Manufacturing Technology Notes

Definition of Manufacturing Technology: Understanding manufacturing technology within mechanical engineering and its relevance to Singapore's industry.
Singapore's Manufacturing Landscape: Examining the current state of manufacturing in Singapore.
Roles in Manufacturing: Identifying the various roles of people involved in manufacturing.
Key Manufacturing Attributes: Discussing essential attributes in manufacturing.
Basic Manufacturing Processes: Reviewing fundamental manufacturing processes.

Origin: The term "manufacture" comes from the Latin words "manus" (hand) and "factus" (make), originally meaning made by hand.
Traditional Definition (Narrow): Transformation of raw materials into finished products.
Broader Definition: Encompasses the entire product realization cycle:
- Research and Development
- Design
- Planning
- Production
- Within an economic and social context
Example: Considering whether a fast-food restaurant selling a hamburger is providing a service or manufacturing a product.

Transformation: Manufacturing firms now convert ideas into products and services.
Modern Landscape: Manufacturers are now:
- Inventors
- Innovators
- Global supply chain managers
- Service providers
Expanded Scope: The field has evolved from just production to include research, design, and service provision.

Product Manufacturers: Focus on value generation through production.
Service-Led Producers: Provide services based on substantial production capabilities.
Service Manufacturers: Generate value primarily from services related to a product, with little to no production.
System Integrators: Control the channel to customers and manage external production networks.

Approximate Number of Parts in Products:
- Common Pencil: ~4
- U.S. Dollar Bill: ~1
- Rotary Lawn Mower: ~300
- Personal Computer: ~15,000
- Automobile: ~15,000
- Boeing 747-400: ~6,000,000
Average Life Expectancy of Various Products (Years):
- Car Battery: ~2
- Hair Dryer: ~4
- Automobile: ~8
- Dishwasher: ~10
- Kitchen Disposal Unit: ~10
- Vacuum Cleaner: ~10
- Water Heater (Gas): ~12
- Clothes Dryer (Gas): ~13
- Clothes Washer: ~13
- Air-Conditioning Unit (Central): ~15
- Manufacturing Cell: ~15
- Refrigerator: ~17
- Furnace (Gas): ~18
- Machinery: ~30
- Nuclear Reactor: ~40

2021 GDP: $533$ billion.
Manufacturing Contribution: 22% of GDP.
Sector Breakdown:
- Finance and Insurance: 15%
- Business Services: 12%
- Infocomm: 6%
- Transport and Storage: 6%
- Construction: 3%
- Wholesale and Retail Trade: 19%
- Others: 17%
Manufacturing Sub-sectors:
- Electronics
- Precision Engineering
- Biomedical Manufacturing
- Energy and Chemicals
- Transport Engineering
- General Manufacturing

Shift: From labor-intensive to research & knowledge-based.
GDP Contribution Over the Years:
- 1960: 11%
- 2013: 18.5%
- 2015: 19.8%
- 2018: 20.0%
Strengths: Electronics (semiconductors, hard disks), Chemicals, and Precision Engineering (semiconductor assembly machines).
Future Direction: Manufacturing needs to be more knowledge- and innovation-intensive to increase added value.

World-Class Ecosystem: Singapore is a strategic manufacturing hub attracting leading firms like Shell, Micron, and Merck.
Exports: The world's 4th largest exporter of high-tech goods.
Pharmaceuticals: Produces 5 of the world's top 10 drugs.
Refined Oil: The 5th largest producer of refined oil.
Ecosystem Components: Top Engineering, Procurement, and Construction firms, and research institutes collaborating with companies.
Comprehensive Presence: Companies site headquarters, R&D, and supply chain management functions in Singapore.

Innovation Ranking: Ranked 5th for manufacturing value-added in the 2017 Bloomberg Innovation Index.
Industry 4.0 Momentum: Attracting global suppliers like ABB and Siemens to establish Advanced Manufacturing Centers of Excellence.
Smart Industry Readiness Index: A tool developed to help companies leverage Industry 4.0.

Skilled Workforce: Singapore has a highly-skilled and adaptable workforce, ranked 2nd in the 2017 Global Talent Competitiveness Index.
SkillsFuture Series: Government initiatives to equip the workforce with skills for advanced manufacturing.
Skills Frameworks: Tailored to each industry, with career pathways, skills listings, and available courses.

Designer: Determines part or product form, including shape, size, configuration, materials, and manufacturing processes.
Materials Engineer: Investigates and develops improved materials.
Industrial Engineer: Designs fabrication, assembly, and warehousing systems.
Manufacturing Engineer: Develops manufacturing tools and fixtures, and manages their use.
Technicians: Handle machine setup, maintenance, and repair.

Focus: Manufacturing processes (traditional definition).
Five Main Factors to Consider:
- Materials
- Geometry/shape, accuracy, and roughness
- Economic batch size (cost)
- Production rate
- Lead time

Material Class: Polymer, ceramic, metal, etc. based on required mechanical properties (strength, stiffness).
Application Specific: The application may dictate the material (e.g., transparent materials for lenses).
Software Tools: Ansys Granta EduPack can help narrow down material choices.
Linkage: Materials and manufacturing are closely linked to final product performance.

Properties:
- Mechanical
- Physical
- Chemical
Manufacturability
Availability
- Shape, size
- Reliability of supply
Service Life
Material Substitution Considerations: Cost, efficiency, performance, maintenance, supply, compliance, robustness, recycling.

Three Main Indicators: Shape, accuracy, and surface finish.
Application Insights:
- Axisymmetric or continuous section parts
- Sliding parts
- Bearing surfaces
- Fatigue loading

Production Rate: Market demand and product life cycle determine productivity.
Lead Time: How quickly the product needs to be available.
Economic Batch Size: Output required for a process to be competitive/profitable.

What materials are commonly used today?
What manufacturing processes are known for making materials into components or finished goods?

Manufacturing (Narrow Definition): Making a single piece part in a single step.
Fabricating: Irreversibly joining standard shapes to get a single piece part (e.g., welding).
Assembling: Reversibly joining things together to make an assembly.
Broader Definition: Manufacturing includes all three processes.

What must be assembled?
What must be a single piece part (manufactured or fabricated)?
Can commonly available stock material (sheet, plate, bar, tube, box section, I beam) be used?