MEC 323

PRIMARY MANUFACTURING
UNIT – 1
General Introduction
To
Manufacturing Processes
 What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means “made by hand”

 “Made by hand” accurately described the fabrication

methods that were used when the English word
“manufacture” was first coined around 1567 A.D.

 Most modern manufacturing operations are

accomplished by mechanized and automated
equipment that is supervised by human workers
 Manufacturing Processes
Manufacturing Process: The process of producing the desired object from the raw
material is called manufacturing process.
Classification :
Primary Shaping Processes: Primary shaping processes include:
a) Casting b) Forging c) Smithy d) Drawing
e) Rolling f) Bending g) Extruding h) Squeezing
i) Shearing j) Crushing k) Spinning l) Piercing
m) Forming n) Embossing
Machining Processes: Machining operations are performed on various machines (e.g.
Lathe, Shaper, Milling , Drilling , Grinder etc.)
a) Shaping b) Turning c) Milling d) Drilling
e) Grinding f) Boring g) Threading h) Slotting
i) Planing j) Gear Cutting k) Knurling l) Sawing
m) Broaching n) Hobbling.
 Manufacturing Processes
 Surface Finishing Processes:
These processes are used to provide a good surface finish to the metal surface of
the product.
In this, either a negligible amount of metal is removed or a small amount of
material is added to the surface of the product.
Various surface finishing processes are:
a) Sand blasting b) Buffing c) Lapping
d) Belt grinding e) Polishing f) Honing
g) Electroplating h) Metal spraying i) Anodizing
j) Phosphating k) Parkerizing l) Tumbling
m) Pickling n) Hot dipping o) Superfinishing
p) Galvanizing q) Painting.
• Parkerizing, bonderizing, phosphating, or
phosphatizing is a method of protecting a
steel surface from corrosion and increasing its
resistance to wear through the application of
a chemical phosphate conversion coating.
 Manufacturing Processes
 Joining Processes:
These processes are used for joining two or more pieces of metal parts. Various
joining processes are:
a) Welding b) Soldering c) Brazing
d) Riveting e) Screwing f) Adhesive joining
g) Sintering h) Pressing i) Coupling
j) Keys and cotter joints k) Nut and bolts joints.

 Processes Affecting Change in Properties:

These processes are used to impart certain specific properties to the metal part for
specific conditions of use. The following processes are used for this purpose:
a) Annealing b) Normalizing c) Hardening
d) Tempering e) Patenting f) Age hardening
g) Shot peening h) Grain refining i) Homogenizing
Another Classification Method
Manufacturing Processes

Two basic types:

1. Processing operations - transform a work material
from one state of completion to a more advanced state
– Operations that change the geometry, properties, or
appearance of the starting material

2. Assembly operations - join two or more components to

create a new entity
Classification of Manufacturing
Processes
 Processing Operations
Alter a material’s shape, physical properties or
appearance in order to add value
 Three categories of processing operations:
1. Shaping operations - alter the geometry of the
starting work material
2. Property-enhancing operations - improve
physical properties without changing shape
3. Surface processing operations - to clean, treat,
coat, or deposit material on exterior surface of
the work
Shaping Processes – Four Categories

1. Solidification processes - starting material is a

heated liquid or semi-fluid

2. Particulate processing - starting material

consists of powders

3. Deformation processes - starting material is

ductile solid (commonly metal)

4. Material removal processes - starting material is

a ductile or brittle solid
Solidification Processes

Starting material is heated sufficiently to transform it into a

liquid or highly plastic state
 Examples: metal casting, plastic molding
Particulate Processing

Starting materials are powders of metals or ceramics

 Usually involves pressing and sintering, in which
powders are first compressed and then heated to bond
the individual particles
Deformation Processes

