IPE 141: Manufacturing Processes-I

Introduction
Syllabus
IPE-141: MANUFACTURING PROCESSES ‑ I
3.00 credits: 3 Hrs/week,

 Introduction to manufacturing processes.

 Machining Processes: Types, def inition, concepts and applications: Turning, Drilling, Shaping, Milling,
Knurling; Thread cutting, Grinding, Reaming, Boring, Broaching, etc.

 Casting Processes: Def inition, Classif ication, Molding: design of molds, riser, runner, gate, sprue and
core, cost analysis; Casting: casting processes for ferrous and non ferrous metals, sand, die,
centrifugal, slush, plaster mould, loam mould, precision investment casting etc., casting defects.

 Conventional Joining Processes: Definitions, Classification, Welding processes: Soldering, Brazing,

Gas, Arc, TIG, MIG, Termite, Resistance, Friction, Electro slag etc., Welding Defects.
Reference Books
 Fundamentals of Modern Manufacturing Materials, Processes, and Systems
Mikell P. Groover
Fourth Edition
John Willy & Sons, Inc.

 Manufacturing Engineering and Technology

S. Kalpakjian, S.R. Schmid
Pearson Foundation

 DeGarmo’s Materials and Processes in Manufacturing

Tenth Edition
John Willy & Sons, Inc.

 Introduction to Basic manufacturing Processes and Workshop Technology

Rajender Singh
New Age International P. Limited

 Manufacturing Processes
Manufacturing: What is it?
 The word “manufacturing” is derived from the two Latin words:
 Manu ► Hand
 Factus ►Made
meaning ‘made by hand’.

 In modern context, manufacturing can be defined as:

 making of products from raw materials using various
 processes
 operations
 equipment
 manpower
according to a detailed plan.

 During Processing/Manufacturing,
 the raw material undergoes changes, and Manufacturing is no longer a simple operation
 finally, becomes a product/a part of a product. but has become a system where number of
 Once processed, it should have worth in the market or a value. interact in a dynamic manner.
subsystems

 Manufacturing, therefore, represent organized activities that convert raw materials into salable
Duality of Manufacturing

Technical Process Economic Process

Added value
Manufacturing: as Technical Process
 Technological Perspective
 The application of physical and chemical processes to alter:
 geometry,
 properties, and/or appearance
of a given starting material to make parts or products.
 Also includes assembly of multiple parts to make products.
 The processes to accomplish manufacturing involve a combination of machinery, tools, power, and
labor.
 Manufacturing is almost always carried out as a sequence of operations.
 Each operation brings the material closer to the desired final state.
Manufacturing: as Economic Process
Manufacturing: Requirements for a Manufacturing Activity
 Manufacturing process and its interaction with the five Ms:
Manufacturing Processes
 A designed procedure that results in physical and/or chemical changes to a starting work
material with the intention of increasing the value of that material.
 Usually carried out as a unit operation
 a single step in the sequence of steps required to transform the starting material into a
desired final product.
 Manufacturing operations can be divided into two basic types:
 Processing operations
 Transform a work material from one state of completion to a more advanced state, which is
closer to the final desired product.
 Adds value by changing the geometry, properties, and/or appearance of the starting material.
 Assembly operations
 Join two or more components to create a new entity, called
 an assembly,
 subassembly, or
 some other term that refers to the joining process (e.g., a welded assembly is called a
weldment).
Manufacturing Processes
Classification of Manufacturing Processes
Manufactured Products
Consumer goods
 Products purchased directly by consumers or general public.
 Example: cars, personal computers, TVs, and rackets etc.

Capital goods
 Products purchased by companies to produce goods and/or to provide services.
 Also known as producers goods.
 Example: aircraft, buses, machine tools etc.
Products are often made by putting many parts together.
 Ball pen: Body, refill, barrel, cap, and refill operating mechanism.
 Car: More than 20000 parts are put together
 Machine Tool: More than 24000 parts are assembled together.
Primary vs. Secondary Manufacturing Processes
 Primary manufacturing processes
 Convert raw materials into standard stock
Bauxite ore ► aluminum
Petroleum ► polyester resin
Wood ► lumber

Secondary manufacturing processes

 Convert standard stock into usable or salable parts/products
Aluminum rod ► fuel valve
Polyester resin ► medical tubing
Lumber ► furniture
Secondary Manufacturing Processes
 The manufacturing processes that create or add value to a product.
 The manufacturing processes can be classified as:
1. Casting, Foundry or Moulding Processes
2. Forming or Metalworking Processes
3. Machining (Material Removal) Processes
4. Joining and Assembly
5. Surface Treatment (Finishing)
6. Heat Treatment (Conditioning)

 Casting, Foundry and Molding processes

 hold liquid or semi-liquid materials in a mold cavity until the material hardens.
 Very intricated shapes can be manufactured.
 Range of size of the products manufactured by the casting process is unlimited.
Secondary Manufacturing Processes
 Forming processes
 Use a shaping device and suitable force, pressure, stress or their combination to cause permanent
deformation of a material to give it a required shape and size.
 No material is removed and wasted, but is only displaced and deformed.

