvements in productivity.

- Encourage efforts for continuous improvement in quality

- Increase flexibility of operation for faster response to product demands in both the domestic and global marketplace

- Ultimately and most importantly, focus on customer satisfaction