Starting workpart is shaped by application of forces

that exceed the yield strength of the material
 Examples: (a) forging, (b) extrusion
 Material Removal Processes
Excess material removed from the starting piece so what
remains is the desired geometry
 Examples: machining such as turning, drilling, and milling;
also grinding and nontraditional processes
Waste in Shaping Processes
 Desirable to minimize waste in part shaping
 Material removal processes are wasteful in unit
operations, simply by the way they work
 Most casting, molding, and particulate processing
operations waste little material
 Terminology for minimum waste processes:
– Net shape processes - when most of the starting
material is used and no subsequent machining is
required
– Near net shape processes - when minimum amount
of machining is required
Property- Enhancing Processes
Performed to improve mechanical or physical properties of
work material

 Part shape is not altered, except unintentionally

– Example: unintentional warping of a heat treated part
 Examples:
– Heat treatment of metals and glasses
– Sintering of powdered metals and ceramics
 Surface Processing Operations
 Cleaning - chemical and mechanical processes to
remove dirt, oil, and other contaminants from the
surface

 Surface treatments - mechanical working such as

sand blasting, and physical processes like diffusion

 Coating and thin film deposition - coating exterior

surface of the workpart
 Assembly Operations
Two or more separate parts are joined to form a new entity

 Types of assembly operations:

1. Joining processes – create a permanent joint
 Welding, brazing, soldering, and adhesive
bonding

2. Mechanical assembly – fastening by mechanical

methods
 Threaded fasteners (screws, bolts and nuts);
press fitting, expansion fits
Importance of Manufacturing
Manufacturing is Important
 Technologically
 Economically
 Historically
Manufacturing - Technologically
Technology - the application of science to provide
society and its members with those things that are
needed or desired

 Technology provides the products that help our

society and its members live better

 What do these products have in common?

– They are all manufactured

 Manufacturing is the essential factor that makes

technology possible
Manufacturing - Technologically
Application of physical and chemical processes to alter
the geometry, properties, and/or appearance of a
starting material to make parts or products
 Manufacturing also includes assembly
 Almost always carried out as a sequence of
operations
Figure (a):
Manufacturing
as a technical
process
Manufacturing – Economically
Manufacturing is one way by which nations
create material wealth
Manufacturing - Economically
Transformation of materials into items of greater value
by means of one or more processing and/or assembly
operations
 Manufacturing adds value to the material by
changing its shape or properties, or by combining it
with other materials
Figure (b):
Manufacturing
as an economic
process
Manufacturing - Historically
Throughout history, human cultures that were better
at making things were more successful

 Making better tools meant better crafts & weapons

– Better crafts allowed people to live better
– Better weapons allowed them to conquer other
cultures in times of conflict

 To a significant degree, the history of civilization is

the history of humans' ability to make things
Manufacturing Industries
Industry consists of enterprises and organizations that
produce or supply goods and services

 Industries can be classified as:

1. Primary industries - those that cultivate and exploit

natural resources, e.g. farming, mining
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and capital
goods - manufacturing is the principal activity
3. Tertiary industries - service sector
Manufacturing Industries

 Secondary industries include manufacturing,

construction, and electric power generation

 Manufacturing includes several industries whose

products may be apparel, beverages, chemicals, and
food processing

 For our purposes, manufacturing means production of

hardware
– Nuts and bolts, forgings, cars, airplanes, digital
computers, plastic parts, and ceramic products
 Production Quantity Q

The quantity of products Q made by a factory has an

important influence on the way its people, facilities, and
procedures are organized

 Annual production quantities can be classified into three

ranges:

Production range Annual Quantity Q

Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of
 Product Variety P
Product variety P refers to different product types or
models produced in the plant
 Different products have different features
– They are intended for different markets
– Some have more parts than others

 The number of different product types made each year in

a factory can be counted

 When the number of product types made in the factory is

high, this indicates high product variety
P versus Q in Factory Operations

Figure 1.2 P-Q Relationship

 More About Product Variety

 Soft product variety - small differences

between products, e.g. between car models
made on the same production line, with
many common parts among models

 Hard product variety - products differ

substantially, e.g. between a small car and a
large truck, with few common parts (if any)
 Manufacturing Capability
A manufacturing plant consists of processes and systems
(and people, of course) designed to transform a certain
limited range of materials into products of increased value

