The word "manufacture" comes from the Latin words "manus" (hand) and "factus" (make), meaning "made by hand."
Originally, manufacturing accurately described fabrication methods used around 1567 A.D.
Modern manufacturing uses mechanized and automated equipment supervised by human workers.
It includes:
Product design
Raw material selection
Choosing the sequence of processes for making items
Is Manufacturing Important?
Making things has been essential throughout human history.
Manufacturing is important to developed and developing nations technologically and economically.
Manufacturing: Technological
It involves applying physical and chemical processes to change a starting material's geometry, properties, and/or appearance to create parts or products.
Technological Importance
Technology uses science to provide society with needed or desired items.
Technology provides products that improve our society.
These products are all manufactured.
Manufacturing enables technology.
Manufacturing - Economical
It transforms materials into higher-value items through processing and/or assembly operations.
Economic Importance
Manufacturing adds value to products, determining their marketable price.
A higher standard of living correlates with a higher level of manufacturing activity in a country.
U.S. Economy Sector:
Agriculture and natural resources: 5\%
Construction and public utilities: 5\%
Manufacturing: 15\%
Service industries: 75\%
Total: 100\%
Manufacturing Industries
Industry consists of enterprises and organizations that produce or supply goods and services.
Industries can be classified as:
Primary industries: cultivate and exploit natural resources (e.g., agriculture, mining)
Secondary industries: convert primary industry outputs into consumer and capital goods (e.g., aerospace, automobile)
Tertiary industries: service sector (e.g., banking, insurance)
Capital goods: products purchased by companies to produce goods/services (e.g., aircraft, computers, communication equipment, medical apparatus)
Manufacturing Capability
A manufacturing plant transforms materials into higher-value products using processes and systems.
The three blocks are materials, processes, and systems
Manufacturing capability includes:
Technological processing capability
Physical product limitations
Production capacity
1. Technological Processing Capability
It's the available manufacturing processes in a plant (or company) to make products.
Plants specialize in certain materials by specializing in specific processes.
It includes physical processes and personnel expertise.
Examples:
A machine shop cannot roll steel.
A steel mill cannot build cars.
2. Physical Product Limitations
Size and weight limitations exist for parts/products made in a plant.
Product size and weight affect:
Production equipment
Material handling equipment
Production and material handling equipment and plant size must accommodate products within a size and weight range.
3. Production Capacity
Defined as the maximum quantity a plant can produce in a given time (e.g., month or year) under assumed operating conditions.
Operating conditions: shifts per week, hours per shift, direct labor levels.
Usually measured in output units (e.g., tons of steel, number of cars).
Also called plant capacity.
History of Manufacturing (Until 1700)
Before 4000 B.C.:
Metals and Casting: Gold, copper, meteoric iron.
Various Materials and Composites: Earthenware, glazing, natural fibers.
Forming and Shaping: Hammering.
Joining: None noted.
Tools, Machining, and Manufacturing Systems: Tools of stone, flint, wood, bone, ivory, composite tools.
4000-3000 B.C.:
Metals and Casting: Copper casting, stone and metal molds, lost-wax process, silver, lead, tin, bronze.
Various Materials and Composites: Glass beads, potter's wheel, glass vessels.
Forming and Shaping: Stamping, jewelry.
Joining: Soldering (Cu-Au, Cu-Pb, Pb-Sn).
Tools, Machining, and Manufacturing Systems: Corundum (alumina, emery).
3000-2000 B.C.:
Metals and Casting: Bronze casting and drawing, gold leaf.
Forming and Shaping: Wire by slitting sheet metal
Joining: Riveting, brazing
Tools, Machining, and Manufacturing Systems: Hoe making, hammered axes, tools for ironmaking and carpentry
2000-1000 B.C.:
Metals and Casting: Wrought iron, brass.
Forming and Shaping: Stamping of coins.
Joining: Forge welding of iron and steel, gluing.
1000-1 B.C.:
Metals and Casting: Cast iron, cast steel
Various Materials and Composites: Glass pressing and blowing
*Tools, Machining, and Manufacturing Systems: Improved chisels, saws, files, woodworking lathes
1-1000 A.D.:
*Metals and Casting: Zinc, steel
Various Materials and Composites: Venetian glass
1000-1500:
Metals and Casting: Blast furnace, type metals, casting of bells, pewter.
