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BMCG 2312 – 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

Raw Material(s)

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
ECONOMIC PROCESS Process
2) Economic – manufacturing is the
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.
Starting Material in Processed
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
LAYOUT NET SHAPE PROCESS
ADDITIVE PROCESS
JOINING PROCESS
QUALITY AND METROLOGY

SUSTAINABLE MANUFACTURING
DEVELOPMENT
DEVELOPMENT
PRODUCT
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/P
RODUCTION
TEAM

Who ARE involve in manufacturing PROCESS?


HOW DISCUSSION TAKE PLACE?

CUSTOMERS PLANNING ENGINEERING/PR


SUPPLIERS
ODUCTIO N
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/PR
TEAM ODUCTION 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
Process available
Extrusion

• Casting
• forming and shaping (F&S) (bulk deformation process)
• F&S (Polymer)
• F&S (Sheet Metal)
• Machining
• Joining
Type of
Industries
TYPE OF INDUSTRIES

Industries can be classified as:

@jurie 2007 – Lecture 1


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
PRIMARY INDUSTRY

• Agriculture • Automotive • Banking


• Forestry the economy.

SECONDARY
INDUSTRY

TERTIARY INDUSTRY
• Beverages • Communications
• 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?
TYPE OF MANUFACTURING SYSTEM/OPERATIONS11
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 the following:

Product quantity Intermittent


Product variety
PROJECT
The system can be divided into two
BATCH
categories; JOBSHOP
Intermittent and Continuous system
Continuous
MASS
TYPE OF MANUFACTURING OPERATIONS

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


RELATIONSHIP BETWEEN PRODUCT QUANTITY AND PRODUCT VARIETY
Above 10,000 units Continuous Production
System
Mass 100 to 10,000 units Intermitted Production
QUANTITY/VOLUME System
High Batch 10 to 100 units
Product

Job shop 1 to 10 units


Medium
Project
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
- Product position – remains stationary during the manufacturing process – size,
weight, location of the product.
- 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
- Also known as 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.
- Operation is done base on specific product
- 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 with
the design of best structure to
contain all these facilities”.

Goal of Plant Layout


To maximize the profit by arrangement of all the plant
facilities to the best advantage of total manufacturing of
the product.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
Plant Layout
Objectives of plant layout
• 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
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
Fixed position Layoutproject
Product LayoutMass Production
Process LayoutBatch/jobshop
Cellular Layout??

http://slideplayer.com/slide/3715352/
PROJECT

1. Fixed position layout


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

The product layout is selected Product A


when the volume of production L L M D
of a product is high such that a
separate production line to Product B
manufacture it can be justified. LL M M D
D

In a strict product layout, Product C


LL G G D
G
machines are not shared by
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

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