General Introduction: ISYE6061-Manufacturing Engineering Technology in SI Units, 6 Edition

ISYE6061-Manufacturing Engineering Technology in SI Units, 6th Edition
General Introduction
Copyright © 2010 Pearson Education South Asia Pte Ltd

Chapter Outline
1. What Is Manufacturing?
2. Product Design and Concurrent Engineering
3. Design for Manufacture, Assembly, Disassembly, and
Service
4. Green Design and Manufacturing
5. Selection of Materials
6. Selection of Manufacturing Processes
7. Computer-integrated Manufacturing
8. Quality Assurance and Total Quality Management
9. Lean Production and Agile Manufacturing
10. Manufacturing Costs and Global Competition
11. General Trends in Manufacturing

What Is Manufacturing?
Example 1.1
Incandescent Light Bulbs
 Components of a common incandescent light bulb

Example 1.1
Incandescent Light Bulbs
 Manufacturing steps in making an incandescent light
bulb

Product Design and Concurrent Engineering
The Design Process

 Design and manufacturing
activities take place

sequentially

The Design Process

 It would be more desirable to:
1. Use a different material
2. Use the same material but in a different condition
3. Modify the design of a component
Concurrent Engineering
 Also called simultaneous engineering
 From the earliest stages of product design and
engineering, all are simultaneous

Concurrent Engineering
 Any iterations will require a
smaller effort and less wasted
time would occur

Life Cycle
 Life cycle of a new product consists of:
1. Product start-up
2. Rapid growth of the product in the marketplace
3. Product maturity
4. Decline
 Life-cycle engineering requires that the entire life of a

product be considered

Role of Computers in Product Design

 Product models are simplified through computer-
aided design (CAD) and computer-aided
engineering (CAE) techniques
 CAD systems are capable of rapid and complete
analysis of designs
 This is the process known as paperless design
 Performance of structures can be analysed

Role of Computers in Product Design (Con’t)

 Computer-aided manufacturing involves all phases
of manufacturing
 Performing tasks such as:
1. Programming for numerical control machines
2. Designing tools, dies, moulds, fixtures, and work-
holding devices
3. Maintaining quality control

Prototypes
 A prototype is a physical model of an individual
component or product
 Rapid prototyping use CAD/CAM and various
specialized technologies
 Prototypes developed can review for
possible modifications to the original
design, materials, or production methods

Virtual Prototyping
 It is a software-based method that uses advanced
graphics and virtual-reality environments
 To allow designers to view and examine a part in detail
 Also known as simulation-based design

Design for Manufacture, Assembly, Disassembly,
and Service
 Design for manufacture (DFM) integrate the design

process with production methods, materials, process
planning, assembly, testing, and quality assurance
 Design for assembly (DFA), Design for manufacture
and assembly (DFMA), and Design for disassembly
(DFD) are all important for manufacturing
 Assembly requires a consideration of the ease, speed,
and cost of individual components of a product

Green Design and Manufacturing
 Manufacturing operations produce waste like:
1. Chips from machining and trimmed materials
2. Slag from foundries and welding
3. Additives in sand used in sand-casting
4. Hazardous waste and toxic materials
5. Lubricants and coolants
6. Liquids from heat treating
7. Solvents from cleaning operations
8. Smoke and pollutants from furnaces

 Environmentally conscious design and
manufacturing considers all possible adverse
environmental impacts of materials, processes,
operations and products
 Design for recycling (DFR) - two basic activities
1) Biological cycle
- Organic materials degrade and lead to new soil that
sustain life
2) Industrial cycle
- Product that can be recycled and reused continuously

Cradle-to-cradle Production emphasizes:

1. Sustainable and efficient manufacturing activities
2. Waste-free production
3. Using recyclable and nonhazardous materials
4. Reducing energy consumption
5. Using renewable energy
6. Maintaining ecosystems
7. Using available materials and energy sources
8. Exploring the reuse and recycling of materials

Guidelines for Green Design and Manufacturing

1. Reduce waste of materials
2. Reduce hazardous materials products and processes
3. Investigate environmental-friendly manufacturing
technologies
4. Improvements in methods of recycling and reusing
5. Minimize energy use
6. Encourage recycling