Various Materials and Composites: Crystal glass
Forming and Shaping: Armor, coining, forging, steel swords
Joining: Wire drawing, gold- and silversmith work
Tools, Machining, and Manufacturing Systems: Etching of armor, Sandpaper, windmill-driven saw
1500-1600:
Metals and Casting: Cast-iron cannon, tinplate.
Various Materials and Composites: Cast plate glass, flint glass
1600-1700:
Metals and Casting: Permanent-mold casting, brass from copper and metallic zinc
Various Materials and Composites: Porcelain
Forming and Shaping: Rolling (lead, gold, silver), shape rolling (lead); Water power for metalworking, rolling mill for coinage strips
*Tools, Machining, and Manufacturing Systems: Hand lathe for wood; Boring, turning, screw-cutting lathe, drill press
History of Manufacturing (1700-1960)
1700-1800 (Industrial Revolution):
Metals and Casting: Malleable cast iron, crucible steel (iron bars and rods).
Forming and Shaping: Extrusion (lead pipe), deep drawing, rolling
*Tools, Machining, and Manufacturing Systems: Shaping, milling, copying lathe for gunstocks, turret lathe, universal milling machine, vitrified grinding wheel
Joining: Oxyacetylene; arc, electrical-resistance, and thermit welding
*Tools, Machining, and Manufacturing Systems: Geared lathe, automatic screw machine, hobbing, high-speed-steel tools, aluminum oxide and silicon carbide (synthetic)
1900-1920 (WWI):
Various Materials and Composites: Automatic bottle making, bakelite, borosilicate glass.
Forming and Shaping: Tube rolling, hot extrusion
1920-1940:
Metals and Casting: Die casting
Various Materials and Composites: Development of plastics, casting, molding, polyvinyl chloride, cellulose acetate, polyethylene, glass fibers.
*Tools, Machining, and Manufacturing Systems: Tungsten carbide, mass production, transfer machines
1940-1950 (WWII):
Metals and Casting: Lost-wax process for engineering parts
Various Materials and Composites: Acrylics, synthetic rubber, epoxies, photosensitive glass
Joining: Coated electrodes
*Tools, Machining, and Manufacturing Systems: Phosphate conversion coatings, total quality control
1950-1960:
Metals and Casting: Ceramic mold, nodular iron, semiconductors, continuous casting
Various Materials and Composites: Acrylonitrile-butadiene-styrene, silicones, fluorocarbons, polyurethane, float glass, tempered glass, glass ceramics
Forming and Shaping: Cold extrusion (steel), explosive forming, thermomechanical processing
Joining: Submerged arc welding; Gas metal arc, gas tungsten arc, and electroslag welding; explosion welding
*Tools, Machining, and Manufacturing Systems: Electrical and chemical machining, automatic control
History of Manufacturing (1960-2000s)
1960-1970 (Space Age):
Metals and Casting: Squeeze casting, single-crystal turbine blades
Various Materials and Composites: Acetals, polycarbonate, cold forming of plastics, reinforced plastics, filament winding
Forming and Shaping: Hydroforming, hydrostatic extrusion, electroforming
Metals and Casting: Compacted graphite, vacuum casting, organically bonded sand, automation of molding and pouring, rapid solidification, metal-matrix composites, semisolid metalworking, amorphous metals, shape-memory alloys (smart materials), computer simulation
Various Materials and Composites: Adhesives, composite materials, semiconductors, optical fibers, structural ceramics, ceramic-matrix composites, biodegradable plastics, electrically conducting polymers
Forming and Shaping: Precision forging, isothermal forging, superplastic forming, dies made by computer-aided design and manufacturing, net-shape forging and forming, computer simulation
Joining: Friction stir welding, lead-free solders, laser butt-welded (tailored) sheet-metal blanks, electrically conducting adhesives
*Tools, Machining, and Manufacturing Systems: Micro- and nano-fabrication, LIGA (a German acronym for a process involving lithography, electroplating and molding), dry etching, linear motor drives, artificial neural networks, six sigma
Materials in Manufacturing
Most engineering materials are classified into:
Metals
Ceramics
Polymers
Their chemistries, mechanical, and physical properties differ.
These affect the manufacturing processes used.
Methods of Manufacture
A product can be made using many materials and various methods.
Chart For Selecting Shapes & Manufacturing Process
A table that related the product Shape or feature to the Production Method
Scales in Manufacturing
Illustration of the range of common sizes of parts and the capabilities of manufacturing processes. Parts can range from very small to large.