 The three building blocks - materials, processes, and

systems - are the subject of modern manufacturing

 Manufacturing capability includes:

1. Technological processing capability
2. Physical product limitations
3. Production capacity
 Technological Processing Capability
The available set of manufacturing processes in the plant
(or company)
 Certain manufacturing processes are suited to certain
materials
– By specializing in certain processes, the plant is also
specializing in certain materials
 Includes not only the physical processes, but also the
expertise of the plant personnel
 Examples:
– A machine shop cannot roll steel
– A steel mill cannot build cars
 Physical Product Limitations
Given a plant with a certain set of processes, there are size
and weight limitations on the parts or products that can be
made in the plant

 Product size and weight affect:

– Production equipment
– Material handling equipment

 Production, material handling equipment, and plant size

must be planned for products that lie within a certain size
and weight range
 Production Capacity
Defined as the maximum quantity that a plant can
produce in a given time period (e.g. month or year) under
assumed operating conditions

 Operating conditions refer to number of shifts per

week, hours per shift, direct labor manning levels in the
plant, and so on

 Usually measured in terms of output units, such as tons

of steel or number of cars produced by the plant

 Also called plant capacity

 Effects of various elements
• Increasing carbon content increases hardness and strength and
improves hardenability. But carbon also increases brittleness and
reduces weldability
• Sulphur improves machinability
• Manganese is added to steel to improve hot working properties and
increase strength, toughness and hardenability.
• Nickel strongly increases the hardenability of steel, and markedly
improves the corrosion resistance of alloys
• Phosphorus increases strength and hardness, but at the expense of
ductility and impact to toughness. It increases resistance to corrosion
and improves machinability in free-cutting steels
• Chromium is added to steel to increase resistance to oxidation
• Molybdenum adds corrosion resistance and high temperature strength
• Vanadium increases hardenability strongly in small quantity. It
increases the yield strength and the tensile strength of carbon steels
 Selection of Materials
Introduction
Materials lie at the base of all technological advances. A wide range of materials find use
in engineering applications. Materials are the building block of technology. Materials
and processing methods are necessary for good quality products.

Classifications of Materials
Engineering materials may be classified as follows:
1) Metals 2) Non-metals
Metals are further divided into categories:
1) Ferrous Metals: Ferrous metals contain iron as the main constituent e.g., Cast Iron,
Wrought Iron, Steel and alloys (Silicon steel, High speed steel, spring steel etc.).
2) Non-ferrous Metals : Non-ferrous materials are those which do not contain iron as
the main constituent e.g. copper, aluminum, zinc, lead etc. and alloys (brass, bronze,
duralumin etc.)
 Selection of Materials
Properties of Ferrous Metals
CAST IRON
The cast iron is obtained by re-melting pig iron with coke, limestone and steel scrap in
furnace known as cupola. It is primarily an alloy of iron and carbon. The carbon
percentage varies from 1.7 to 4.5 per cent. It also contains small amount of silicon,
manganese, phosphorus and sulphur.

Properties:
Cast iron is brittle, having low cost, good casting characteristics, high compressive
strength, high wear resistance, excellent machinability,
Tensile strength - 100 to 200 Mpa, Compressive strength - 400 to 1000 MPa.
Shear strength - 120 Mpa
Cast iron is weak in tension so it cannot be used for making bolts and machine parts
which are liable to tension.
Selection of Materials

Types of Cast Iron: Cast Iron may be classified as follows:

1. Grey cast iron
2. White cast iron
3. Nodular cast iron
4. Malleable cast iron
5. Alloy cast iron
6. Mechanite cast iron
7. Chilled cast iron
 Selection of Materials
Grey Cast Iron

