Manufacturing Processes

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 Course Contents
1. Introduction
2. Dimensions, Surfaces, and Their Measurement
3. Metal Casting
4. Metal Forming
5. Material Removal Processes
6. Particulate Processing of Metals and Ceramics
7. Property Enhancing & Surface processing Operation
8. Assembly Technology

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 Chapter 1: Introduction
Content
1. What is Manufacturing?

2. Materials in Manufacturing

3. Manufacturing Processes

4. Production System

5. Trends in Manufacturing

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 What is Manufacturing?

“manufacture” = manus (hand) + factus (make) =

“made by hand” – an artificial item;

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 Manufacturing & Technology
- Manufacturing is a technology process:
Transforming materials into items of greater value by
adding value to the materials (changing its shape,
properties, or by combining it with other materials ...)
- Manufacturing is a series of processing/assembly
opeations

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 Manufacturing & Economics
Manufacturing increases value of material;

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 Modern Manufacturing

Apply new technology such as computer, control

theory to automated manufacturing (human only
control processes).
Three things to consider:
- Material

- Processes

- System

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 Roles of manufacturing

- Realization the technology

Use new material to reduce the weight of
bicycle from 16000g to 7324 g.

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 Roles of manufacturing

- Increase the value of items

-> gain profit to economy
Cost 100 $ Cost $ 1746

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 Roles of manufacturing

Level 1 level 2 Level 3

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Roles of manufacturing
Level 4

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 Industries
A part of economy, consisting of enterprises and
organization that produce or supply goods and services for
consumption or other manufacturing activities.
Manufacturing industries are classified:
- Primary industries: cultivate and exploit natural
resources such as agriculture and mining
- Secondary industries: take the outputs of the primary
industries and convert them into consumer or capital good
(manufacturing, construction, and power utilities)
- Tertiary industries: constitute the service sector of the
economy (banking, insurance, transportation…)
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 Industries – cont.

This course concerned with manufacturing industry –

secondary one, which produces a hardware (nuts, bolts,
to digital computers and military weapons …)

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 Manufacturing & Production
Difference:
- Manufacturing: processes affect DIRECTLY on
material to create items -> focusing on sequence of
processes.
Example: Manufacture phone cover, car frame…
- Production: has a broader meaning, focuses on
activities such as planning, organizing which make
items from raw material to finish item
Example:
Produce phone, automobiles …

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 Production Quantity - Q

Annual production quantity of a shop/company:

Low production: 1 – 100 units/year;

Medium production: 100 – 10.000 units/year

High production: 10.000 to millions of units

Q has strong effect to organization, equipment and

facilities, operation and production management

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 Product Varieties - P
Different product designs or types that are produced in the
plant. If the number of product types and designs is large →
Large product variety
P and Q have inverse correlation in terms of factory
operation.
A company produce only two kind of gloves but 5
millions for each/yr -> small P but large Q.
Boeing produces some decades of airplane each year but
including millions of different components -> small Q
and large P
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P- Q Correlation

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 Chapter 1: Introduction

1. What is Manufacturing?

2. Materials in Manufacturing

3. Manufacturing Processes

4. Production System

5. Trends in Manufacturing

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 Material in Manufacturing
Most of engineering materials can be classified into:
(1) Metals
(2) Ceramics
(3) Polymer
(4) Composites is a mixtures of the other three basic
types
Based on their properties, each has own manufacturing
processes

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 1. Metal
Classified into 2 group: ferrous and nonferrous
- Ferrous Metals: are based on iron (steel and cast iron),
more than three fourths of metal tonnage throughout the
world.
Steel: Fe+C; C = 0,02 ÷ 2%, and some other metal such
as Mg, Cr, Ni, Mb -> enhance properties
Cast iron: Fe+C; C = 2 ÷ 4% and Silicon
- Nonferrous Metal: include the other metallic elements and
their alloys: Al, Cu, gold, Mg, Ni, silver, Cr, Mn, Zn, Ti, W …

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 2. Ceramics
- Compound containing metallic
and nonmetallic elements
(oxygen, nitrogen, carbon,
alumina, silicon carbide,
nitrides)
- Divided into 2 groups:
crystalline ceramics and glasses
- Properties: Hard, britle, good
against wearing, heat, acid,
alkali
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 3. Polymers

-A compound formed of
repeating structural units
called mers, whose atoms
share electrons to form
very large molecules

- Usually consist of carbon plus one or more other

element such as hydrogen, nitrogen, oxygen, and
chlorine
- Divided into three categories: (1) thermoplastic
polymers, (2) thermosetting polymers, (3) elastomers
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 3. Polymers
-Thermoplastic polymers : multiple heating and cooling
cycles without substantially altering the molecular
structure of the polymer (polyethylene, polystyrene,
polyvinyl chloride, and nylon)
-Thermosetting polymers chemically transform (cure) into
a rigid structure on cooling from a heated plastic
condition; (phenolics, amino resins, and epoxies). Some
of these polymers cure by mechanisms than heating.
- Elastomers are polymers that exhibit significant elastic
behavior; hence the name elastomer (natural rubber,
neoprene, silicone, and polyurethane)
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 4. Composites

A material consisting of two or more phases that are

processed separately and then bonded together to achieve
properties superior to those of its constituents.
The term phases refers to a homogeneous mass of material
such as an aggregation of grains of identical unit cell
structure in a solid metal
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4. Composites

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 Chapter 1: Introduction

1. What is Manufacturing?

2. Materials in Manufacturing

3. Manufacturing Processes

4. Production System

5. Trends in Manufacturing

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Manufacturing processes

D
2

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 Manufacturing Processes
2 basic types:
- Processing Operations – transform a material from a state
to a more advanced state closer to the final desired product
-> it adds value by changing the
geometry, properties, or appearance of
the starting material

