Manufacturing Processes for Engineering Materials

(5th Edition in SI Units)

Chapter 1: Introduction

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

What is Manufacturing?
Manufacturing is the process of converting raw materials into products. Nations with largest GDP growth concentrated on high value-added products, such as automobiles and machinery. Labour intensive products such as clothing and toys are concentrated in countries where labour rates are lower.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Product Design and Concurrent Engineering

Traditionally design and manufacturing activities have taken place sequentially. Design process requires a clear understanding of the functions and the performance expected of that product.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Product Design and Concurrent Engineering

Concurrent or simultaneous engineering is a systematic approach integrating the design and manufacture of products. It optimizes all elements involved in the life cycle of the product.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Design for Manufacture, Assembly, Disassembly & Service

Design for manufacture (DFM) integrates product design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance. Assembly is an important phase of the overall manufacturing operation.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Environmentally Conscious Design, Sustainable Manufacturing & Product Life Cycle

Design for recycling (DFR) and Design for the environment (DFE) anticipates the negative environmental impact during initial stages of design. The basic guidelines for sustainable manufacturing are: 1. Reducing waste of materials 2. Reducing use of hazardous materials 3. Proper disposal of all waste 4. Improvements in waste treatment and in recycling

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Environmentally Conscious Design, Sustainable Manufacturing, & Product Life Cycle

Product Life Cycle (PLC) Consists of the stages that a product goes through to its ultimate disposal and recycling. Product Life Cycle Management (PLCM) It is defined as the strategies employed by the manufacturer as the product goes through its life cycle.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Selecting Materials
The following are the factors in selection of materials: 1. Material Substitution 2. Material Properties 3. Cost and Availability 4. Service Life and Recycling

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Selecting Manufacturing Processes

Processing methods for materials can be listed as follows: Casting Forming and shaping Machining Joining Micromanufacturing and nanomanufacturing Finishing

1. 2. 3. 4. 5.

6.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Selecting Manufacturing Processes

Part Size and Dimensional Accuracy Size, thickness and shape complexity of a part have a major bearing on the process selected.

The size and shape of manufactured products also vary widely.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Selecting Manufacturing Processes

Manufacturing and Operational Costs Lead time required to begin production and the tool and die life are of major importance. Quantity of parts and production rates determine the processes that are used and the economics of production. Net-Shape Manufacturing Additional finishing operations might be needed for finished parts or products to desired specifications
Chapter 1: Introduction Manufacturing Processes for Engineering Materials
2008 Pearson Education South Asia Pte Ltd

Computer-Integrated Manufacturing
Computer-integrated manufacturing has the capability for: 1. improved responsiveness to demand and product modification 2. better use of materials and resources 3. better control of manufacturing operation 4. manufacturing of high quality products at a lower cost

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Computer-Integrated Manufacturing
Some examples: 1. Computer numerical control (CNC) 2. Adaptive control (AC) 3. Industrial robots 4. Automated handling 5. Automated and robotic assembly systems 6. Computer-aided process planning (CAPP) 7. Group technology (GT) 8. Just-in-time production (JIT)
Chapter 1: Introduction Manufacturing Processes for Engineering Materials
2008 Pearson Education South Asia Pte Ltd

Lean Production and Agile Manufacturing

Lean production or lean manufacturing involves 1. assessment of each activity regarding the efficiency and effectiveness of its operations 2. efficiency of the machinery and equipment used in the operation 3. number of personnel involved in a particular operation 4. thorough analysis to reduce cost of each activity Agile manufacturing is ensuring flexibility in manufacturing so that it can respond to changes in demand and customer needs.
Chapter 1: Introduction Manufacturing Processes for Engineering Materials
2008 Pearson Education South Asia Pte Ltd

Quality Assurance and Total Quality Management

Product quality influences the marketability of a product and customer satisfaction. Product integrity is defined by the degree to which a product is suitable for its purpose, market need, life expectancy and ease of use. Human-factors engineering and ergonomics are also important in the design and manufacture of safe products.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

Manufacturing Costs and Global Competitiveness

Cost of a product is taking into consideration the products marketability and customer satisfaction. 1. 2. 3. 4. Major impact on manufacturing includes: Global competition Market conditions fluctuated widely Customers demand Product complexity

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd

General Trends in Manufacturing

Materials The trend is for better control of material overall properties while keeping costs low. Processes, Equipment, and Systems. A major impact on the efficiency and reliability of all manufacturing processes and equipment.

Chapter 1: Introduction Manufacturing Processes for Engineering Materials

2008 Pearson Education South Asia Pte Ltd