Selection of Manufacturing Process
Type of basic manufacturing process mainly depends on:
Type of the Work Material
Nature (i.e. ductile or brittle) and its Hardness
Melting Temperature of the Work Material
Production Volume or Batch Size of the Production
*Basic nature of the manufacturing process affects the
Cost
Properties and
Characteristics of the Final Product
Application Range of Manufacturing Processes According to Melting Temp of Materials & Batch Size
Graph showing the relationship between Material, Processes, and Batch Size
Manufacturing Attributes of Manufacturing Processes
Matrix of Manufacturing Processes and their attributes
Type of manufacturing process and their Manufacturing attributes:
*Primary forming processes: high capital cost, high tooling cost, low labour cost, High Production Rate, Low to medium Quality, Low Flexibility
*Material removal or machining processes: medium capital cost, medium tooling cost, high labour cost, Low to Medium Production Rate, high Quality, High Flexibility
*Deforming processes: high capital cost, high tooling cost, low labour cost, Medium to High Production Rate, Low to medium Quality, Low Flexibility
*Joining processes: Low capital cost, low tooling cost, high labour cost, Low to Medium Production Rate, Low to medium Quality, High Flexibility
*Finishing and surface treatment processes: High capital cost, Medium to high labour cost, Low Production Rate, High Quality, High Flexibility
*Property changing or heat treatment processes: High capital cost, low tooling cost, low labour cost, Low Production Rate, High Quality, Medium to high Flexibility
How to Select Processes [A] According to the Batch Size:
Smaller batch size requires flexible manufacturing processes like machining, which can produce variety of geometrical features. (up to 500 products).
*Larger batch size allows use of primary forming and deforming processes so as to offset the relatively high costs of machine tools and tooling. Primary forming processes from 75 onwards. Deforming processes more than 1000.
Classification of Manufacturing Processes
All Manufacturing Processes can be Put into Basic SIX Categories according to their Nature:
Primary Forming Processes [Additive or Accretion]
Material Removal or Machining [Subtractive]
Deforming Processes [Formative]
Joining or Fabrication or Consolidation [Assembling]
Mechanical assembly: fastening by mechanical methods
*Threaded fasteners (screws, bolts, and nuts); press fitting, expansion fits
Production Machines and Tooling
Manufacturing operations are accomplished using machinery, tooling, and people.
Types of production machines:
Machine tools: power-driven machines used to operate cutting tools previously operated manually
Other production equipment:
Presses
Forge hammers
Plastic injection molding machines
Production Systems
People, equipment, and procedures used for the materials and processes that constitute a firm's manufacturing operations.
A manufacturing firm must have systems and procedures to efficiently accomplish its production.
Two categories of production systems:
Production facilities
Manufacturing support systems
People make the systems work.
Production Facilities
The factory, production equipment, and material handling systems.
Includes the way the equipment is arranged - the plant layout.
Equipment is usually organized into logical groupings called manufacturing systems. Examples:
Automated production line
Machine cell consisting of an industrial robot and two machine tools
Production facilities "touch" the product.
Trends in Manufacturing
Lean production and Six Sigma
Globalization and outsourcing
Environmentally conscious manufacturing
Microfabrication and Nanotechnology
Lean Production and Six Sigma
Lean production: Doing more work with fewer resources, yet achieving higher quality in the final product. Underlying objective: eliminate waste in manufacturing.
Six Sigma: Quality-focused program that utilizes worker teams to accomplish projects aimed at improving an organization’s organizational performance.
Globalization
Globalization: The recognition that we have an international economy in which barriers once established by national boundaries have been reduced.
This has enabled the freer flow of goods and services, capital, technology, and people among regions and countries.
Once underdeveloped countries such as China, India, and Mexico have developed their manufacturing.
Outsourcing
Outsourcing: Use of outside contractors to perform work that was traditionally accomplished in-house.
Local outsourcing: Jobs remain in the U.S.
Outsourcing to foreign countries:
Offshore outsourcing: production in China and other overseas locations
Near-shore outsourcing: production in Canada, Mexico, and Central America
Environmentally Conscious Manufacturing
Environmentally Conscious Manufacturing: Determining the most efficient use of materials and natural resources in production, and minimizing the negative consequences on the environment.
Associated terms: green manufacturing, cleaner production, sustainable manufacturing
Basic approaches:
Design products that minimize environmental impact
Design processes that are environmentally friendly