ENGINEERING

MANUFACTURING II
(MMF22A)

UNIT 1
LECTURE 1: INTRODUCTION
 INTRODUCTION - MANUFACTURING
• Manufacturing is about making products.
• A manufactured product may be used to make other products,
such as
• a large press to shape flat sheet metal into automobile bodies.
 INTRODUCTION - MANUFACTURING
• A manufactured
item typically
starts with raw
materials.

• It is then
subjected to a
sequence of
processes to
make individual
products, with a
certain value.
 INTRODUCTION - MANUFACTURING
• Manufacturing adds value to the material by
changing its shape or properties, or by
combining it with other materials that have
been similarly altered.
• The material has been made more valuable
through the manufacturing operations
performed.
• A nail has a value over and above the cost of
the short piece of wire or rod from which it is
made (low value product).
• Products such as computer chips, electric
motors, etc. are known as high-value-added
products.
 PRODUCT DESIGN
• Product design involves the creative and systematic
creation of the shape and characteristics of a
product to achieve specified objectives while
simultaneously satisfying several constraints.
• Design is an important activity, because it has been
estimated that as much as 80% of the cost of
product development and manufacture is
determined by the decisions made in the initial
stages of a design.
 PRODUCT DESIGN
• Innovative approaches are essential in successful
product design, as are clearly specified functions
and a clear statement of the performance expected
of the product, which may be new or a modified
version of an existing product.
• The market for the product and its anticipated use(s)
also must be clearly defined;
• this aspect involves the assistance of market analysts
and sales personnel who will bring valuable and timely
input to the manufacturer, especially regarding market
trends.
PRODUCT DEVELOPMENT PROCESS
 PRODUCT DEVELOPMENT PROCESS
The life cycle of a new product generally consists of
the following five stages:
1. Product development
2. Product start-up (introduction)
3. Rapid growth of the product in the marketplace
4. Product maturity
5. Decline.
 PRODUCT DEVELOPMENT PROCESS
• Aim to bring products to
the marketplace as
quickly as possible, to
gain a higher percentage
share of the market and
thus higher profits.
 CONCURRENT ENGINEERING
• From the earliest stages of product design and
engineering, all relevant disciplines are
simultaneously involved.
• As a result, any iterations that may have to be made
will require a smaller effort and thus result in much
less wasted time than occurs in the traditional
approach to design.
• Itshould be apparent that a critical feature of this
approach is the recognition of the importance of
communication among and within all disciplines.
CONCURRENT ENGINEERING
CONCURRENT ENGINEERING
 PRODUCT DEVELOPMENT PROCESS
Role of Computers in Product Design.
•A product design first requires the preparation of
analytical and physical models of the product for the
purposes of visualization and engineering analysis.
• Although the need for such models depends on
product complexity, constructing and studying these
models have become highly simplified through the
use of computer-aided design (CAD) and computer-
aided engineering (CAE) techniques.
 PRODUCT DEVELOPMENT PROCESS
Role of Computers in Product Design.
PRODUCT DEVELOPMENT PROCESS
• Computer-aided manufacturing
• Computers greatly assist in organizing the
information developed and performing such tasks
as:
• programming for numerical control machines and
robots for material-handling and assembly
operations
• designing tools, dies, moulds, fixtures, and work-
holding devices
• maintaining quality control
PRODUCT DEVELOPMENT PROCESS
 PRODUCT DEVELOPMENT PROCESS
Prototypes
•A prototype is a physical model of an individual
component or product.
• The prototypes developed are carefully reviewed
for possible modifications to the original design,
materials, or production methods.
• An important and continuously evolving technology
is rapid prototyping (Additive manufacturing)
 PRODUCT DEVELOPMENT PROCESS
Prototypes
 SELECTION OF MATERIALS
• During the concept phase of the product development
process the selection of the material for the product need
to be decided upon.
• This decision will have an important influence on the cost
and manufacturing process of the product.
• A wide variety of materials are available, each type having
its own:
• Material properties and manufacturing characteristics.
• Advantages and limitations.
• Material and production costs.
• Consumer and industrial applications.
 SELECTION OF MATERIALS
• The availability of materials is a very important
factor to consider during the selection process of a
suitable material for a product.
• If suitable materials
are not available in the desired
quantities, shapes, dimensions, alternative materials
or additional manufacturing processes may be
required, which influence the cost of a product.
• Another consideration is appearance, which
includes characteristics such as color, surface
texture, and feel, which can play an important role in
a product’s acceptance by the market.
SELECTION OF MATERIALS
 SELECTION OF MATERIALS
• Ferrous metals: Carbon, alloy, stainless, and tool and die
steels
• Nonferrous metals: Aluminum, magnesium, copper, nickel,
titanium.
• Plastics (polymers): Thermoplastics, thermosets, and
elastomers.
• Ceramics, glasses, glass ceramics, graphite, diamond, and
diamond-like materials.
• Composite materials: Reinforced plastics and metal-matrix
and ceramic-matrix composites.
• Nanomaterials,Shape-memory alloys (also called smart
materials), amorphous alloys, semiconductors, and
superconductors.
 PROPERTIES OF MATERIALS
• Mechanical properties include strength, ductility,
hardness, toughness, elasticity, fatigue, and creep
resistance.
• Physical properties include density, specific heat,
thermal expansion and conductivity, melting point,
and electrical and magnetic properties.
• Manufacturing properties indicate whether a certain
material can be cast, formed, machined, joined, and
heat treated with relative ease.
 MATERIAL SUBSTITUTION IN
PRODUCTS
• For a variety of reasons, numerous substitutions are often
made in materials, as evidenced by a simple inspection
and comparison of common products such as home
appliances, sports equipment, or automobiles.
• As a measure of the challenges faced in material
substitution, consider the following examples:
• (a) metal vs. wooden handle for a hammer,
• (b) aluminum vs. cast-iron lawn chair,
• (c) aluminum vs. copper wire,
• (d) plastic vs. steel car bumper,
• (e) plastic vs. metal toy, and
• (f) alloy steel vs. titanium submarine hull.
 SELECTION OF MANUFACTURING
PROCESSES
• Thereis often more than one method that can be used to
produce a component for a product from a certain material.
• Thefollowing manufacturing methods are used to produce
metallic as well as nonmetallic products:

