Manufacturing: An Introduction

• What is manufacturing
• Manufacturing (or Production): The process of converting raw
materials into products that have value in the marketplace

• Manufacturing concerns about making cars, airplanes, stoves,

shoes, toys, TVs, mobile phones, and etc.

• Manufacturing is the backbone of modern society and

creates the wealth of a nation
Manufacturing
Process

Value Added

Starting Material Completed part

material in processing
 Economy Evolution
Knowledge

Technology

Manufacturing
1. RESOURCES/COMMODITY DRIVEN
(1918 – Industrial Revolution)
Resources
2. MANUFACTURING DRIVEN
( - 1980) Mass production, cheap energy
3. TECHNOLOGY DRIVEN
(1981-1990s) Cheap chips, telecommunication, electronics, information highway
4. KNOWLEDGE DRIVEN
(1990 - ) Knowledge intensive tools, methods and employment
Challenges in Manufacturing Systems

• Facts
• Rapid changing market
• Fast development of new technology
• vacuum tubes -> transistors -> IC -> VLSI
• wiring -> thru-hole PCB -> Surface Mount Component

• To survive:
• Lower cost
• High quality
• Lower product development cycle
Factors affecting the evolution of manufacturing systems

P
Management e Ideas,
o Knowledge
Analysis / Teamwork p Synthesis /
l Wisdom
Reduction e Integration
Engin
Scienc eerin
g
e Evolution of
Discovery of Manufacturing Design
New Knowledge, Systems Manufacture
Basic Laws Econ Maintenance
Policy omic
Conte Co ntext
xt
T
e Capital Formation & Cost,
Societal Needs c
The Public Good, Standards, Devices h Investment
Processes n
Laws o Ideas
Systems l Information
o
g
y
Manufacturing: Historical Perspective
Jaikumar, R., “200 Years to CIM,” IEEE Spectrum, September, 1993.

• Completely custom - craftsman (pre 1800)

• English system (1800s)
• Introduction of general purpose machines that could be used for a variety of
products.
• American system (1850s)
• Emphasized precision and interchangeability. Changed from a “best fit” to a
“greatest clearance without loss of functionality” focus.
Manufacturing: Historical Perspective
• Scientific management (1900s)
• Pre-specified worker motions - Moved the control totally into the hands of
management.
• Process improvement (SPC) (1950s)
• Identical procedures produce different results on same machine at different times.
Emphasized outliers instead of mean performance.
• Numerical control (1970s)
• Combining the versatility of general purpose machines with the precision and control
of special-purpose machines.
Manufacturing: Historical Perspective
• Computer integrated manufacturing (1980s)
• Pervasive use of computers to design products, plan production, control operations,
and perform various business-related functions.
• Agile/Lean Manufacturing / Mass Customization (1990s)
• Creation of highly flexible organizational structures that allow systems to produce
highly customized products.
• Future? Technology, Global, Rapid Change
 1920-50
Mass Production Systems
1960-70
1980-95
Lean Manufacturing Systems
1995-now
Flexible Manufacturing
Systems Volume
Reconfigurable
Q uality
Manufacturing Variety
Systems
Mass Customization
Manufacturing Goals and Technologies
 Manufacturing Paradigms
• Manufacturing Paradigm: A manufacturing model that has a set of principles by
which it can be explained

UM, ERC/RMS center