BMKU1412 – Manufacturing Process

Chapter 1 - Introduction to
Manufacturing
Overview
Example of an Engineering Product
1. Aeroplanes – what are they made of?
2. Twin Tower Petronas – What is this building
composed of?
What is manufacturing?
Source: Automotive manufacturing solutions
WHAT IS MANUFACTURING

Machinery

Tooling

Power

Labor
Product
Raw materials Manufacturing
Process Profit

1) Technology – manufacturing is the application of physical and chemical processes to

alter the geometry, properties, and/or appearance of a given starting material to make
parts or products.
Manufacturing also includes the assembly of multiple parts to make products.
WHAT IS MANUFACTURING
Manufacturing
2) Economic – manufacturing is the Process

transformation of materials into items of

Value
greater value by means one or more added

processing involve. Therefore,

manufacturing is “added value” to the
Material in Processed
material. Starting
material processing material
WHAT WILL YOU LEARN?

Raw Material(s) Process(es) Products

• STEEL • TYPE OF • PROCESSES • SUBTRACTIVE PROCESSES
MANUFACTURING • FORMING AND SHAPING • CONTINOUS PROCESS
OPERATION AND • NET SHAPE PROCESS
LAYOUT
• ADDITIVE PROCESS
• JOINING PROCESS
QUALITY AND METROLOGY

SUSTAINABLE MANUFACTURING
 DEVELOPMENT
PRODUCT
INPUT FROM COMMENTS
CUSTOMERS INPUT FROM FROM
SUPPLIERS CUSTOMER

PRODUCT PRODUCT
PROJECT PROPOSAL PROJECT PLANNING DESIGN Project Done
MANUFACTURE LAUNCH

How manufacturing starts ?

 PLANNING
TEAM

PRODUCT
DESIGN TEAM
ENGINEERING/PRODUCTION
TEAM

Who ARE involve in manufacturing PROCESS?

HOW DISCUSSION TAKE PLACE?

CUSTOMERS PLANNING ENGINEERING/

SUPPLIERS
PRODUCTION
New feature
Quantity to produce Does the design can fit the
Destination market current equipment
Production location Need new machine?
Product life
Similar competitor model

PRODUCT DESIGN
TEAM
Translate planning design
Into manufacturable
design

Why concurrent engineering is important?

Traditional “waterfall” or sequential development vs. Iterative
development method in Concurrent Engineering
PLANNING TEAM PRODUCT DESIGN ENGINEERING/
TEAM PRODUCTION
TEAM

Sequential/over the wall engineering

How to select the right processes
DESIGN MATERIAL EXTERNAL REGULATIONS
• Size and shape of the final product • Material to be used (type and basic • Environment and
and raw material properties) • safety
• Geometry complexity • Castability/ weldability/Machinability
• parts with thin cross-sections
QUALITY MACHINES AND TOOLS
cannot be cast properly; complex
• Dimensional accuracy (tolerances) • Availability of machines
parts cannot be formed easily.
required and equipment
• Surface finish required -additional • Flexibility to change the
COST operations: grinding, polishing (better design at any time
• Economics (cost) of tooling, finish but more expensive!)
capital, scrap rate etc
• Operational and Cost QUANTITY
considerations: • Number of parts or products required
• Design and cost of tooling and
• desired production rate

TIME FRAME
• Lead time required to
begin production Additional reading
https://writepass.com/journal/2016/08/factors-that-affect-
selection-of-manufacturing-process-design-at-apple-inc/
Type of Process
Extrusion
 Type of
Industries
TYPE OF INDUSTRIES
Industries can be classified as:
SECONDARY
INDUSTRY

PRIMARY TERTIARY
INDUSTRY INDUSTRY

MANUFACTURING
INDUSTRIES
 Take the outputs of the
primary industries and
Those that CULTIVATE CONVERT them into
AND EXPLOIT natural consumer and
resources; capital goods.

Constitute with
• Aerospace SERVICE SECTOR of
• Agriculture
PRIMARY INDUSTRY

• Automotive • Banking
• Forestry • Beverages •the economy.
Communications

SECONDARY
INDUSTRY

TERTIARY INDUSTRY
• Fishing • Building materials • Education
• Livestock • Chemicals • Entertainment
• Quarries • Computers • Financial services
• Mining • Consumer appliances • Health and medical
• Petroleum • Electronics • Government
• Equipment • Hotel
• Food processing • Insurance
• Glass, ceramic • Restaurant
• Paper • Retail trade
• Pharmaceuticals • Tourism
• Plastics (shaping) • Transportation
• Textiles • Real estate
• Tire and rubber
• Wood and furniture
WHICH INDUSTRIES ARE INVOLVED IN THE EXAMPLES BELOW?
 11

• Manufacturing system can be defined as a transformation system in which a

product or service is created by working upon a set of inputs.

