Chapter one

Focused science of this unit

1 Introduction on Manufacturing Engineering
1.1Systematic Surveying of Production Process in
Metal Working Industries.
1.2 Classification of manufacturing engineering
and process
1.3 Break-even analysis
 Introduction on Manufacturing Engineering
What is manufacturing?
Literal:- Manufacture = Manus (hand) + Factus (make)
Made by hand
Technological:-Application of physical and chemical
processes to make parts or products, including
assembly of products.
Economical:-transformation of materials into items of
greater value by means of processing and/or assembly
operations.
CIRP definition:-Design + production + assembly
• (CIRP = International Academy for Production Eng.)
Representation of ‘manufacturing’ in a technological way
Representation of ‘manufacturing’ in a
economical way
1.1 PRODUCTION PROCESS Vs. MANUFACTURING PROCESS

 PRODUCTION PROCESS: it is the process followed in a plant

for converting semi- finished products or raw materials into
finished products or raw materials into finished products.
 The art of converting raw material into finished goods with
application of different types of tools, equipment's, machine
tools, manufacturing set ups and manufacturing processes, is
known as PRODUCTION.
Generally there are three basic types of production system that are
given as under.
1. Job production
2. Batch production
3. Mass production

Job production:-comprises of an operator or group of

operators to work upon a single job and complete it before
proceeding to the next similar or different job.
 The production requirement in the job production system is

extremely low. It requires fixed type of layout for developing

same products.
Batch production;- it refers Manufacturing of products
(less in number say 200 to 800) with variety of similar
parts with very little variation in size and shape.
Note;-
 Whenever the production of batch is over, the same
manufacturing facility is used for production of other
batch product or items.
 The batch may be for once or of periodical type or of
repeated kinds after some irregular interval.
Mass production;- involves production of large
number of identical products (say more than
50,000) that needs line layout type of plant
layout
 which is highly rigid type and involves
automation and huge amount of investment in
special purpose machines to increase the
production.
 Production systems
Consist of people, equipment and procedures
Production facilities: factory, production equipment
 material handling equipment
 Plant layout + Manufacturing systems
 Influence of production quantity (low, medium, high)
 Manufacturing support systems
 Manufacturing engineering process planning
 Production planning and control logistics,
 ordering materials and parts, scheduling
 Quality control
 MANUFACTURING PROCESS
 Manufacturing process is that part of the production process
which is directly concerned with the change of form or
dimensions of the part being produced.
 It does not include the transportation, handling or storage of
parts, as they are not directly concerned with the changes into
the form or dimensions of the part produced.
 It is also sequence of operations and processes designed to
create a specific product
 Classification of Manufacturing processes
1) Processing operations
2) Assembly operations
 Permanent joining: welding, brazing, adhesives
 Mechanical assembly: bolts, screws, rivets, etc.
3) Production machines and tooling
 Machine tools: lathe, milling machine, etc.
 Presses, forge hammers, rolling mills
 Welding machines and equipment
 General and special purpose equipment
 Tooling
Materials in Manufacturing
 1.1 MANUFACTURING ENGINEERING
 In modern context it involves making products from
raw material by using various processes, by making
use of hand tools, machinery or even computers.
 It is therefore a study of the processes required to
make parts and to assemble them in machines.
 Process Engineering, in its application to engineering
industries, shows how the different problems related to
development of various machines may be solved by a
study of physical, chemical and other laws governing
the manufacturing process.
Advance manufacturing engineering involves the
following concepts
 Jigs and Fixtures.  Process planning.
 Dies and Moulds
 Manufacturing Information
 Process sheets and
Generation.  planning
 CNC part programs.  Route sheets.
 Robot programmers.
 Flexible Manufacturing  Tooling.
Systems (FMS),  Cutting tools, machine
 Group Technology (GT) and
Computer  tools (traditional,
 integrated manufacturing  numerical control (NC),
(CIM)
 and computerized (CNC
 1.2 Engineers in Manufacturing
Manufacturing Engineer
Select and coordinate specific processes and equipment
Industrial Engineer
Responsible for the manufacturing system design
Materials Engineer
Develop and select materials based on desired material
properties and manufacturing process
Key Manufacturing Engineering Skills
Technical
PLCs, Networking, Industrial Computer Technology,
Equipment Troubleshooting, Simulation, Process Layout &
Optimization, Tooling & Fixture Design, Value Stream Mapping,
Process Improvement Tools, Factory Automation – Justification,
Acquisition, & Deployment, Production Planning, Asset
Utilization,
Maintenance Reliability, Building Codes, Product Introduction,
Leadership
Team Based Work Systems, Integrity, Championing Change,
Coach & Develop, Customer Focus, Planning, Strategic
Thinking, Diversity, Communication
 Safety
Emergency Management and Response,
Environmental Regulations, Industrial
Hygiene, Equipment Safety, Control of
Hazardous Substances
Quality
Problem Solving, Continuous Improvement,
Manufacturing, Quality Planning, Quantitative
Methods, Six Sigma Methodology, AIAG Core Tools
(FMEA, APQP, PPAP, MSA, SPC, etc), Customer
Focus
 1.3 Production Process In Metal Working Industries

