MEEN 40030 Manufacturing Engineering II

Semester I

Manufacturing Engineering II
Dr. Eamonn Ahearne Dr. Vincent Hargaden Semester I (2011-2012)

UCD School of Mechanical and Materials Engineering

MEEN 4008 Manufacturing Engineering

Lectures I and II

Introduction to Manufacturing Engineering II

Eamonn Ahearne, Vincent Hargaden

UCD School of Mechanical and Materials Engineering

 UCD AMS, 2011

Lecture Content

1. Module Coordination & Description 2. The Economic Importance of Manufacturing / High Value Manufacturing 3. Manufacturing Paradigms / The Productivity Revolution 4. Scope of Module 5. Supply Chain Management 6. Innovation, Research and Development 7. Product Design and Design for X 8. The Engineer in Manufacturing and Manufacturing Engineering 9. Manufacturing Technologies Focus

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Module Coordinators

Professor Gerry Byrne

gerald.byrne@ucd.ie Manufacturing Engineering Processes & Technology

Dr. Eamonn Ahearne

eamonn.ahearne@ucd.ie Manufacturing Engineering Processes & Technology

Dr. Vincent Hargaden

vincent.hargaden@ucd.ie Production Operations/Supply Chain Management

UCD School of Mechanical and Materials Engineering

 UCD AMS, 2011

Manufacturing and The Modern Economy

Definition of Manufacturing
Manufacturing is the process of converting raw materials into products [Kalpak.] Manufacturing is the conversion of information into products by the controlled flow of energy [Van Brussel]

The Economic Importance of Manufacturing

Represents 20-30% of GDP in 1st World Economies: Japan, Germany, Italy, France, Sweden, Irelandbut USA, UK? EU is a nett exporter of high value added manufactured products Irish economic growth due to inward investment by manufacturing companies (Chemical-Pharmaceuticals, Computer-Electronics, Medical Devices) Irish manufacturing sales revenues of 90 Billion in 2007 High value-added manufacturing: a basis for sustained economic growth ?

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High Value Manufacturing

Medical Technologies Sector*
Estimated Output 7 billion PA

ICT Manufacturing and Services

Estimated Output 10 billion PA

Engineering Sector
including aerospace, automotive and precision engineering Estimated Output 5 billion PA

Green Engineering
Estimated Output 2.8 billion PA

*Med. Tech. Sector

Stats.

Chemical & Pharmaceuticals

Estimated Output 30.0 billion PA

More than 160 Med. Tech. Companies 15 of Global Top 25 Companies More than 24.000 employees

Food
Estimated Output 18.0 billion PA
[Extracted from Forfas-National Competitiveness Council Report Driving Export Growth, Dec 2009 & estimates from CSO trade statistics]

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High Value Manufacturing

Transformation of Industrial Base

59,000 60Bn
Modern Manufacturing

Employment 40Bn 86,000

Sales
Traditional Manufacturing

158,000

20Bn
Internationally-traded Services

Source: Forfs, 2008

15 1990 1995 2000 2007

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High Value Manufacturing

[Report of the High Level Group on Manufacturing, March 2008]

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High Value Manufacturing

[Report of the High Level Group on Manufacturing, March 2008]

UCD School of Mechanical and Materials Engineering

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Manufacturing Paradigms

Late 1800s Craft production, Karl Benz (1883) Early 1900s Mass production, vertical integration, Henry Ford, scientific management Mid 1900s Technical development, model variety 1970s Oil crisis, market saturation, global view 1980s Lean production, Toyota 1990s Outsourcing, consolidation 21st Century Mass customisation 21st Century Servitization Manufacturing + Services

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Manufacturing Engineering Module Scope

Global Level: Design of Manufacturing Supply Chains

Micro Level: Manufacturing Process Technology

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Supply Chain Management

Second tier supplier

First tier supplier

First tier customer

Second tier customer

End customer

Supply side

Demand side

Information flow Physical flow

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Supply Chain
Customer Customer Customer Customer