• Inputs are usually in the form of men, machine, money, materials etc. Production
systems are usually classified on the basis of product quantity and variety.

Intermittent Continuous
Project Mass
Batch
Jobshop
1) Project – 1 to 10 units.
[Low production]
2) Job shop – 10 to 100 units.

3) Batch – 100 to 10,000 units. [Medium production]

4) Mass – Above 10,000 units. [High production]

@jurie 2007 – Lecture 1

ATIONSHIP BETWEEN PRODUCT QUANTITY AND PRODUCT VAR

Above 10,000 units Continuous Production

System
Mass 100 to 10,000 units Intermitted Production
System
QUANTITY/VOLUME

High Batch 10 to 100 units

Product

Job shop 1 to 10 units

Medium
Project

Low

Product VARIETY

Production quantity: number of unit produced annually of a particular product type.

Product variety: different product designs or types that are produced in the plant.
Type of
Manufacturing
Operations
 TYPE OF MANUFACTURING OPERATIONS
1) PROJECT
• Position – remains stationary
during the manufacturing
process

• Materials, people, machinery

are brought to the product
site.

• Based on customer
specifications.

• Example: bridge, building

construction, aircraft, ships,
locomotive.
 A job shop is a type of manufacturing process in which small batches of a variety
of custom products are made. In the job shop process flow, most of the products
2) JOB SHOP produced require a unique set-up and sequencing of process steps.

 Low volume. Make-to-order

 Satisfies a market for nonstandard or
unique product.
 Layout – different machines with similar
functional are grouped together as
department.
 Require high skill levels labor – to
operate a variety of equipment
 A short duration activities to provide
custom goods.
 Example: Car workshop.
3) BATCH
 Batch production produce or process any product in groups
called “batches”.
 Can produce a variety of products – opposed to a
continuous production process, or a one time production.
 Useful for industries that makes seasonal items/products
 Example: Similar standard items made periodically in
batches: bakery, paint, hand tools.
 Same facilities used to manufacture all the different items.

Batch Production Examples:

Baked goods
Clothing
Computer software
Die- or mold-making
Electrical goods
- Reduce initial capital outlay
- due to a single production line can be used to several products
- machines can be used more effectively, materials can be bought in bulk
- workers can specialize in that task.

DISADVANTAGES

- Requires very careful production planning & control – next batches; when, types.
- When switching to another batches – takes time (“down time”) – can cause loss of output
(low yield).
- Resulted “WIP” or create inventory/stock – increases costs such as inventory
cost, cost because of damage to stock.
The example production line (shown below) is that of an engineering company, manufacturing small steel
products such as hinges and locks. They manufacture batches of five hundred at a time. The workers are
unskilled and semi skilled. As each task is completed the item being manufactured is passed down the
production line to the next worker, until it is complete.
 Mass production often involves the assembly of a number of
sub-assemblies of individual components. Parts may be bought
from other companies.

4) MASS
 A.k.a flow production, repetitive flow
production
 Producing goods in large quantities at low cost
per unit and produce in a short period of time.
 Involved fewer labor cost and a faster rate of
production.
 Work piece is transfer automatically from one
machine to another.
 Example: Cola-cola drinks, light bulbs,
refrigerator, tv.
Type of Plant
Layout
Manufacturing Plant Layout

Plant layout refers to an

optimum arrangement of
facilities including
personnel, operating
equipment, storage space,
material handling
equipment and all other
supporting services along Goal of Plant Layout
with the design of best To maximize the profit by arrangement of all the plant
structure to contain all facilities to the best advantage of total manufacturing of
these facilities”. the product.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
Plant Layout - Objectives
• Streamline the flow of materials through the plant.
Facilitate the manufacturing process.
• Minimize materials handling and cost.
• Effective utilization of men, equipment and space.
• Flexibility of manufacturing operations and
arrangements.
• Provide for employee convenience, safety and
comfort.
• Minimize investment in equipment.
• Minimize overall production time.
• Maintain flexibility of arrangement and operation.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
 Principles of
Plant Layout