Composition:
It is basically an alloy of carbon and silicon with iron. It contains C = 2.5- 3.8%, Si =
1.1-2.8%, Mn = 0.4-1%, P = 0.15% and S = 0.10%.
Properties:
1. This Iron contains greater part of carbon in the form of graphite flakes. This is
obtained by allowing the molten metal to cool and solidify slowly.
2. When fractured, a bar of grey cast iron gives grey appearance.
3. Grey cast iron is having good fluidity, so it can be cast into complex shapes and
thin sections efficiently.
4. It possesses lowest melting point of the ferrous alloy.
5. It possesses machinability better than steels.
6. It has high resistance to wear.
7. It possesses high vibration damping capacity.
 Selection of Materials

8. It possesses high compressive strength. It can withstand about 60 to 75 kgf/

mm2 (600 to 750 N/mm2) before fracturing.

9. Its shear strength is approximately 150 to 225 N/mm2.

10. Its hardness ranges from 150-240 BHN (Brinell Hardness Number).

11. It is brittle and may easily be broken if a heavy hammer is used.

12. Grey cast iron has low ductility and low impact strength as compared with steel.
Selection of Materials

Uses:
1. Rolling mill and general machinery parts.

2. Machine tool structures e.g. bed, frame etc.

3. Manhole covers.

4. Cylinder blocks and heads for I.C. engines.

5. Frames for electric motors.

6. Sanitary works.

7. Household appliances.

8. Gas or water pipes for underground purposes.

Selection of Materials

White Cast Iron

Composition:
Iron 94%, graphite carbon = 0.5%, combined carbon = 3.5%, Si = 0.5 1.5%, Mn =
0.2-0.8%, P = 0.18%, S = 0.10%.
Properties:
1. Because carbon is in combined form (cementite), that is why it is hard and
brittle, so it cannot be machined easily. Hardness ranges from 400 to 600
BHN.
2. Tensile strength is good.
3. Freshly broken surface shows a bright white fracture that is why it is called
white cast iron.
4. This is obtained by the presence of relatively large quantities of manganese, a
very small amount of silicon and by rapid cooling.
Selection of Materials

5. Highly resistant to wear.

6. Due to its poor fluidity, it does not fill the mould freely.
7. White iron casting can be made in sand moulds.
8. The solidification range of white iron is 2550-2065°F.

Uses:
1. Used for inferior castings and does not rust so much as grey variety.
2. Used for parts subjected to excessive wear, e.g. in rim of car wheel
or railway brake block.
Selection of Materials

Malleable Cast Iron

Malleable cast iron is an alloy in which all the combined carbon in white cast iron
has been changed to free or temper carbon by suitable heat treatment.

Properties:
1. It is more like low carbon steels than cast irons.
2. It is more costly than grey cast iron because of the time required for annealing,
but cheaper than softer steels.
3. It has tensile strength of approximately 3800 kgf/cm2 with an elongation of
18%.
4. It is stronger and more resistant to shocks than grey cast iron.
5. It possesses high yield strength.
6. It can be hammered and rolled to different shapes.
7. It has high Young's Modulus and low coefficient of thermal expansion.
Selection of Materials

Uses:

1. Tractor springs.
2. Washing machine parts.
3. Rail road etc.
4. Brake pedals.
5. Automotive crankshafts.
6. Differential and steering gear housings.
 Effects of various elements
• Increasing carbon content increases hardness and strength and
improves hardenability. But carbon also increases brittleness and
reduces weldability
• Sulphur improves machinability
• Manganese is added to steel to improve hot working properties and
increase strength, toughness and hardenability.
• Nickel strongly increases the hardenability of steel, and markedly
improves the corrosion resistance of alloys
• Phosphorus increases strength and hardness, but at the expense of
ductility and impact to toughness. It increases resistance to corrosion
and improves machinability in free-cutting steels
• Chromium is added to steel to increase resistance to oxidation
• Molybdenum adds corrosion resistance and high temperature strength
• Vanadium increases hardenability strongly in small quantity. It
increases the yield strength and the tensile strength of carbon steels
Selection of Materials