For producing of products in any Metal Working

Industries, materials are needed.
 It is therefore important to know the
characteristics of the available engineering
materials. Raw materials used manufacturing of
products, tools, machines and equipment's in
factories or industries are extracted from ores.
The ores are suitably converted the metal into a
molten form by reducing or refining processes
in foundries.
 This molten metal is poured into moulds for providing
commercial castings, Called ingots.
 Such ingots are then processed in rolling mills to obtain
market form of material supply in form of bloom,
billets, slabs and rods.
 These forms of material supply are further subjected to
various manufacturing processes for getting usable
metal products of different shapes and sizes in various
manufacturing shops.
All these processes used in manufacturing
concern for changing the ingots into usable
products may be classified into six major
groups.
 primary shaping processes,
 secondary machining processes,
 joining processes,
 surface finishing processes
 processes effecting change in properties.
And metal forming processes
 1.3.1 primary shaping processes
• Primary shaping processes are manufacturing of a
product from an amorphous material.(materials
having no fixed form or shape)
• Some processes produces finish products or articles
into its usual form where as others do not, and require
further working to finish component to the desired
shape and size.
• The parts produced through these processes may or
may not require to under go further operations. Some
of the important primary shaping processes is
Casting, Powder metallurgy, Plastic technology, Gas
cutting, Bending Forging
1.3.2 secondary machining processes
 As large number of components require further
processing after the
 The jobs undergoing these operations are the roughly
finished products received through primary shaping
processes.
 The process of removing the undesired or unwanted
material from the work piece or job or component to
produce a required shape using a cutting tool is known
as machining.
 This can be done by a manual process or by using a
machine called machine tool
 (traditional machines namely lathe, milling machine,
drilling, shaper,planner, slotter)
 These secondary processes are mainly required
for achieving dimensional accuracy and a very
high degree of surface finish.
 Some of the common secondary or machining
processes are Turning, Threading, Knurling,
Milling, Drilling, Boring, Planning, Shaping,
Grinding, Gear cutting, and Thread cutting
 Unconventional machining processes namely
machining
 Machining with Numerical Control (NC)
machines tools or Computer Numerical Control
(CNC) machines tools.
 1.3.3 Joining Processes
 Many products observed in day-to-day life, are
commonly made by putting many parts together may be
in subassembly.
 More than 800 parts are put together to make various
subassemblies and final assembly of car or aero-plane.
 The process of putting the parts together to form the
product , which performs the desired function, is called
assembly.
 An assemblage of parts may require some parts to be
joined together using various joining processes. But
assembly should not be confused with the joining
process.
 Joining processes are widely used in fabrication and
assembly work. For which two or more pieces of metal
parts are joined together to produce desired shape and size
of the product.

