Chapter 1 Overview of Manufacturing Processes and Technology

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OVERVIEW
Sustainable manufacturing
3
Role of manufacturing
in nation’s economy
2 4 Industrial revolution and

virtual manufacturing
5 Competitiveness aspects in
Introduction to
manufacturing
1 manufacturing processes
(Reference: Kalpakjian, 5th Edition) 1
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1 What is manufacturing?
the process of converting raw materials into products
Also involves activities in which the manufactured product itself, is used
to make other products e.g., sewing machine to make clothing.
Manufacturing is a complex activity involving variety of resources and activities viz.:

1. Product design
2. Machinery and tooling
3. Process planning
4. Materials
5. Production control
6. Support services
7. Marketing etc…
3
1 What is essential in manufacturing?
DESIGN REQUIREMENT, ECONOMICAL & QUALITY FLEXIBLE MATERIALS,

PRODUCTS ENVIRONMENTALLY PRODUCTION
SPECIFICATIONS & FRIENDLY METHODS &
STANDARD COMP.
INTEGRATION
SYSTEM CONTINUOUS PRODUCTIVITY

4
PRODUCT
IMPROVEMENT
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1 Types of Production
1. Low‐Quantity Production @ Job shop production
1‐100 units/year
e.g aircraft, ship
2. Medium‐Quantity Production @ Batch production
100‐10 000 units/year
e.g team jersey
3. High‐Quantity Production @ Mass production
10 000‐millions units/year
e.g car 5
1
Product Life Cycle
A well designed product are:
1. Functional (design)
2. Well manufactured (production)
3. Well packaged (arriving safely to the customer)
4. Durable (function effectively for its intended purpose)
5. Maintainable
6. Resource efficient (can be disassembled for recycle)
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1 Design for X
1. Design for Manufacture (DFM)
Integrates process with materials, mfg methods, process
planning, assembly, testing & quality assurance
2. Design for Assembly (DFA) & disassembly
Easy to assemble & disassemble the product
3. Design for Service/Maintenance
Individual parts @ sub‐assemblies in a product can easily reach
for service or maintenance
4. Design for Manufacture & Assembly (DFMA)
Correlation between mfg of component & their assembly into
final product
Product design process & concurrent
1
engineering
Product design:
A critical activity since 70‐80% of the cost of the product development &
manufacture is determined by the decision made in the initial design stage.
The design of a product first requires a thorough understanding of the function

and the expected performance of the product
Product design involves constructing & studying analytical models using product
design tools:
CAD CAE CAM
technology concerned
technology concerned
with the use of computer technology concerned
with the use of computer
systems to assist in with the use of computer
systems to plan, manage
creation, modification, systems to analyze CAD 8
& control manufacturing
analysis, and geometry
operations
optimization of a design
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1 Product design process & concurrent
engineering
concurrent engineering = simultaneous engineering
An approach where all discipline are involved in the early design stage so the
iteration result in less wasted effort and time. Integrates the design &
manufacture of a product with a view toward optimizing all elements involved in
life‐cycle of a product
Key: well organized communication within various discipline
Concurrent engineering reduces:
1.Changes in product design & engineering (enhance quality & productivity)
2.Time & cost from design concept to marketplace (faster time to market & 9
competitiveness advantage)
Product design process & concurrent
engineering
1
(Left) Chart showing various steps
involved in design and manufacturing
a product. Depending on the
complexity of the product and the
type of materials used, the time span
between the original concept and the
marketing of a product may range
from a few months to many years,
(Right) Chart showing general product
flow in concurrent engineering, from
market analysis to selling the product
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Selection of Materials and Process
1
Factors to be consider in material Factors to be consider in process selection
1. Selection of processing method
selection
2. Dimensional accuracy
1. Properties of materials
3. Operational & mfg cost
2. Cost & availability 4. Net‐shape mfg:
3. Appearance, service life & the first operation is made near to the
recycling desired product as possible
Consequences of improper selection of materials & processes
a. stop functioning
b. not function properly 11
c. unsafe for further use
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Example of Process Selection (1)
1
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1
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1 Example of Process Selection (4)
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2 Role of Manufacturing in Nation’s Economy
Gross National Product (GNP) is the market value of all goods and services
produced in one year by labour and property supplied by the residents of a country
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Industrial Production Index
(IPI) is a measure of the rate
of change in the production
of industrial commodities in
real terms over time for
Manufacturing, Mining and
Electricity Sectors.
It is measured based on
volume changes in
production.
IPI give the overview of the
current trend of industrial
activities and used for
economic analysis.
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3 2
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https://sustainabledevelopment.un.org/sdgs
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Target & Indicator please refer to: https://sustainabledevelopment.un.org/sdg9
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Target & Indicator please refer to: https://sustainabledevelopment.un.org/sdg12
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3 Sustainable Manufacturing (SM)
Can be defined as a method for manufacturing that minimises waste and reduces
the environmental impact.
should integrate sustainable activities at all levels of manufacturing – product,