 Machining processes
 remove unwanted material from a given workpiece to get a desired size, shape and surface finish.

 Material is removed from unwanted region of the raw material.

Secondary Manufacturing Processes
 Heat Treatment Processes
 Use heat, chemical reactions, or mechanical means to change the properties of a material

 Finishing processes
 Modify the surface of a material to improve appearance or performance
Manufacturing System vs Production System
 Manufacturing System
 A collection or combination of manufacturing processes or operations performed in a
sequence to produce desired product(s) or components.
 A complex arrangement of physical elements i.e. machines or machine tools required.
 The manufacturing system takes inputs and produces products for the external customer.
 Production System
 The manufacturing system along with all other functional areas of the company.
 It includes all aspects of commerce e.g. Manufacturing, Distribution, Marketing, Sales,
Management etc.
Manufacturing System Design
 Based on quantity of product, manufacturing system can be classified as:
 Custom Manufacturing
 Batch Manufacturing
 Continuous Manufacturing
 Custom Manufacturing System
 Also known as job shop production.
 Suitable for small industries that usually meet individual customer demand.
 one or very few numbers of the product having a
 specific design and
 specification
 Characterized by
 Low quantity (in the range of 1-100 units) and large varieties of products (customized products).
 General purpose machine.
 Functional or process layout.
 Highly skilled and intelligent labors.
 Commonly used for make-to-order situation.
Manufacturing System Design
 Batch Manufacturing System
 Jobs are produced in lot or in a certain quantity and varies between job shop and continuous
production.
 Suitable for medium scale industries that meet the local market demand.
 Characterized by
 Medium quantity range (in the range of 100-10000 units) and less variety of products.
 General purpose machine.
 Flow shops or line layout: continuous or interrupted (order may be repetitive or non-repetitive).
 Requirements for good managerial skill to achieve an economic plan in production.

 Commonly used for make-to-stock situation.

Manufacturing System Design
 Continuous Manufacturing System
 Also known as mass production or continuous production without loss of time.
 Characterized by
 Manufacture of identical products (single type of product) in a bulk quantities (in the range of
10000 - millions units).
 High demand rates for the product
 The whole system is dedicated to the production of that product.
 Special purpose machine.
 Initial investment required for machines and tooling is very high.
 Commonly used for make-to-stock situation.
Manufacturing Industries Cost of Manufacturing
 Industries can be classified as primary, secondary, and tertiary.
 Primary industries
 cultivate and
 exploit
natural resources.
 Examples: agriculture and mining.
 Secondary industries
 take outputs of the primary industries, and
 convert them into consumer and capital goods.
 Tertiary industries
 constitute the service sector of the economy.

 Why Businesses Need to Know the Cost of Its Products

 To set prices.
 To calculate profit when products are sold.
 To prepare financial statements.
Cost of Manufacturing: Manufacturing vs Nonmanufacturing Costs
 Manufacturing Cost
 Associated with the production of goods.
 Occurs in the factory while being produced.
 Also known as product cost.
 Recorded into asset (inventory) accounts and reported on the Balance Sheet.
 They stay on the balance sheet until the goods are sold.
 When goods are sold, the costs are
 transferred to income statement, and
 reported as Cost of Goods Sold.

The ke y t o unde r st anding if a cost is

manufacturing or non-manufacturing
 Nonmanufacturing Cost  is to think about where in the process the
 Associated with the period in which they are incurred. cost occurs.
 Cost occurs after the product is produced or outside the factory.
 Also known as period cost.
 Costs are
Cost of Manufacturing: Manufacturing Costs
 Manufacturing Costs
 Direct Materials
 Material and parts that
 Become the integral part of a finished product
 Can be easily or directly traced to a finished product.
 Considered as variable cost

 Direct labor
 Cost of labor that is directly traced to a product.
 Considered as variable cost.

 Manufacturing Overhead
 Cost of all manufacturing activities other than direct labor and direct material.
Cost of Manufacturing: Manufacturing Costs
 Manufacturing Costs
 Manufacturing Overhead
 Indirect Labor
 Not traceable to a particular product.
 Includes
 factory supervisor salaries,
 factory janitors’ salaries or wages,
 factory maintenance workers salaries or wages, and
 other costs for factory-related workers who do not directly contribute to producing a
particular product.

 Factory Related Cost

 Can not be easily traced or identified with a particular product.
 Includes
Cost of Manufacturing: Manufacturing and Nonmanufacturing Costs

Distribution of Costs
 Manufacturing Cost:
The largest part of the
selling price.
 M a t e r i a l C o st : Th e
l a r ge s t pa r t o f t h e
manufacturing costs.
Cost of Manufacturing: Manufacturing Costs
 Nonmanufacturing Costs
 All costs not associated with the production of goods.
 Also known as period cost.
 Some examples of period costs are:
 Selling, advertising, marketing costs

 Cost Flow in a Manufacturing Firm

Direct
Materials

Direct Work-in- Finished Cost-of

Labor Process Goods Goods Sold

Mfg.
 Delivery of products to customers (e.g., freight-out, transportation-out, delivery expense)
Overhead
 General and administrative costs