Some of the important and common joining processes are

 Welding (plastic or  Soldering,
fusion), Diffusion  Riveting,
welding and Explosive
 Nut and bolt joints
 welding
 Screwing,
 Brazing,,
 Keys and cotters joints
 Adhesive bonding
1.3.4 Surface Finishing Processes
 Surface finishing processes are utilized for imparting
intended surface finish on the surface of a job
 By imparting a surface finishing process, dimension of
part is not changed functionally; either a very negligible
amount of material is removed from the certain material is
added to the surface of the job
 These processes should not be misunderstood as metal
removing processes in any case as they are primarily
intended to provide a good surface finish or a decorative or
protective coating on to the metal surface
cleaning process also called as a surface finishing process.
Some of the commonly used surface finishing processes
are:
 Super finishing, Polishing,
 Sanding, Electroplating,
 Metal spraying, Painting,
 Inorganic coating, Anodizing,,
 Galvanizing, Plastic coating
 Metallic coating, Anodizing E.T.C
1.3.5 Processes Effecting Change in Properties
 Processes effecting change in properties are generally
employed to provide certain specific properties to the
metal work pieces for making them suitable for
particular operations or use.
 Heat treatments affect the physical properties and also
make a marked change in the internal structure of the
metal.
 Similarly the metal forming processes effect on the
physical properties of work pieces.
 A few such commonly used processes are Annealing,
Normalizing, Hardening, and Case hardening.
Annealing is a process involving heating and cooling,
usually applied to produce softening.
 Full Annealing
 Box Annealing Bright Annealing
 Stress Relieving
Normalizing may be defined as heating the steel to
austenite phase and cooling it in air
Case-hardening may be defined as a process for
hardening a ferrous material in such a manner that the
surface layer, known as the case, is substantially harder
than the remaining material, known as the core.
1.3.5 Metal Forming Processes
Definition of Metal Forming
Metal forming is the manufacturing by plastic
(permanent) change of the form of a solid body by
preserving both the mass and the cohesion.
 Large group of manufacturing processes in which
plastic deformation is used to change the shape of metal
work pieces
 The tool, usually called a die, applies stresses that
exceed yield strength of metal to be deformed .
Note;-The metal takes a shape determined by the
geometry of the die
 1.5 Metal Forming Processes
Sheet Metal-working Bulk Deformation
 Also called “Press-  Compressive deformation
working”. force.
 Cold working processes.  Significant deformations.
 Use set of punch and die.  Massive shape changes.
 Performed on metal sheets, Starting work shapes
strips and coils. include
 Generally two-axial stress  billets and rectangular bars.
states:  Generally multi-axial
 tensile-tensile/tensile compressive
compressed  stress states
1.5.1 Importance of Metal Forming in
Manufacturing Engineering
 Net Shape or Close to Net Shape.
 High Production Rate.
 High Profit Margin.
 Low Scrap Rate.
 Improving Material Properties.
1.5.2Current Issues of Metal Forming Industry
 Lack of Experienced Metal Forming Engineer.
 Short Product Life Cycle.
 New Metallic Materials.
 Developing New Hybrid Process.
 High Accuracy and Small Feature Products.
1.5.3 Skills Needed for Metal Forming
Engineering
Mechanics.
Material Science.
Manufacturing Process.
Design and Control.
Machinery.
Computer Skills.
FEA.
1.5.4 Applications and Products of Metal
forming in
 Macro Scale
 Automotive
 Aerospace
 Appliance
 Cookware
 • Etc.
Engineering Costs General Cost Terms
Manufacturing Costs
 Direct materials
 Direct labor
 Mfg. Overhead
Non-manufacturing Costs
 Overhead
 Marketing
 Administrative
Cost Components
Material Cost
 Direct material cost – Bill of Material (BOM) Non-
formula material cost – expense of consumables used
during processing.
Conversion Cost
 Capital depreciation
 Direct labor
 MBR – management budget review
 Scrap
 Tools and Dies
 Transportation
Cost Classification for Predicting Cost
Behavior
 Cost Behaviors
 Fixed costs.
 Variable costs.
 Average unit costs
Variable Costs
Def.: Costs that vary depending on the level of
production or sale.

Cost behavior: Increase or decrease proportionally

according to the level of volume

Examples: Costs of raw material, packaging material,

direct labor, machine utilities are main variable costs.