STEEL

It is an alloy of iron and carbon, with carbon content upto a maximum of 1.5%.
Other elements such as silicon, sulphur, phosphorus and manganese are also
added to improve the various qualities of steels. Carbon present in the steel is in
combined form.
Plain carbon steels are classified according to their carbon content, as follows:
1. Mild steel
2. Medium carbon steel
3. High carbon steel
Selection of Materials
Mild Steel
1. Mild Steel is having carbon 0.15 to 0.3 per cent.
2 . It is having bright fibrous structure.
3 . It is tough and more elastic than wrought iron.
4 . It can be easily forged and welded.
5. It is malleable and ductile.
6 . It absorbs shocks.
7 . Its tensile strength is better than cast iron and wrought iron.
8. Compressive strength is better than wrought iron but less than cast
iron.
8 . It rusts readily.
9 . Its melting point is 1400°C.
Selection of Materials

Uses:
1. Mild steel containing 0.15 to 0.20% carbon:
It is used in structure steels, universal beams, screws, drop forgings, case
hardening steel, bars, rods, tubes, angles and channels etc.
2. Mild steel containing 0.20-0.30% carbon:
It is used in machine and structure work, gears, free cutting steels, shafting
and forging etc.
Selection of Materials

Medium Carbon Steels having carbon from 0.3 to 0.8 %

They usually are produced as killed or semi killed steels and
are hardenable by heat treatment.
Hardenability is limited to thin sections or to the thin outer
layer on thick parts.
Medium carbon steels in the quenched and tempered
condition provide a good balance of strength and ductility.
Selection of Materials

Killed steel is steel that has been completely deoxidized before

casting, so that there is practically no evolution of gas during
solidification.
They are characterized by a high degree of chemical
homogeneity and freedom from gas porosity.

Semi-killed steel refers to steel that has been partially

deoxidized with minimal gas release during solidification.
Semi-killed steel presents a high degree of homogeneity on the
molecular level.
It also has minimal degrees of gas porosity, making it ideal for
heat treatment.
Generally, more gas is evolved in semi-killed steel than in killed
steel.
Selection of Materials

1. Medium carbon steels having carbon % 0.30 to 0.45 :

Axles, special duty shafts, connecting rods, forgings, machinery steel,
spring clips, turbine rotors, gear shafts, key stock, forks and anchor bolts.

2. Medium carbon steels having carbon % 0.45 to 0.60 :

Railway coach axles, crank pins, crankshafts, axles, spline shafts, loco
tyres, rails.

3. Medium carbon steels having carbon % 0.60 to 0.80 :

Drop forging dies, die blocks, bolt heading dies, self-tapping screws, valve
springs, lock washers, hammers, cold chisels, hacksaws, jaws for vices
etc.
Selection of Materials

High Carbon Steels

1. These steels have carbon percentage from 0.8 to 1.5%.
2. Because of their high hardness, these are suitable for wear resistant parts.
3. Spring steel is also high carbon steel available in annealed and pre-tempered
strips and wires.
4. High carbon steel loses their hardness at temperature from 200°C to 250°C.
Therefore they may only be used in the manufacture of cutting tools operating
at low cutting speeds.
5. These steels are easy to forge and simple to harden
Selection of Materials

Uses:
1. When carbon % is from 0.80 to 0.90.
Railway rails, rock drills, circular saws, punches and dies, leaf springs.

2. When carbon % is from 0.90 to 1.20.

Punches and dies, springs, balls, pins, railway springs, mandrels, taps, tools,
thread metal dies.

3. When carbon % is from 1.20 to 1.5

Files, dies for wire drawing, broaches, saws for cutting steel, tools for turning
chilled iron etc.
Comparison of Cast iron, Mild steel and Hard steel

Sr. Mild Steel Hard Steel

No. Cast Iron
(Low Carbon Steel) (High Carbon Steel)

1 It contains 2 to 5% Contains 0.08 to 0.35 % carbon Contains 0.55 to 1.5 % carbon

carbon.
2 It is hard and brittle Tough and more elastic than Tough and more elastic than
wrought iron. mild steel.

