Methods and Processes Involved

with Manufacturing: Cement, Steel,

Glass, Plastic, Rubber, Electronics,
and Wood Works
 Table of Contents

Methods and processes involved with manufacturing :

Cement Glass Rubber

Steel Plastic Electronics

Wood Works
 Cement
The process of making cement involves four The three manufacturing
steps: processes—wet, dry, and
1. Crushing and grinding the raw materials semidry—are so named when
2. Blending the materials in the correct the raw materials are ground
proportions dry and supplied to the kiln as
3. Burning the prepared mix in a kiln and, nodules, ground dry and fed to
4. Grinding the burned product, known as the kiln as a dry powder, or
“clinker,” together with some 5 percent of ground dry and subsequently
gypsum (to control the time of set of the moistened to create nodules.
cement).
 Steel
Today, the manufacturing of steel is done by using one of these two methods :
1. Blast furnace: In a furnace, raw 2. Electric arc furnaces: The electric arc furnace (EAF)

iron ore and tiny quantities of process involves melting a lot of steel scrap into liquid using
high-current electric arcs produced by electrodes. The
steel scrap are combined using
experts add additional ferroalloys while the steel scrap
the blast furnace process,
metal is melting until the metal liquid has the correct
commonly referred to as the
proportion of steel to other alloys, such as chromium and
basic oxygen process (BOP). The
nickel, which make stainless steel. Then, lime and fluorspar
furnace is then heated by the
are added, and oxygen is blasted into the furnace to further
introduction of pure oxygen. As a
purify the steel. Slag is created when these compounds
result of the high temperature
combine with the impurities in the steel. The pure steel is
and reduction of the carbon
then left behind when the slag floats to the top of the molten
content to its optimal ratio, liquid steel and is removed.
steel is produced.
 Glass
Process:
The primary raw materials in glass 1.Batching of raw materials
are sand, soda, limestone, 2.Melting of raw materials in the furnace
clarifying agents, coloring and 3.Drawing the molten glass onto the tin bath
glistening glass. Glass sand is 4.Cooling of the molten glass in the
about ¾th of the entire glass annealing lehr
composition. 5.Quality checks, automatic cutting, and
storage
 Plastic

Here are the basic plastic manufacturing processes:

1. PLASTIC EXTRUSION- A metal die is used to construct the final shape of the polymer as it is
heated within a barrel to a predetermined temperature and forced through by a screw. The
plastic is then chilled to give it a fixed, continuous shape.
2. INJECTION MOULDING- The plastic polymer is fed into a heated barrel and screw through a
hopper. The split mould tool that forms the product's shape is temperature-controlled, and
the screw melts the plastic before injecting the liquid polymer into it.
3. EXTRUSION AND INJECTION BLOW MOULDING- Air pressure causes the hollow plastic to
expand into the mold or extrusion shape, leaving the interior of the product hollow. This
method is very similar to plastic extrusion and injection molding.
 Rubber
Rubber is a special form of polymer called an elastomer, meaning that the
polymer molecules stretch and flex.

Natural Rubber Manufacturing Process :

The natural rubber manufacturing process begins with harvesting latex from rubber trees. Water
is squeezed out of the coagulum of rubber using a series of rollers. The resulting thin sheets, about
1/8 inch thick, are dried over wooden racks in smokehouses. The drying process generally requires
several days. The resulting dark-brown rubber, now called ribbed smoke sheet, is folded into bales
for shipping to the processor.
Not all rubber is smoked, however. Rubber dried using hot air rather than smoking is called an air-
dried sheet. This process results in a better grade of rubber. An even higher quality rubber called
pale crepe rubber requires two coagulation steps followed by air-drying.
 Electronics
The electronics industry produces consumer electronics, electrical components, and
industrial electronics. It involves a series of steps during its manufacturing process.
Electronics Manufacturing Process:
Step 1: Bill of Materials (BoM)
During this process, manufacturers determine their overall costs and
Detailed Design: The detailed design is used to
the types of materials they need. create the engineering drawings and schematics
that guide the manufacturing process.
Step 2: Designing Design for Manufacturability (DFM): This involves
During the design phase, every part of the material the manufacturer optimizing the design to reduce production costs,
will employ to construct an electrical tool or device must be
improve production efficiency, and ensure that
measured.
the product can be manufactured using the
Product Requirements: The requirements are used to guide the
design process and to ensure that the final product meets the needs available equipment and processes.
and expectations of the customer.
Conceptual Design: The conceptual design is used to evaluate the Step 3: Testing
feasibility of the product, and to make any necessary changes or A device is tested after it is produced.
modifications.
 Wood works
Wood Manufacturing Transformation Process:
Stickering: Lumber destined for dry production is
Head Rig: The primary saw cuts the tree into sawn
stacked with spacers (known as stickers) that
pieces.
allow air to circulate within the stack. (Green
Edging: Removing irregular edges and defects
product skips this stage).
from sawn pieces.
Drying: Lumber is kiln-dried to facilitate natural
Trimming: The trimmer squares off the ends of
moisture content evaporation.
lumber into uniform pieces based on market
Planing: Smoothing the surface of each lumber
dimensions.
piece and making its width and thickness
Rough Lumber Sorting: Pieces are segregated
uniform.
based on the dimension and final product
Grading: The process of assessing the
production: unseasoned (known as green), or dry.
characteristics of each lumber piece in order to
assign its “grade” (quality).