CHAPTER 1

Introduction

Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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What is manufacturing?
- Manufacturing:
In its broadest sense, the process of converting raw materials into products, consisting of the design and making of goods, using various production methods and techniques

- Automobile has about 15,000 parts,

C-5A transport plane more than 4 M parts Boeing 747-400 6M parts.

Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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- Origin: Manu factus (made by hand) in Latin - Manufacture was initially used in 1567 and manufacturing appeared in 1683 - Manufacturing in U.S.A. and Production Engineering in E.U. and Japan - Discrete products or Continuous products - Value addedness

Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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- Meet design requirements and specifications - Produced by the most economical ways - Quality - Flexibility of the processes - Require new materials, production methods, and computer integration - Reviewed as a large system - Strive for higher Productivity

Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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The design process and concurrent engineering

Design process:

Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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- Concurrent engineering is a systematic approach integrating the design and manufacture of products with the view of optimizing all elements involved in the life cycle of the product. - Direct engineering utilizes a database representing the engineering logic used in the design of each part of a product. If a design modification is made on a part. DE will determine the manufacturing consequences of that change. - CAD, CAE, CAM, and Rapid prototyping
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Design for manufacture and assembly

- DFM is a comprehensive approach to production of goods and integrates the design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance. - DFA and DFD 3-D conceptual designs and solid models. - Design for manufacture and assembly.
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Selecting materials
- Ferrous materials (carbon steels, etc) - Nonferrous materials (aluminium, magnesium, copper, titanium alloys, etc.) - Plastics (thermoplastics, thermoset, and elastomers) - Ceramics, glass ceramics, glasses, graphite, diamond - Composite materials (reinforced plastics, metal-matrix and ceramic-matrix composites, and honeycomb structures)
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- Properties of materials - Cost and availability - Appearance, service life, and recycling

Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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Selecting manufacturing processes

Casting Forming and shaping Machining Joining Finishing

Dimensional and surface finish considerations. Operational and manufacturing cost considerations. Consequences of improperly selecting materials and processes. Net-shape manufacturing.
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Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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Computer-integrated manufacturing
- Machine control systems: NC, CNC, AC, automated handling of materials, industrial robots - Computer technology: CIM CAD, CAM, CAPP, GT, FMS, JIT, AI, Expert System, Neural Network, Shared manufacturing
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Quality assurance and total quality management

- Quality must be built into a product from design stage through all subsequent stage of manufacture and assembly. Control the processes and not products. - Total quality management (TQM) and quality assurance - Statistical process control (SPC) - Experimental design
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Global competitiveness and manufacturing costs

- The design should be as simple as possible to manufacture, assemble, and recycle. - Materials should be chosen for the appropriate manufacturing characteristics. - Dimensional accuracy and surface finish specified should be as broad as permissible. - Because they can add significantly to cost, secondary and finishing processing of parts should be avoided or minimized.

Kalpakjian, Manufacturing Processes for Engineering Materials

1997 Addison Wesley

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Lean production and agile manufacturing

- Lean production or lean manufacturing involves a major assessment of each of a companys activities. - Agile manufacturing ensures flexibility in the manufacturing enterprise so it can quickly respond to changes in product demand and customer needs.
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Environmentally conscious design and manufacturing

- Reducing waste of materials at their source by refinements in product design and reducing the amounts of materials used. - Conducting R&D in environmentally safeproducts and manufacturing technologies. - Reducing the use of a hazardous materials in products and processes. - Ensuring proper handling and disposal of all waste. - Making improvements in recycling, waste treatment, and reuse of materials.
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Product liability
- The aspects that deal with product safety and the resource a customer has if and when a product is defective. - Protection strategy for legal and technical aspects for the consequence of using a product that has malfunctioned, causing bodily injury, or even death, and financial loss to a person or organization.
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Organization for manufacture

- View the people in the organization as important assets. - Emphasize the important and need for teamwork and involvement in problem solving and decisionmaking processes in all aspects of operations. - Encourage product innovation and improvements in productivity. - Encourage efforts for continuous improvement in quality - Increase flexibility of operation for faster response to product demands in both the domestic and global marketplace - Ultimately and most importantly, focus on customer satisfaction
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