3 Can neither be forged Can be easily forged and welded. Can be easily forged and
nor welded. welded.

4 It has crystalline, coarse It has fibrous structure (Bright) It has fine granular structure.
granular structure.

5 It can be hardened by Can be hardened and tampered Can be hardened and

heating and sudden but not easily tampered easily.
cooling but cannot be
tempered.

6 Neither malleable nor Malleable and ductile. Brittle and less ductile.
ductile.

7 Does not rust easily. Rusts readily. Rusts rapidly.

Sr. Mild Steel Hard Steel
No. Cast Iron
(Low Carbon Steel) (High Carbon Steel)
8 Cannot absorb shocks. It absorbs shocks. It absorbs shocks.
9 Melting point = 1200°C. Melting point = 1400°C. Melting point = 1300°C.
It
10 Cannot be magnetised. It can be permanently magnetised. It can be permanently
magnetised.
11 Tensile strength is least Tensile strength is better than cast Tensile strength is better than
iron and wrought iron. cast iron, wrought iron and
mild Steel.

12 Compressive strength is Compressive strength is better Compressive strength is better

good than wrought iron but less than then cast iron, wrought iron
cast iron and mild steel.
13 Uses: (i) It is used for all kind of (i) Used for dies, cutlery and
(i) It is used for making structure work in bridges and edge tools.
bed plates, columns, buildings (e.g."girders, rails,
rail chairs, machine angles). (ii) Used in prestress
parts concrete.
(ii) Used for rivets bolts, wire
(ii) It is used for screws, tapes and for making sheets.
drain pipes, water pipes
because of good
corrosion resistance.
 Selection of Materials

High Speed Tool Steels

 High Speed Steels (HSS) have been given this name due to the fact that these

may be operated as cutting tools at much higher speeds than is possible with

plain carbon tool steels.

 HSS cutting tools operate at cutting speed 2 to 3 times higher than for carbon

steels.

 At higher cutting speeds, sufficient heat may be developed during the cutting

operation. This heat causes the cutting edge of the tool to reach a high heat (red

hot).

 This heat softens the carbon tool steel and thus the tool will not work efficiently

for a longer period.

Selection of Materials

 High speed steels have the property of retaining their hardness even
when heated to red hot.
 High hardness at elevated temperatures is developed by addition of
elements such as tungsten, chromium and vanadium to high carbon
steels.
 There are four general types of high speed steels:
 High Speed Steel
 Cobalt High Speed Steel
 Molybdenum High Speed Steel
 Vanadium High Speed Steel
 Selection of Materials

High Speed Steel

This steel contains 18 per cent tungsten, 4 per cent chromium and 1
per cent vanadium.
It is considered to be one of the best of all purpose tool steels.
This brand of high speed steel is used for machining operations on
steel and non-ferrous materials.
Uses: It is extensively used for lathe, planer and shaper tools, drills,
reamers, broaches, milling cutters, punches etc.
 Selection of Materials

Cobalt High Speed Steel

This is also known as super high speed steel, because cutting tool made of
this steel can be operated at much higher speeds than 18-4-1 high speed
steel.
In this steel, cobalt is added from 2 to 15 percent in order to increase the
cutting efficiency especially at high temperatures.
Generally cobalt high speed steel contains 20% tungsten, 4% chromium, 2%
vanadium and 12% cobalt.
Since the cost of this steel is more, therefore, it is principally used for heavy
cutting operations which impose high pressure and temperature on the tool
Selection of Materials

Molybdenum High Speed Steel

Generally, this steel contains 6% molybdenum, 6% tungsten, 4%
chromium and 2% vanadium.
It has excellent toughness and cutting ability.
Molybdenum high speed steel are better and cheaper than other types of
steels particularly for drilling and tapping operations.
Selection of Materials

Vanadium High Speed Steel

Generally, this steel contains more than 1 per cent vanadium and 0.70%
carbon. This steel has better abrasive resistant than 18-4-1 HSS steel.
It is preferred for machining difficult to machine materials.