• Forming and shaping: Rolling, forging, extrusion,

drawing, sheet forming, powder metallurgy, and
moulding.
• Machining: Turning, boring, drilling, milling
• Broaching; grinding; ultrasonic machining; chemical,
electrical, and electrochemical machining; and high-
energy-beam machining.
 SELECTION OF MANUFACTURING
PROCESSES
• Joining: Welding, brazing, soldering, diffusion
bonding, adhesive bonding, and mechanical joining.
• Finishing: Honing, polishing, deburring, surface
treating, coating, and plating.
• Microfabrication and nanofabrication: Technologies
that are capable of producing parts with dimensions
at the micro (one-millionth of a meter) and nano
(one-billionth of a meter) levels.
 TYPES OF PRODUCTION
1. The number of parts to be produced (e.g., the
annual quantity)
2. The rate (number of pieces made per unit time)
are important economic considerations in determining
the appropriate manufacturing processes and the
types of machinery required.
 PROCESS SELECTION
• The selection of a particular manufacturing process
or, more often, sequence of processes, depends on
the geometric features of the parts to be produced,
including the dimensional tolerances and surface
texture required, and on numerous factors
pertaining to the particular workpiece material and
its manufacturing properties.
 DESIGN FOR MANUFACTURE (DFM)
• It is important
to analyse and optimise a design for ease of
manufacturing and assembly at minimum product cost.
• Successful implementation of DFM requires a designer to
fully understand:
• Characteristics, capabilities, and limitations of materials.
• Manufacturing processes.
• Machinery, equipment, and tooling used during the
manufacturing process.
• Variability in machine performance, dimensional accuracy
and surface finish of the work piece, processing time, and
the effect of processing methods on product quality.
 DESIGN FOR MANUFACTURE (DFM)
• Assembly is an important phase of
manufacturing and requires a consideration of
the ease, speed, and cost of assembling
numerous individual components of a product.
• Assembly costs in manufacturing operations
can be 20 to 60% of the total product cost.
 DESIGN FOR SERVICE
• In addition to design for assembly and for
disassembly, design for service is important in
product design.
• The design should consider that for ease of access
components that are most likely to be in need of
servicing to be placed, if possible, at the outer
layers of the product.
 GREEN DESIGN AND
MANUFACTURING
• Manufacturing processes can have a significant environmental
impact.
• Manufacturing operations generally produce some waste, such
as:
• Chips from machining, and molding operations.
• Slag from foundries and welding operations.
• Hazardous waste and toxic materials used in various
products.
• Lubricants and coolants used in machining operations.
• Liquids from processes such as heat treating and plating.
• Solvents from cleaning operations.
• Smoke and pollutants from furnaces.
 GREEN DESIGN AND
MANUFACTURING
Design for recycling
• Recycling may involve one of two basic activities:
• Biological cycle: Organic materials degrade
naturally, and in the simplest version, they
lead to new soil that can sustain life.
• Thus, product design involves the use of (usually)
organic materials. The products function well for
their intended life and can then be safely
discarded.
 GREEN DESIGN AND
MANUFACTURING
Polylactic Acid (PLA) pastic.
• Is derived from renewable resources like corn starch
or sugar cane
• PLA is biodegradable and has characteristics similar
to PP, PE and PS.
• Fumes from this plastic smell sweet and like candy.
 GREEN DESIGN AND
MANUFACTURING
• Industrialcycle: The materials in the product are
recycled and reused continuously.
• For example, aluminum beverage cans are recycled
and reused after they have served their intended
purpose.
• It has been determined that producing aluminum
from scrap, reduces production costs by as much as
66% and reduces energy consumption and pollution
by more than 90%.
 GUIDELINES FOR GREEN DESIGN
AND MANUFACTURING
• Reduce waste of materials, by refining product design and selecting
manufacturing processes that minimize scrap (forming vs machining).
• Reduce the use of hazardous materials in products and processes.
• Investigate manufacturing technologies that produce environmentally
friendly safe products and by-products.
• Make improvements in methods of recycling, waste treatment, and
reuse of materials.
• Minimize energy use, and whenever possible, encourage the use of
renewable sources of energy.
• Encourage recycling by using materials that are a part of either
industrial or biological cycling.
 PROCESS SUBSTITUTION