Distributio n center

Distributio n center

Manufacturer

Tier 1

Tier 2

Tier 3 Legend Supplier of services Supplier of materials

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Supply Chain

Mercedes-Benz A Class

Johnson Controls + Intier Eybl: door claddings

Brose: door modules

Johnson Controls: seats

Leoni: cable harnesses

Johnson Controls: dashboards

Radsystem: complete wheel

Nher: Intier Nher: carpeting WOCO: pedal modules

Decoma: front modules

Faurecia: exhaust system 15

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Supply Chain - V Class Minivan Seat

ABS Resin Bayer AG

Molding Simoldes Plasticos, Portugal Product Development Daimler-Benz Seat Manufacture Grupo Antolin Irausa, Spain Assembly Plant Daimler-Benz

50% lighter Reduced parts count Integrated seat belts 20% cost saving
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Innovation / Research and Development

6 Weight kg 3
6,2 kg

Market Led / Technology Led Continuous / Disruptive Product Development Drivers Market (Performance, Functionality and Price) Environment Cost or Profit o Reduced Quality Costs o Reduced Material Costs o Reduced Number of Components o Reduced Manufacturing Costs Legislation

[Bosch]

3,8 kg 2,6 kg 2,5 kg

1,8 kg

1989

1992

1995

1998

2001

Lab-on-Chip [HSG-IMIT]

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Innovation / Research and Development

The Development of an Industry: Communications

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Innovation / Research and Development Ceramic Valves

Improved Valve Dynamics Higher Valve Acceleration Reduction of Mechanical

Losses
Reduction of Valve Spring

Losses
Increase in Efficiency

Weight Comparison
Estimated Reduction of Fuel

Metal Ceramic
0 25 50 75 100

Consumption with the use of Ceramic Valves in Germany 250 Million Litres per Annum
[AWK]

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Innovation / Research and Development / The Design Process

[Kalpakian]

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Life Cycle Engineering / Example Design for Assembly

Design for Assembly

Redesign of Parts to Facilitate Automated Assembly. Source: Reprinted from G. Boothroyd and P. Dewhurst, Product Design for Assembly, 1989 by Courtesy of Marcel Dekker, Inc.

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The Engineer in Manufacturing

Role of Engineer in Manufacturing Management / Strategic Research and Development Product Design / Development Manufacturing System Design / Process Development Manufacturing Management / Team Leaders (Quality, Maintenance, Facilities etc.) Systems Design and Development (Quality, Maintenance, Facilities etc.) Technical Support (Specialists)
Managing Director

Marketing & Sales

R&D / Product Design

Manufacturing Engineering

Manufacturing

Accounts

Personnel

Quality

Maintenance

Purchasing

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Manufacturing Engineering / Definition [1]

Is an engineering activity / science which is concerned with all relevant functions within a manufacturing system. It involves: design for production the design, operation and control of production processes and production methods the planning scheduling and control of production (stock control) quality assurance Further, it links with and uses such disciplines as mechanical, electrical, chemical, materials and systems engineering as well as management. Manufacturing engineering embraces all the technical aspects of management, i.e. the operation and control of production. It also involves human, legal and social aspects of work and working in manufacturing industry.
[1] Dictionary of Production Engineering 3 (CIRP), ISBN 3-540-20555-1, Springer-Verlag

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Manufacturing System Change Drivers

Shorter Product Life-Cycles Higher Product Variety / Lower Volumes Reconfiguarable Production Systems Quality of Design Quality of Conformance Process Capability (Accuracy and Precision) Process Stability and Reliability Traceability & Certification Reduced Cost Capital Labour Quality Materials etc Human Resource Availability Environmental Legislation Design for Recycling Design for Disassembly Waste Management
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92 93 94 95 96 97 98 99 00 01 02 0.25 m 0.13 m 0.18 m

W SP W

0.35 m 0.6 m 1.0 m 0.b8 m

Year

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The Engineer in Manufacturing: System Control

Instructions

Schedules

Key Performance Indicators

Production Output Waste Time

Materials Click to enlarge Components Tooling Staff

Products

Manufacturing Processes

Scrap Data Analysis Yield

Time Machines Test Equipment Cost per unit

Time

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The Engineer in Manufacturing: System Control

Instructions Schedules

Manufacturing Processes

Materials Make Parts Components Make subassembly Tooling Test Staff Data Waste Assembly Scrap Products

KPIs

Machines

Test equipment

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Manufacturing Technologies Focus

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THE END
Thanks !

UCD School of Mechanical and Materials Engineering