Selection of Materials
 General types of materials used:
1. Ferrous metals
2. Nonferrous metals
3. Plastics (polymers)
4. Ceramics, glasses
5. Composite materials
6. Nanomaterials
7. Shape-memory alloys, amorphous alloys,
semiconductors and superconductors

Properties of Materials
1. Mechanical properties
2. Physical properties
3. Chemical properties
4. Manufacturing properties
5. Appearance

Availability
 If materials are not available in the desired quantities,
shapes, dimensions, and surface texture, substitute
materials can be considered
 Reliability of supply is important in order to meet
production schedules
 A country’s self-reliance on resources is a political goal

Service Life
 A shortened service life of a product is due to:
1. Improper selection of materials
2. Improper selection of production methods
3. Insufficient control of processing variables
4. Defective parts or manufacturing-induced defects
5. Poor maintenance
6. Improper use of the product

Material Substitution in Products
 We would want to consider the following substitutions:
1. Metal vs. wooden handle for a hammer
2. Aluminium vs. cast-iron lawn chair
3. Aluminium vs. copper wire
4. Plastic vs. steel car bumper
5. Plastic vs. metal toy
6. Alloy steel vs. titanium submarine hull

Example 1.2
Baseball Bats
 Cross sections of baseball
bats made of aluminium and
composite material

Example 1.3
U.S. Pennies
 Materials used undergone changes throughout history
due to periodic material shortages and the cost of
appropriate raw materials

Selection of Manufacturing Processes
 Some examples of manufacturing methods are:

1. Casting
2. Forming and shaping
3. Machining
4. Joining
5. Finishing
6. Microfabrication and nanofabrication




Process Selection
 Selection of process depends on geometric features of
the parts and workpiece material and properties
 Some mechanical tools are
being replaced by laser cutting
 Size of manufactured products
are getting smaller such as
microscopic gears

Net-shape and Near-net-shape Manufacturing

 Part is made in only one operation to the final desired
dimensions, tolerances and surface finish
 Difference between the two is the degree of how close the
product is to its final dimensional characteristics
 Examples of net-shape manufacturing are precision
casting, forging, forming sheet metal, powder metallurgy,
injection molding of metal powders and injection molding
of plastics

Ultraprecision Manufacturing
 Advantages are dimensional accuracies and mirror-like
surfaces on metals
Types of Production
 Job shops: less than 100
 Small-batch production: 10 to 100
 Batch production: 100 and 5000
 Mass production: over 100,000

Example 1.4
Saltshaker and Pepper Mill
 The two metal pieces for the
pepper mill are made by
powder-metallurgy techniques

Computer-integrated Manufacturing
 Computer-integrated manufacturing (CIM) integrates

computer graphics, computer-aided modelling, and
computer-aided design and manufacturing activities
 Capable of making possible
1. Responsiveness to rapid changes
2. Better use of materials, machinery, and personnel
3. Reduction in inventory
4. Better control of production
and management

 Various elements in CIM include:
1. Computer numerical control (CNC)
2. Adaptive control (AC)
3. Industrial robots
4. Automated materials handling
5. Automated assembly systems
6. Computer-aided process planning (CAPP)
7. Group technology (GT)
8. Just-in-time production (JIT)
9. Cellular manufacturing (CM)
10. Flexible manufacturing systems (FMS)
11. Expert systems (ES)
12. Artificial intelligence (AI)
13. Artificial neural networks (ANN)


Example 1.5
Mold for Making Sunglasses Frames
 Machining a mold cavity for making sunglasses
 Computer model of the sunglasses as designed and
viewed on the monitor
 Machining of the die cavity using a computer numerical-
control milling machine

Quality Assurance and Total Quality Management
 Product quality influences customer satisfaction

 Quality must be built into the product from its initial design
 Quality assurance and total quality management (TQM)
are the responsibility of everyone involved in the design
and manufacture of products and their components
 Product integrity define the degree to which a product
1. Functions reliably
2. Suits its intended purposes
3. Can be maintained with relative ease