• Itis common practice in industry that, for a variety of reasons

and after a review of all appropriate and applicable processes, a
particular production method that may have been used in the
past can be substituted with another.
• The following products that can be produced by any one of
these processes:
• Cast vs. forged.
• Stamped sheet-metal vs. forged or cast automobile wheels.
• Welded vs. riveted sheet-metal parts.
 PROCESS SUBSTITUTION

• Net-shape and near-net-shape manufacturing is an

important manufacturing practice by which a part is
made in only one operation at or close to the final
desired dimensions, tolerances, and surface finish.
• The difference between net shape and near net
shape is a matter of degree of how close the
product is to its final dimensional characteristics.
 COMPUTER-INTEGRATED
MANUFACTURING
• Computer-integrated manufacturing (CIM), make use of
computer based software during the design and
manufacturing of a product, from initial product concept
through its production and distribution in the marketplace.
• Improve responsiveness to rapid changes in product
design modifications and to varying market demands.
• Result in the optimised usage of materials, machinery,
and personnel.
• Better control and management over the production and
manufacturing operations.
 COMPUTER-INTEGRATED
MANUFACTURING
• Computer numerical control (CNC) is a method of
controlling the movements of machine components
by coded instructions in the form of numerical data.
• Adaptive control (AC). The processing parameters in
an operation are automatically adjusted to optimize
the production rate and product quality.
• Assist in reducing manufacturing costs. During
manufacturing the part can be constantly monitored
if the specifications deviate from the specified range,
the system adjusts the variables until the
specifications are within the specified range.
 COMPUTER-INTEGRATED
MANUFACTURING
• Industrial robots are used in operations that are repetitive,
dangerous, and boring, resulting in consistency and
improved productivity during in assembly operations.
• Automated assembly systems are continued to be
developed to do these assembly operations, replacing
human operators on assembly lines.
 SERVICE LIFE
• Generally, a product is considered to have failed
when it stops functioning or perform within required
specifications or becomes unreliable or unsafe for
further use
• This could be due to:
• the failure of one or more of its components, such
as a broken shaft, gear, bolt, or turbine blade or a
burned-out electric motor,
• worn gears or bearings,
• the erratic behavior of a switch, poor connections
in a printed-circuit board.
 SERVICE LIFE
• A shortened service life of a product, can often can
be traced to:
• Improper selection of materials.
• Improper selection of production methods.
• Insufficient control of processing variables (poor
quality control or lack of it).
• Substandard manufactured parts
• Poor maintenance.
• Improper use of the product.
 QUALITY ASSURANCE AND
TOTAL QUALITY MANAGEMENT
• Product quality is one of the most critical aspects of
manufacturing, because it directly influences
customer satisfaction, which is very important for a
product’s success in the global marketplace.
• The traditional approach of inspecting products after
they are made has largely been replaced by more
efficient processes.
• Such as that quality must be built into the product
from its initial design through all subsequent stages
of manufacturing and assembly.
 QUALITY ASSURANCE AND
TOTAL QUALITY MANAGEMENT
• Quality assurance and total quality management (TQM)
are widely recognized as being the responsibility of
everyone involved in the design and manufacture of
products and their components.
• Product Liability. Designing and manufacturing safe
products is among the essential aspects of a
manufacturer’s responsibilities.
• All those involved with product design, manufacture, and
marketing must fully recognize the consequences of a
product’s failure, including failure due to foreseeable
misuse of the product.
 LEAN PRODUCTION
• Lean production involves a thorough assessment of each
activity of a company, with the basic purpose of
minimizing waste at all levels and eliminating of
unnecessary operations that do not provide any added
value to the product being made.
• Lean production focuses on
• The efficiency and effectiveness of each and every
manufacturing operation.
• The efficiency of the machinery and equipment used.
• The activities of the personnel involved in each
operation.
 AGILE MANUFACTURING