- Assembly operation – joins two

or more components to create a
new entity
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 Processing Operations
- Use energy to alter a workpart’s shape, physical
properties, or appearance to add value to the material.
Three types:
1. Shaping operation: change geometry of the work
material (solidification, particulate processing,
deformation and material removal process)
2. Property-Enhancing Processes – improve mechanical
or physical properties of the work material
3. Surface processing – (1) cleaning, (2) surface
treatments, (3) coating & thin film deposition processes
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 Assembly operation
Two basic methods:
1. Permanent joining processes:
▪ Welding, brazing,
soldering, and adhesive
bonding…
2. Mechanical assembly:
available to disassembly
▪ Threaded fasteners, rivets,
press fitting, and
expansion fits

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 Production machines & Tooling
Machine tools: supplied energy
(presently electricity) to perform
material removal processes –
variety and flexibility
Other kinds of machines: Pressing
machine, hammer machine,
rolling machine, welding machine
…
Manufacturing tools classified
into two types: multi-purpose and
dedicated

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 Chapter 1: Introduction

1. What is Manufacturing?

2. Materials in Manufacturing

3. Manufacturing Processes

4. Production System

5. Trends in Manufacturing

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 Overview
Production system consists of : Human, production
facilities, and manufacturing support systems.
Containing two main factors:
Production systems

Manufacturing
Production facilities
support systems
- Machines, tools - Manufacturing engineering
- Production layout/line - Planning, manufacturing
management
- Quality management
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 1. Production Facilities

Consisting of: Machine, tool, clamping devices,

production layout/shop
Equipments are effected directly to workpart
Facility layout to fit to types of productions -> called
plan layout.
All above are grouped to Manufacturing system.

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 Workshop layout base on production quantity
Three types of workshop layout
- Process layout:

- Fixed position layout

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Workshop layout base on production quantity
- Product layout:

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Workshop layout base on production quantity

• Quantity and production types

– Low-Quantity production: 1-100 units/year:
• Small product: -> Job shop
• Large/Huge product
Fixed position layout Process layout

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 Workshop layout base on production quantity

Medium-Quantity Production: 100 – 10.000 SP

- Batch production: Machine A process number of
workpieces, then change cutting tools, clamping
devices to process another one. The processed part is
moved to machine B or C to continue processing.
- Fit as product variety is hard -> consuming time to
change tools and set up

Process Layout

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 Workshop layout base on production quantity

Medium-Quantity Production: 100 – 10.000 SP

- Cellular manufacturing: Machine tools and tools are
organized into cell, including some kind of machines to
process a kind of product -> reduces the moving time of
workpart
- Fit as product variety is soft
-> time for setup and changing
tool is short
- Cellular layout

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 Workshop layout base on production quantity
High/mass production: > 10.000 units/yr
- Quantity production:
• Process single parts on single pieces of equipment
by standard machines equipped with special tooling
• Typical layout used: process or cellular layout
- Flow line production
• Highest productivity, equipment
or workstations arranged in
sequence, and the work unit are
physically moved through the
sequence to complete the
product
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 2. Manufacturing supports system
Classified into three groups:
- Manufacturing engineering: is responsible for planning
the manufacturing processes; designing and ordering the
machine tools and other equipment
- Production planning and control: responsible for logistic
problems (ordering material and purchased parts,
scheduling production, and making sure the necessary
capacity to meet the production schedule
- Quality control: design and build products that conform to
specification and satisfy/exceed customer expectations
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 Chapter 1: Introduction

1. What is Manufacturing?

2. Materials in Manufacturing

3. Manufacturing Processes

4. Production System

5. Trends in Manufacturing

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 Trends in manufacturing

4 basic trends:

(1) Lean production and six sigma

(2) Globalization and outsourcing

(3) Environmentally conscious manufacturing

(4) Microfabrication and Nanotechnology

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 Lean production and six sigma

Object to improve product quality and efficiency.

- Lean Production (Toyota Motor) is defined as „create
more with less resources“
Objectives of lean production is to eliminate 7 wastes:
(1) production of defectiv eparts, (2) production of
more parts than required, (3) excessive inventories,
(4) unnecessary processing steps, (5) unnecessary
movement of workers, (6) unnecessary movement
and handling of materials, and (7) workers waiting
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 Lean production and six sigma
6 Sigma was started in the 1980s at Motorola
Corporation in the United States.The objective was to
reduce variability in the company’s processes and
products to increase customer satisfaction.
Today, 6 Sigma can be defined as ‘‘a quality-focused
program that utilizes worker teams to accomplish
projects aimed at improving an organization’s
operational performance.’

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 Globalization and outsourcing
Globalization: as the world is becoming more and more integrated,
creating an international economy in which barriers once
establishedby national boundaries have been reduced or
eliminated.This has enabled a free flow of goods and services,
capital, technology, and people among regions and countries.

In manufacturing, outsourcing refers to the use of outside

contractors to perform work that was traditionally accomplished in
house. It can be done in several ways: the use of local suppliers or
job remain in the country) or in a foreign countries

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Environmentally conscious manufacturing

- This is a program to determine methods of using

material in the most efficiency to make products,
minimize the negative consequences to environment.

- Some terminology in common use: “green

production”, “clean production”, and “stability
production”

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 Microfabrication and Nanotechnology

New development trends to micro dimension range

which can not see by human eyes.

Microfabrication: produce element/product in micro

range (10-6 m) (printer head, DVDs disk..)

Nanotechnology: fabricate
element/product in nano
range (10-9 m) (LCD
screen, cancer drugs, ..)

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End of Chapter 1

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