process and system
Key Benefits from Sustainable Manufacturing
• Lower Resource and Production Costs
• Lower Regulatory Compliance Costs
• Improved Sales and Brand Recognition
• Greater Access to Financing and Capital
• Easier Employee Hiring and Retention 26
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3 Sustainable Manufacturing (SM)
Why companies are pursuing sustainability:
• Increase operational efficiency by reducing costs and waste
• Respond to or reach new customers and increase competitive advantage
• Protect and strengthen brand and reputation and build public trust
• Build long‐term business viability and success
• Respond to regulatory constraints and opportunities
Ways that companies progress further on the path to sustainability include:
• Address sustainability in a coordinated, integrated and formal manner, rather than in an
ad hoc, unconnected and informal manner
• Focus on increased competitiveness and revenues rather than primarily focusing on cost‐
cutting, risk reduction and improved efficiency
• Use innovation, scenario planning and strategic analysis to go beyond compliance
• Integrate sustainability across business functions 27
• Focus more on the long term
• Work collaboratively with external stakeholders
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3 Tool to implement SM
Tool used: the Life Cycle Assessment (LCA)
An approach to examine fully the environmental impact of different activities performed.
Steps in LCA:
1 Define appropriate scope
2
Develop a quantitative analysis of the material and energy
inputs to the product or process at all levels
3 Relate the outputs of the system at each stage to direct

