Lecture 1 Manufacturing Concepts

Workshop Practice

Lecture 1: Manufacturing Concepts

• Instructor: Ravindra G Bhardwaj

Objectives

• Understand Manufacturing Processes

• Selection of Manufacturing Processes

• Types of Production Process

• Introduction to Safety

Manufacturing Process

• Definition: A product is anything offered to a market to satisfy customer needs.

• Manufacturing: The process of making the product, known as the Manufacturing Process.

• Components of Manufacturing:

  • Material

  • Machines

  • Methods

  • Money

  • Manpower

  • Manufactured Product

Importance of Manufacturing

• Modernization: Vital for development and technological advancement.

• Employment: Generates jobs and supports economic growth.

• Foreign Exchange: Contributes to the country's economy.

• Regional Disparities: Addresses economic inequality across regions.

• Gross Domestic Product (GDP): Significant contributor to GDP.

Types of Manufacturing Processes

1. Casting

2. Machining

3. Forming

4. Powder Metallurgy

5. Joining

Casting Process

• Definition: Material is shaped by a melting process.

• Applications:

  • Frying pans

  • Machine bases

  • Automobile engines and carburettors

  • Gun barrels

Machining

• Definition: Removing unwanted material from a workpiece to achieve the desired shape.

• Applications:

  • Gears

  • Automobile parts

  • Nuts and bolts

• Metal Cutting Processes:

  • Drilling

  • Turning

  • Milling

  • Grinding

Forming

• Definition: Material deforms plastically under applied force to obtain the required shape, with stress greater than yield stress but less than ultimate stress.

• Applications:

  • Kitchen utensils

  • Wires

  • Collapsible tubes

  • Rails

• Forming Processes:

  • Rolling

  • Forging

  • Drawing

  • Extrusion

Powder Metallurgy

• Definition: Involves blending fine powders, pressing into shape, and heating to bond particles and achieve desired properties.

• Applications:

  • Gears

  • Tungsten wires for electric bulbs

  • Cutting tools

Joining Process

• Definition: Joining multiple pieces to create the required size/shape.

• Permanent Joining: Fusing metals, possibly using filler material (e.g., welding, brazing).

• Temporary Joining: Using mechanical fasteners (e.g., nuts, bolts, screws).

• Examples: Riveting, fasteners, knuckle joints.

Selection of Manufacturing Process

• Factors influencing process selection:

  1. Volume of production

  2. Expected quality/properties

  3. Technical viability

  4. Economy

Types of Production

• Job Shop Production: Low-volume production with specific designs. Examples include space vehicles and custom tools.

• Batch Production: Medium quantity, either repetitive or unique orders. Examples include textbooks, furniture.

• Mass Production: High volume of standardized products using assembly lines. Examples include pens, cars.

Safety in Manufacturing

• Importance: Safety must be practiced, not just studied.

• Risks from machines, tools, high speed, sharp edges, etc.

• Potential for injury and equipment damage.

Human Error

• Categories of Errors:

  • Violations

  • Routine errors

  • Situational errors

  • Exceptional errors

  • Mistakes (rule-based, knowledge-based, skill-based)

Common Shop Floor Hazards

• Potential Hazards:

  • Explosion or fire risks

  • Burn injuries

  • Industrial deafness

  • Body injuries

  • Electrical shocks

• Sources of Hazards:

  • Welding equipment

  • Hot metal parts

  • Sparks and noise from processes

  • Falls and sharp tools

Enforcing Safety

• Regulations under Factory Acts and Industrial Safety Acts.

• Equipment must be certified safe by authorities.

• Laws provide deterrents for negligence.

• Example: ESI Act, 1942 mandates compensation for injuries at work.

Responsibility for Safety

• Safety is everyone's responsibility; foreseeing hazards is crucial.

• Evaluate and eliminate potential risks during job planning.

General Safety Instructions

• Follow the SAFETY FIRST rule.

• Guidelines include:

  1. Dress appropriately for work.

  2. Always protect your eyes.

  3. Operate machines only after proper training.

  4. Handle tools carefully to prevent accidents.

  5. Ensure proper clamping.

  6. Be aware of rotating parts.

  7. Handle cutting tools and waste material with care.

  8. Report injuries immediately.

  9. Address potential risks like fatigue and poor work conditions.

Conclusion

• Thank you for your attention! (Ravindra G Bhardwaj)