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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)
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
PRODUCT
DESIGN TEAM
ENGINEERING/P
RODUCTION
TEAM
PRODUCT DESIGN
TEAM
Translate planning design
Into manufacturable
Design
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
Constitute with
• Aerospace SERVICE SECTOR of
PRIMARY INDUSTRY
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:
1) Project – 1 to 10 units.
[Low production]
2) Job shop – 10 to 100 units.
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.
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”.
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 Layoutproject
Product LayoutMass Production
Process LayoutBatch/jobshop
Cellular Layout??
http://slideplayer.com/slide/3715352/
PROJECT
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