impact on the external world
4 Make recommendations from the findings obtained in step 1‐3
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3 SM Approach
Increase circularity in manufacturing to reduce utilization of resources so
that less material is extracted from earth
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3 Activities introduced to achieve SM
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https://www.industr.com/en/sustainable-manufacturing-
principles-applications-and-directions-2333598
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Environmentally Conscious Design And
3
Manufacturing
Process/ manufacturing activities that cause harm to the environment
1. Lubricants & coolant for machining
2. Various fluids & solvent used in cleaning
3. By‐products from manufacturing plant e.g. water, oil from heat‐
treating facilities
4. Metallic and non‐metallic scrap
MAJOR CONCERN: water and air pollution, acid rain, ozone depletion
the greenhouse effect, hazardous wastes and global warming.
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3 Environmentally Conscious Design And
Manufacturing
Certain guidelines can be followed to reduce the risk:
1. Reducing waste of materials, by refinements in product design and reducing
the amount of materials used.
2. Reducing the use of hazardous materials in products and processes.
3. Conducting research and development into environmentally safe products
and into manufacturing technologies.
4. Ensuring proper handling and disposal of all waste.
5. Making improvements in recycling, waste treatment, and reuse of
materials.
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Environmentally Conscious Design And
3
Manufacturing
Design for the Environment (DFE) or green design.
Anticipates the possible adverse environmental impact of materials,
products, and processes, so that it can be taken into account at the
earliest stages of design and production.
Main objectives : to prevent pollution at the source and to strongly
promote recycling and reuse instead of disposal.
These goals led to the concept of design for recycling (DFR).
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4 Industrial Revolution
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Computer Integrated Manufacturing
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(CIM)
Extending the use of computers by integrating the hardware and software from
production concept through product distribution in market.
CIM Capability:
1. Responsive to rapid changes in market demand and product modifications.
2. Better use of materials, machinery, personnel and reduction in inventory
3. Better control of production and management of the total manufacturing
operation.
4. The manufacture of high‐quality products at low cost
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Computer Integrated Manufacturing
4
(CIM)
Major applications of computers in manufacturing
1. Computer numerical control (CNC)
A method of controlling the movements of machine components by
direct insertion of coded instructions in the form of numerical data
2. Adaptive control (AC)
Parameters in a manufacturing process are adjusted automatically to
optimize production rate and product quality, and to minimize cost.
3. Industrial robots
Replacing humans in operations that are repetitive, dangerous, and
boring, thus reducing the possibility of human error, decreasing
variability in product quality, and improving productivity.
4. Automated handling of materials
Handling of materials and components in various stages of
completion (work in progress).
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4 Computer Integrated Manufacturing
(CIM)
5. Computer‐aided process planning (CAPP)
Improving productivity by optimizing process plans, reducing planning
costs, consistency of product quality and reliability, cost estimating and
monitoring of work standards (time required to perform certain operation)
6. Group technology (GT)
Parts are grouped and produced by classifying them into families,
according to similarities in design and the manufacturing processes.
7. Just‐in‐time production (JIT)
8. Cellular manufacturing (CM)
Utilizes workstations (manufacturing cells) that usually contain several
production machines controlled by a centre; robot, each machine
performing a different operation on the part.
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4 Computer Integrated Manufacturing
(CIM)
9. Flexible manufacturing systems (FMS)
Integrate manufacturing cells into a large unit, all interfaced with a
central computer. Efficiently producing parts in small runs and changing
manufacturing sequences on different parts quickly; this flexibility
enables them to meet rapid changes in market demand for all types of
products.
10. Expert systems (ES)
Complex computer programs and have the capability to perform various
tasks and solve difficult real‐life problems much as human experts would.
11. Artificial intelligence (AI)
Involves the use of machine and computers to replace human
intelligence. Computer‐controlled system are capable of learning from
experience and of making decisions that optimize operations and
minimize costs.
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4 Industrial Revolution 4.0 (IR4.0)
• Industry 4.0 is related to what is called the “smart factory”
(Dutton, 2014).
• In a smart factory, a virtual copy of the physical world and
decentralized decision making can be developed (Buhr, 2015).
Also, physical systems can cooperate and communicate with each
other and with humans in real time, all enabled by the IoT and
related services.
• The concept of Industry 4.0 has its origins in Germany and has
been recognized by other leading industrial nations, although it is
known as “Connected Enterprise” in the United States and the
“Fourth Industrial Revolution” in the United Kingdom.
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4 Industrial Revolution 4.0 (IR4.0)
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4 Virtual Technology
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4 Virtual Technology
Virtual reality (VR) implies a complete immersion experience that shuts out the
physical world. Using VR devices such as HTC Vive, Oculus Rift or Google Cardboard,
users can be transported into a number of real‐world and imagined environments
such as the middle of a squawking penguin colony or even the back of a dragon.