High speed steels are close competitors to carbides for metal cutting-tool
materials such as drills, reamers, milling cutlers etc.
In addition to heat resistance, high speed steels have the desirable
properties of high hardness, high compressive strength and outstanding
wear resistance.
 Ceramics
Compounds containing metallic and nonmetallic elements.

 Typical nonmetallic elements are oxygen, nitrogen, and

carbon

 Ceramics are divided into:

1. Crystalline ceramics – includes:
 Traditional ceramics, such as clay (hydrous
aluminum silicates)
 Modern ceramics, such as alumina (Al2O3)

2. Glasses – mostly based on silica (SiO2)

 Polymers
Compound formed of repeating structural units called
mers, whose atoms share electrons to form very large
molecules
 Three categories:
1. Thermoplastic polymers - can be subjected to
multiple heating and cooling cycles without
altering molecular structure
2. Thermosetting polymers - molecules chemically
transform (cure) into a rigid structure – cannot be
reheated
3. Elastomers - shows significant elastic behavior
 Composites

Non-homogeneous mixtures of the other three basic types

rather than a unique category
 Composites
Material consisting of two or more phases that are
processed separately and then bonded together to achieve
properties superior to its constituents.

 Usual structure consists of particles or fibers of one

phase mixed in a second phase

 Properties depend on components, physical shapes of

components, and the way they are combined to form
the final material
 Production Systems
 A manufacturing firm must have systems and
procedures to efficiently accomplish its type of
production

 Two categories of production systems:

– Production facilities
– Manufacturing support systems

 Both categories include people (people make the

systems work)
 Production Facilities
The factory, production equipment, and material
handling systems
 Production facilities "touch" the product
 Includes the way the equipment is arranged in the
factory - the plant layout
 Equipment usually organized into logical groupings,
called manufacturing systems
– Examples:
 Automated production line
 Machine cell consisting of an industrial robot
and machine tools
Facilities versus Product Quantities
A company designs its manufacturing systems and
organizes its factories to serve the particular mission of
each plant
 Certain types of production facilities are recognized as
the most appropriate for a given type of
manufacturing:
1. Low production – 1 to 100
2. Medium production – 100 to 10,000
3. High production – 10,000 to >1,000,000
 Different facilities are required for each of the three
quantity ranges
 Low Production
Job shop is the term used for this type of production
facility

 A job shop makes low quantities of specialized and

customized products
– Products are typically complex, e.g. space capsules,
prototype aircraft, special machinery
 Equipment in a job shop is general purpose
 Labor force is highly skilled
 Designed for maximum flexibility
Medium Production

Two different types of facility, depending on product

variety:

 Batch production
– Suited to hard product variety
– Setups required between batches

 Cellular manufacturing
– Suited to soft product variety
– Worker cells organized to process parts without
setups between different part styles
High Production
 Often referred to as mass production
– High demand for product
– Manufacturing system dedicated to the
production of that product

 Two categories of mass production:

1. Quantity production
2. Flow line production
Quantity Production

Mass production of single parts on single machine or small

numbers of machines
 Typically involves standard machines equipped with
special tooling

 Equipment is dedicated full-time to the production of

one part or product type

 Typical layouts used in quantity production are process

layout and cellular layout
Flow Line Production
Multiple machines or workstations arranged in sequence,
e.g. production lines
 Product is complex
– Requires multiple processing and/or assembly
operations

 Work units are physically moved through the sequence

to complete the product

 Workstations and equipment are designed specifically

for the product to maximize efficiency
Manufacturing Support Systems
A company must organize itself to design the processes
and equipment, plan and control production, and satisfy
product quality requirements

 Accomplished by manufacturing support

systems - people and procedures by which a
company manages its production operations
 Typical departments:
1. Manufacturing engineering
2. Production planning and control
3. Quality control
Overview of Major Topics

Overview of production system and major topics in

General Introduction to Manufacturing Processes