Safety,
Minimum Minimum Cubic space Maximum
Integration security, and Flow
Distance handling utilization flexibility
satisfaction

A good layout The total Workers Reduces A good Materials to Can be

integrates distance safety and the material layout is move in altered
men, travelled by satisfaction handling to one that forward without much
materials, the men and and the utilizes both direction cost and
and materials safeguards minimum horizontal towards the time, i.e.,
machines in should be the plant and vertical completion future
order to get minimum and space. Also stage requirements
the optimum and as far as machinery the height
utilization of possible against fire,
resources straight line theft, etc.
and movement
maximum should be
effectiveness. preferred
 Type of
Layout

Flow Line Functional

Fixed Position Cellular
(Product) (Process)

 Fixed position Layoutproject

 Product LayoutMass Production
 Process LayoutBatch/jobshop
 Cellular LayoutHybrid

Extra Notes: http://slideplayer.com/slide/3715352/

 PROJECT

1. Fixed position layout

Fixed Position Layout This is also called the project type of layout.
• The material, or major components remain in a fixed location and tools, machinery, men and other
materials are brought to this location.
• Suitable when one or a few pieces of identical heavy products (huge) are to be manufactured and when
the assembly consists of large number of heavy parts, the cost of transportation of these parts is very high
and take a long time to produce.
Process layout is recommended for batch production. 2. Functional (process) layout
• Machines performing similar type of operations are
BATCH
grouped at one location in the process layout e.g., all
lathes, milling machines, etc. are grouped in the shop
will be clustered in like groups (according to
functions)

• The flow paths of material through the facilities from

one functional area to another vary from product to
product.

• Usually the paths are long and there will be

possibility of backtracking.

• Process layout is normally used when the production

volume is not sufficient to justify a product layout.

• Typically, job shops employ process layouts due to

the variety of products manufactured and their low
production volumes.
 MASS

3. Flow line (product layout)

 In this type of layout, machines and • Machines and equipment are positioned
auxiliary services are located along a flow line.
according to the processing • Several flow lines may come together to
sequence of the product. feed the final assembly line.
• Product passes from workstation to
 Plant arrangement to facilitate another workstation along the flow line.
material processing in the same • Special purpose machines are used which
order. perform the required function quickly and
reliably.
 Suitable for mass production system • High level of machine and manpower
as , the facilities can be arranged to utilization
achieve efficient flow of materials • Need to categorize operations to ensure
and lower cost per unit. equal processing time at all work stations
(line balancing).
When Applicable FLOW LINE (PRODUCT) LAYOUT

When the volume of production Product A

of a product is high such that a L L M D
separate production line to
manufacture it can be justified. Product B
L M M D
In a strict product layout,
machines are not shared by Product C
L G G D
different products. Therefore,
the production volume must be
sufficient to achieve satisfactory
utilization of the equipment.

A typical product layout is

shown in the following figure.
Advantages
• Reduced work handling leads to short
cycle time/piece.
• Less WIP
• Simple planning and control.
• Reduced labor skill.
• Good space utilization.

Disadvantages
• Limited flexibility
• Machine breakdown causes major
problem
• High setting up cost.
• Uses expensive special purpose machine
Difference between Process vs. Product Layout
4. Hybrid Layout (Cellular)
 Plant divided into groups or cells in a small unit (individual cell), consisting of one to several
workstations.

 A w/station can contains either one machine (known as a single machine cell), or several machines
(known as a group machine cell) with each machine performing a different operation on the part.

 Cells can process a complete family of parts – need to form families of products.

 The flow among the equipment in the cells can vary depending on the composition of parts within
the part family.

 Good example for the implementation of the concept of group technology.

 The machines at w/stations can be modified, retooled, and regroup for different product lines
within the same family of parts.

 Consist of two subsections which is Just-in-Time (JIT) and Lean Manufacturing

Group technology or GT is a manufacturing technique in which
parts having similarities in geometry, manufacturing process
and/or functions are manufactured in one location using a small
number of machines or processes.
 Relate to quantity &
Plant layout variety of product

Type of
Nature of manufac Tech
work operation
involved
Classificati Definition
Definition on
Intro to
Industry
Manufac Econ
classification
Select
People
process
Example involve
Factors to
consider
Roles