Break-Even Analysis (BEA)
An analysis to determine the point at which revenue
received equals the costs associated with receiving the
revenue. (the income that a company receives
regularly )
Break-even analysis calculates what is known as a
margin of safety, the amount that revenues exceed the
break-even point.
The total revenue depends on the production level.
The higher the production, the higher the total variable
costs.
In BEA, it is assumed that price of product is fixed.
 Benefits and Uses:
The evaluation to determine necessary
levels of service or production to avoid
loss.
Comparing different variables to
determine best case scenario.
 Defining Page:
 USP = Unit Selling Price
 UVC = Unit Variable costs
 FC = Fixed Costs
Q = Quantity of output units
sold (and manufactured)
 OI = Operating Income
 TR = Total Revenue
 TC = Total Cost
 USP = Unit Selling Price
 Getting Started:
Determination of which equation method to use:
Basic equation
Contribution margin equation
Graphical display
 Break-even analysis:
Break-even point
 John sells a product for $10 and it cost $5 to produce
(UVC) and has fixed cost (FC) of $25,000 per year

 How much will he need to sell to break-even?

 How much will he need to sell to make $1000?

 Algebraic approach:
Basic equation
Revenues – Variable cost – Fixed cost = OI
(USP x Q) – (UVC x Q) – FC = OI
$10Q - $5Q – $25,000 = $ 0.00
$5Q = $25,000
Q = 5,000

What quantity demand will earn $1,000?

$10Q - $5Q - $25,000 = $ 1,000
$5Q = $26,000
Q = 5,200
 Algebraic approach:
Contribution Margin equation
(USP – UVC) x Q = FC + OI
Q = FC + OI
UMC
Q = $25,000 + 0
$5
Q = 5,000
What quantity needs sold to make $1,000?
Q = $25,000 + $1,000
$5
Q = 5,200
 Graphical analysis:
Dollars
70,000 Total Cost Line
60,000
50,000
40,000
30,000
20,000
10,000 Total Revenue Break-even point
0 Line
1000 2000 3000 4000 5000 6000
Quantity
 Graphical analysis:
Cont.
Dollars
70,000
60,000 Total Cost Line
50,000
40,000
30,000
20,000
10,000 B Break-even point
Total Revenue Line
0
1000 2000 3000 4000 5000 6000
Quantity
 Scenario 1:
Break-even Analysis Simplified
• When total revenue is equal to total cost the
process is at the break-even point.

TC = TR
 Break-even Analysis:
Comparing different variables
 Company XYZ has to choose between two
machines to purchase. The selling price is $10
per unit.

 Machine A: annual cost of $3000 with per unit

cost (VC) of $5.

 Machine B: annual cost of $8000 with per unit

cost (VC) of $2.
 Break-even analysis:
Comparative analysis Part 1
Determine break-even point for
Machine A and Machine B.

Where: V = FC
SP - VC
 Break-even analysis:
Part 1, Cont.
Machine A:
v = $3,000
$10 - $5
= 600 units
Machine B:
v = $8,000
$10 - $2
= 1000 units
 Part 1: Comparison
Compare the two results to determine minimum
quantity sold.
Part 1 shows:
 600 units are the minimum.
 Demand of 600 you would choose Machine A.
 Part 2: Comparison
Finding point of indifference between Machine A
and Machine B will give the quantity demand
required to select Machine B over Machine A.

Machine A = Machine B
FC + VC = FC + VC
$3,000 + $5Q = $8,000 + $2Q
$3Q = $5,000
Q = 1667
 Part 2: Comparison
Cont.
 Knowing the point of indifference we will
choose:
 Machine A when quantity demanded is
between 600 and 1667.
 Machine B when quantity demanded exceeds
1667.
 Part 2: Comparison
Graphically displayed
Dollars
21,000
Machine A
18,000
15,000
12,000
9,000
6,000
3,000 Machine B
0
500 1000 1500 2000 2500 3000
Quantity
 Part 2: Comparison
Graphically displayed Cont.
Dollars
21,000 Machine A
18,000
15,000
12,000
9,000
6,000
3,000 Point of indifference Machine B
0
500 1000 1500 2000 2500 3000
Quantity
 Summary:
 Break-even analysis can be an effective tool in
determining the cost effectiveness of a
product.
 Required quantities to avoid loss.
 Use as a comparison tool for making a
decision.