• The principle behind agile manufacturing is ensuring

agility and hence flexibility-in the manufacturing
enterprise, so that it can respond rapidly and
effectively to changes in product demand and the
needs of the customer.
• Flexibility
can be achieved through people,
equipment, computer hardware and software, and
advanced communications systems.
 MANUFACTURING COSTS AND
GLOBAL COMPETITION
• The economics of manufacturing has become very important
due to:
• ever-increasing global competition.
• the demand for high-quality products, generally referred
to as world-class manufacturing, at low prices.
• Typically,
the manufacturing cost of a product represents
about 40% of its selling price, which often is the overriding
consideration in a product’s marketability and general
customer satisfaction.
 MANUFACTURING COSTS
• The total cost of manufacturing a product generally consists of
the following :
• Materials.
• Tooling.
• Fixed costs (rent, electricity, insurance).
• Capital (machines, equipment, buildings).
• Labour.
• Outsourcing. A more recent trend has been outsourcing,
defined as the purchase by a company of parts or labor from
an outside source, from either another company or another
country, in order to reduce design and manufacturing costs.
 GENERAL TRENDS IN
MANUFACTURING
• Product variety and complexity continue to increase.
• Product life cycles are becoming shorter.
• Markets have become multi-national and global competition
has been increasing rapidly.
• Market conditions fluctuate widely.
• Customers are consistently demanding high-quality, low-cost
products and on time delivery.
• Materials:
• Material composition, purity, and defects are coming
under more control in order to further enhance overall
properties, manufacturing characteristics, reliability, and
service life.
 GENERAL TRENDS IN
MANUFACTURING
• Developments have occurred in the selection of materials
for improved recyclability.
• Testing methods and equipment are continually being
improved.
• Increasing control over the thermal treatment of materials
is resulting in more predictable and reliable properties.
• Weight savings are being achieved with the use of
materials with higher strength-to-weight and stiffness-to-
weight ratios, particularly in the automotive and
aerospace industries.
 GENERAL TRENDS IN
MANUFACTURING
• Manufacturing operations:
• Improvements are being made in predictive models of
the effects of material processing parameters on product
integrity, applied during a product’s design stage.
• Developments continue in ultra precision manufacturing,
micro manufacturing, and nonmanufacturing,
approaching the level of atomic dimensions.
• Computer simulation, modeling, and control strategies
are being applied to all areas of manufacturing.
• Additive manufacturing technologies are increasingly
being applied to the production of tooling and direct
digital manufacturing.
 GENERAL TRENDS IN
MANUFACTURING
• Manufacturing systems:
• Advances in computer software and hardware
are being applied to all aspects of production.
• Developments have occurred in control systems,
industrial robots, automated inspection, handling
and assembly, and sensor technology.
• Lean production and information technology are
being implemented as tools to help meet major
global challenges.
 GENERAL TRENDS IN
MANUFACTURING

• Goals in manufacturing:
• Meet all design requirements, product
specifications, and relevant national and
international standards for products.
• Build quality into the product at each stage of its
production.
• Implement the most economical and
environmentally friendly (green) manufacturing
methods.
 GENERAL TRENDS IN
MANUFACTURING
• Goals in manufacturing:
• Adopt production methods that are sufficiently flexible
in order to rapidly respond to changing global market
demands and provide on-time delivery to the
customer.
• Continue efforts aimed at achieving higher levels of
productivity and eliminating or minimizing waste with
optimum use of an organisation’s resources.
• Cooperate with customers for timely feedback for
continuous improvement of a company’s products.
 Homework
• Work through pages 1 to 33 in handbook