 At six sigma, defective parts are reduced to only 3.4 per

million parts made.
 Level reached only through manufacturing process
capabilities to reduce variability in product quality
Quality Standards
 Global manufacturing and competitiveness
lead to international quality control methods
 Thus the establishment of ISO 9000
and QS 9000 standards
Human-factors Engineering
 Human-factors approach results in ergonomics design
 Defined as the study of a workplace and the design of
machinery and equipment
Product Liability
 Involved with product design, manufacture and marketing
 Product’s malfunction or failure can cause bodily injury or
even death

Lean Production and Agile Manufacturing
 Lean production involves a thorough assessment of each

activity of a company
 Lean production focuses on:
1. Efficiency and effectiveness of each and every
manufacturing operation,
2. Efficiency of the machinery and equipment used
3. Activities of the personnel involved in each operation

Lean Production and Agile Manufacturing
Agile Manufacturing
 Agile manufacturing is ensuring agility and flexibility
 Methodologies of both lean and agile production require
that a manufacturer benchmarks its operations

Manufacturing Costs and Global Competition
 Manufacturing cost is about 40% of its selling price

 Total cost of manufacturing a product consists of:
1. Materials
2. Tooling
3. Fixed Costs
4. Capital
5. Labour

General Trends in Manufacturing
Global manufacturing trends

1. Product variety and complexity continue to increase
2. Product life cycles are becoming shorter
3. Markets have become multinational
4. Market conditions fluctuate widely
5. Customers are demanding

Materials
6. Material composition, purity, and defects
7. Selection of materials for improved recyclability
8. Developments in nano-technology for materials
9. Testing methods and equipment
10. Increasing control over the thermal treatment
11. Higher strength-to-weight and stiffness-to-weight ratios

Manufacturing operations
12. Predictive models of the effects of material processing
parameters
13. Ultraprecision manufacturing
14. Computer simulation and modelling
15. Rapid-prototyping technologies
16. Optimization of manufacturing processes

Manufacturing systems
17. Computer software and hardware
18. Control systems and automated inspection
19. Lean production and information technology
Goals in manufacturing
20. View manufacturing activities not as individual
21. Meet all design requirements, product specifications
22. Build quality into the product
23. Economical and environmentally friendly (green)
manufacturing methods
Goals in manufacturing
24. Evaluate advances in materials, production methods, and
computer integration
25. Adopt flexible production methods
26. Achieving higher levels of productivity
27. Continuous improvement of a company’s products

General Introduction: ISYE6061-Manufacturing Engineering Technology in SI Units, 6 Edition

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ISYE6061-Manufacturing Engineering Technology in SI Units, 6th Edition

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

The Design Process

activities take place

Copyright © 2010 Pearson Education South Asia Pte Ltd

The Design Process

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Life-cycle engineering requires that the entire life of a

Copyright © 2010 Pearson Education South Asia Pte Ltd

Role of Computers in Product Design

Copyright © 2010 Pearson Education South Asia Pte Ltd

Role of Computers in Product Design (Con’t)

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Design for manufacture (DFM) integrate the design

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Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Cradle-to-cradle Production emphasizes:

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Guidelines for Green Design and Manufacturing

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Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

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Copyright © 2010 Pearson Education South Asia Pte Ltd

 Some examples of manufacturing methods are:

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Copyright © 2010 Pearson Education South Asia Pte Ltd

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Copyright © 2010 Pearson Education South Asia Pte Ltd

Net-shape and Near-net-shape Manufacturing

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 Computer-integrated manufacturing (CIM) integrates

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Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Product quality influences customer satisfaction

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Copyright © 2010 Pearson Education South Asia Pte Ltd

 At six sigma, defective parts are reduced to only 3.4 per

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Lean production involves a thorough assessment of each

Copyright © 2010 Pearson Education South Asia Pte Ltd

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Manufacturing cost is about 40% of its selling price

Copyright © 2010 Pearson Education South Asia Pte Ltd

Global manufacturing trends

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11. Higher strength-to-weight and stiffness-to-weight ratios

Copyright © 2010 Pearson Education South Asia Pte Ltd