Introduction and Overview of Manufacturing

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
5. Manufacturing Economics
6. Recent Developments in Manufacturing
 Manufacturing is Important

• Making things has been an essential human activity

since before recorded history

• Today, the term manufacturing is used for this activity

• Manufacturing is important to the developed and

developing nations
• Technologically
• Economically
 Technological Importance
• Technology - the application of science to provide
society and its members with those things that are
needed or desired
• Technology affects our daily lives, directly and
indirectly, in many ways
• Technology provides the products that help our
society and its members live better
• What do these products have in common?
• They are all manufactured
• They would not be available to our society if they
could not be manufactured
• Manufacturing is the essential factor that makes
technology possible
 Economic Importance

Sector: USA TR .
Agriculture and natural resources 5 15
Construction and public utilities 5 15
Manufacturing 12 20
Service industries 78 50
 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” 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-Technological
• Application of physical and chemical processes to
alter the geometry, properties, and/or appearance of a
starting material to make parts or products
 Manufacturing - Economic

• Transformation of materials into items of greater value

by one or more processing and/or assembly operations
Manufacturing Example:
Artificial Heart Valve
Left: Heart valve Right: Starting titanium billet

©2013 John Wiley & Sons, Inc. M P

Groover, Principles of Modern
Manufacturing 5/e
 Manufacturing Industries

• Industry consists of enterprises and organizations that

produce or supply goods and services
• Industries can be classified as:
1. Primary industries - cultivate and exploit natural
resources, e.g., agriculture, mining
2. Secondary industries - take the outputs of primary
industries and convert them into consumer and
capital goods
3. Tertiary industries - service sector
Specific Industries in Each Category
 Manufacturing Industries

• Secondary industries include manufacturing,

construction, and electric power generation
• Manufacturing includes several industries whose
products are not covered in this course; e.g., 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
 Manufactured Products
• Final products divide into two major classes:
1. Consumer goods - products purchased directly by
consumers
• Cars, clothes, TVs, tennis rackets

2. Capital goods - those purchased by companies to

produce goods and/or provide services
• Aircraft, computers, communication equipment,
medical apparatus, trucks, machine tools,
construction equipment
 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 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 units
 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 vs Q in Factory Operations
 More About Product Variety
• Although P is quantitative, it is much less exact than Q
because details on how much the designs differ is not
captured simply by the number of different designs
• Soft product variety - small differences between
products, e.g., between car models made on the same
production line, with many common parts
• 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) 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
1. Technological Processing Capability

• The set of available manufacturing processes in the plant

(or company)
• Certain manufacturing processes are suited to certain
materials, so 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
• A machine shop cannot roll steel
• A steel mill cannot build cars
 2. 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
 3. 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, e.g.,
tons of steel or number of cars produced
• Also called plant capacity
 Materials in Manufacturing

• Most engineering materials can be classified into

one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
• Their chemistries are different, and their
mechanical and physical properties are different
• In addition, there is a fourth category:
4. Composites
Classification
of engineering
materials
 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
• Alters 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 - clean, treat,
coat, or deposit material on surface of work
 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, adhesive bonding
2. 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 and 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
Model of the Production System
 Production Facilities
• The factory, production equipment, and material
handling systems
• Includes the plant layout
• Equipment usually organized into logical groupings,
called manufacturing systems
• Examples:
• Automated production line
• Machine cell consisting of three machine tools
• Production facilities "touch" the product
 Facilities vs 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
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
 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
Fixed-Position Plant Layout
 Medium Production
• Two different types of facility, depending on product
variety:
• Batch production
• Suited to medium and 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
Process Plant Layout
Cellular Plant Layout
 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, as in a production line
• 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
Product Plant Layout
 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
• The people and procedures by which a
company manages its production operations
• Typical departments:
• Manufacturing engineering, Production
planning and control, Quality control
Typical Cost Breakdown for a
Manufactured Product
Recent Developments in Manufacturing

• Microelectronics
• Computerization in manufacturing
• Flexible manufacturing
• Microfabrication and Nanotechnology
• Lean production and Six Sigma
• Globalization and outsourcing
• Environmentally conscious manufacturing
 Microelectronics

• Electronic devices that are fabricated on a microscopic

scale: Integrated circuits (ICs)
• Today’s fabrication technologies permit billions of
components to be included in a single IC
• A large proportion of the products manufactured today
are based on microelectronics technology
• About 2/3 of the products in Table 1.1 are either
electronics products or their function and operation
depend on electronics
 Computerization of Manufacturing

• Direct Numerical Control (DNC) was one of the first

applications of computers in manufacturing (1960s)
• Mainframe computer remotely controlling multiple
machine tools
• Enabled by advances in microelectronics, the cost of
computers and data processing has been reduced,
leading to the widespread use of personal computers
• To control individual production machines
• To manage the entire enterprise
 Flexible Manufacturing

• Although mass production is widely used throughout

the world, computerization has enabled the
development of manufacturing systems that can cope
with product variety

• Examples:
• Cellular manufacturing
• Mixed-model assembly lines
• Flexible manufacturing systems
Microfabrication and Nanotechnology

• Microfabrication
• Processes that make parts and products whose
feature sizes are in the micron range (10-6 m)
• Examples: Ink-jet printing heads, compact disks,
microsensors used in automobiles
• Nanotechnology
• Materials and products whose feature sizes are in
the nanometer range (10-9 m)
• Examples: Coatings for catalytic converters, flat
screen TV monitors
 Lean Production and Six Sigma

• Lean production
• Doing more work with fewer resources, yet
achieving higher quality in the final product
• Underlying objective: elimination of waste in
manufacturing
• Six Sigma
• Quality-focused program that utilizes worker teams
to accomplish projects aimed at improving an
organization’s organizational performance
 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 now developed their
manufacturing infrastructures and technologies to
become important producers in the global economy
 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

• 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:
1. Design products that minimize environmental
impact
2. Design processes that are environmentally
friendly