Mixed Reality (MR)
MR brings together real world and digital elements. In mixed reality, you interact with
and manipulate both physical and virtual items and environments, using next‐generation
sensing and imaging technologies. Mixed Reality allows you to see and immerse yourself
in the world around you even as you interact with a virtual environment using your own
Augmented reality (AR) adds digital elements to a live view often by using the camera
on a smartphone. Examples of augmented reality experiences include Snapchat lenses
and the game Pokemon Go.
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4 Importance of Virtual Technology
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4 Applications of Virtual Technology
• Healthcare—For training, such as for surgical simulations
• Film and TV—For movies and shows to create unique
experiences
• Virtual travel—For virtual trips to an art museum—or
another planet—all from home
• Professional sports—For training programs like STRIVR to
help pro and amateur athletes
• Gaming—For over 1,000 games already available, from
first‐person shooters to strategy games to role‐playing
adventures
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4 Virtual Technology in Manufacturing
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4 Virtual Technology in Manufacturing
https://www.youtube.com/watch?v=wOlcUK https://www.youtube.com/watch?v=GEds6
poV7o XdHaeI
https://www.youtube.com/watch?v=MRkqgNwkbaU
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4 Impact of Virtual
Technology in
Manufacturing
• Services and business models
• Reliability and continuous productivity
• IT security: Companies like Symantec, Cisco, and Penta Security have already
begun to address the issue of IoT security
• Machine safety
• Product lifecycles
• Industry value chain
• Workers' education and skills
• Socio‐economic factors
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5 Competitiveness Aspect in Manufacturing
Processes
Beginning with the 1960s, the following trends developed that have
had a major impact on manufacturing:
1.Global competition increased rapidly, and the markets became
multinational and dynamic.
2. Market conditions fluctuated widely.
3. Customers demanded high‐quality, low‐cost products and on‐time
delivery.
4. Product variety increased substantially, and products became
complex, and product life cycles became shorter.
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5 General Trends in Manufacturing
Certain important trends
Materials and processes
Manufacturing systems
Organizational trends
For a manufacturing enterprise to be successful, it must respond to the following:
1. View the people in the organization as important assets and emphasize the
importance and need for teamwork and involvement in problem solving and in
decision‐making processes in all aspects of operations.
2. Encourage product innovation and improvements in productivity.
3. Relate product innovation and manufacturing to the customer and the market, seeing
the product as meeting a need.
4. Increase flexibility of operation for rapid response to product demands, in both the
domestic and the global marketplace.
5. Encourage efforts for continuous improvement in quality.
6. Ultimately and most importantly, focus on customer satisfaction on a global scale.
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5 Waste Reduction in Design
Design principles for economic production
1. The design should make the product as simple as possible to
manufacture, assemble, disassemble, and recycle.
2. Materials should be chosen for their appropriate manufacturing
characteristics.
3. Dimensional accuracy and surface finish should be specified as
broadly as is permissible in order to minimize manufacturing costs.
4. Net‐shape manufacturing of parts should be emphasized, and
secondary and finishing operations should be avoided or minimized.
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5 5 Waste Reduction in Manufacturing
Lean Production
A methodology that involves a thorough assessment of each
of the activities of a company in order to minimize waste at
all levels.
Requires a fundamental change in corporate culture, as well as
an understanding of the importance of cooperation and
teamwork among management and the work force.
Agile Manufacturing
Implementation of the principles of lean production on a
broad scale. The principle ensuring agility (hence flexibility)
in the manufacturing enterprise, so that it can respond
rapidly to changes in product demand and customer needs
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Product Improvement
5 through Value
Engineering (VE)
Value, as defined, is the ratio of
a systematic method to improve
function to cost. Value can
the "value" of goods or products
therefore be increased by either
and services by using an
improving the function or reducing
examination of function.
the cost.
Value engineering a technique in In most cases this practice identifies

which the value of a system’s and removes unnecessary
outputs is optimized by crafting a expenditures, thereby increasing the
mix of performance (function) and value for the manufacturer and/or their
costs. customers.
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5 Example of Product Improvement
5
through Value Engineering (VE)
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EXERCISES
1. There are basically three types of production methods. Briefly
explain these three common methods and also give the
advantages and disadvantages
a. unit production
b. batch production
c. mass production
2. What is manufacturing? Describe briefly the role of the
manufacturing sector/industries in the economic development of
Malaysia.
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9/22/2021

2 4 Industrial revolution and

Manufacturing is a complex activity involving variety of resources and activities viz.:

DESIGN REQUIREMENT, ECONOMICAL & QUALITY FLEXIBLE MATERIALS,

SYSTEM CONTINUOUS PRODUCTIVITY

The design of a product first requires a thorough understanding of the function

should integrate sustainable activities at all levels of manufacturing – product,

3 Relate the outputs of the system at each stage to direct

Value engineering a technique in In most cases this practice identifies

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