UNDER THE SUPERVISION
OF
Dr. DK Bhalla
[Professor: ME]
Submitted By: -
Department of Mechanical Engineering
Lingaya’s Vidyapeeth
Faridabad
Presented by: -
Sahil Sharma (Roll no. – 21ME59CL)
Ajeet Kumar Gupta (Roll no. – 21ME41CL)
AGENDA
➢ General Introduction - Overview of manufacturing processes, their
purpose, and efficiency goals.
➢ Manufacturing Examples- List of consumer and industrial goods
produced through manufacturing processes.
➢ History of Manufacturing - Historical evolution from handicraft to
industrial processes, highlighting key developments.
➢ Classification of Manufacturing- Explanation of subtractive, formative,
and additive technologies with examples.
➢ Broad Classification of Processes - Types of primary and secondary
processing operations with focus on shaping, property, and surface
operations.
➢ Key Historical Innovations- Impact of the Industrial Revolution,
assembly line, and specific tools like the spinning jenny.
➢ Stages in Machining Processes - Steps in machining, from designing to
unloading, including CNC and manual processes.
➢ Types of Machining Processes - Details on turning, milling, drilling,
grinding, boring, and knurling.
➢ Surface Operations- Techniques for cleaning, coating, and enhancing
surfaces of materials.
➢ Secondary Assembly Operations- Methods for permanent and semi-
permanent joining of parts.
➢ Manufacturing Support Systems- Functions of R&D, production,
QA/QC, and logistics in manufacturing.
➢ Conclusion
General Introduction
About
Manufacturing Processes
MANUFACTURING PROCESSES
Manufacturing is the process of transforming raw materials into finished goods
using labour, tools, machinery, capital, and chemical processing. The
manufacturing output can either be consumer goods or industrial goods. As
the name suggests, consumer goods are bought by the average customer for
their own needs. On the other hand, industrial goods are sold to
manufacturers and used in the production of other goods. The goal of any
manufacturing process is to not only create the finished product but to do so
as efficiently as possible.
Technologically, manufacturing Processes are the application of physical and
chemical processes to alter the geometry, properties, and/or appearance of a
given starting material to make parts or products; manufacturing Processes
also include assembly of multiple parts to make products. The Manufacturing
processes involve a combination of machinery, tools, power, and labour.
Manufacturing Processes are almost always carried out as a sequence of
operation Each operation brings the material closer to the desired final state.
Economically, the Manufacturing Process is the transformation of materials
into items of greater value by means of one or more processing and/or
assembly operations. Manufacturing Processes adds value to the material by
changing its properties and shape, or by combining it with other materials that
have been similarly altered. The material has been made more valuable
through the manufacturing operations performed on it. When plastic is
moulded into the complex geometry of a table, it is made even more valuable.
MANUFACTURING EXAMPLES
Cell Phone/ Mobile, Digital Camera, Cars, Motor Bikes, Automotive spare parts,
Ball Pen, High-Definition Television, Home security system, Inkjet colour
printer, Industrial Robot, MRI Machines, Medicines, Beverages, Supersonic
aircraft, PVC film, hardware, and many more.
HISTORY OF MANUFACTURING
Today, Manufacturing is a very complex and intricate process that requires
various processes necessary for the production of a product and its
components. Prior to the Industrial Revolution, manufacturing simply meant
creating products or goods by hand. Some of the processes—casting,
hammering (forging), and grinding—date back 6000 years or more. The ancient
Indians & Romans had what might be called factories to produce weapons,
scrolls, pottery and glassware, sculptures, and other products of the time, but
the procedures were largely based on handicrafts. An Indian sculpture of
Dancing shiva was found in the 5th century. Well, we leave the old historical
things and move on to the History of modern manufacturing Processes.
Here are some historical events and discoveries that have a major impact on
the development of modern manufacturing systems.
The Principle of Division of Work –
dividing the total work into tasks and assigning each worker to become a
specialist at performing only one task.
The Industrial Revolution (1760–1830)-
had a major impact on production in several ways. It marked the change from
an economy based on agriculture and handicraft to one based on industry and
manufacturing. The change began in England, where a series of machines were
invented and steam power replaced water, wind, and animal power. These
advances gave the British industry significant advantages over other nations,
and England attempted to restrict the export of the new technologies.
However, the revolution eventually spread to other European countries and
the United States.
JAMES WATT’S STEAM ENGINE-
Power-generating technology for the industries and was one of the driving
forces of the industrial revolution.
MACHINE TOOLS-
John Wilkinson first used a boring machine in 1775. Later on, a lot of machine
tools later like lathe machine, Milling, Drilling, Pressing Machines, etc were
introduced.
THE SPINNING JENNY-
invented in 1964 & one of the key developments in the textile industry for
increment in production and quality. This was a huge change in the textile
industry and changed the way of production. Before then the production of
clothes was a very time-consuming process.
The Factory System-
a new way of organizing large numbers of production machinery & workers
and based on the division of labour.
Second Industrial Revolution-
In this era, most of the scientific management systems introduced like Motion
Study, Time Study, Piece rate system, Incentive system, Use of data collection,
Recordkeeping, etc.
The Assembly line-
Henry Ford (1863–1947) introduced the assembly line in 1913. The assembly
line made possible the mass production of complex consumer products. In an
assembly line, parts are moving from one work-station to the next work-
station. At a specific work-station, each worker assigned to do a specific task to
add more parts to make a complete final assembled product.
Basic Classification of Manufacturing Technologies
Manufacturing technologies have always been improving over time. There has
been a big difference in the way of making things fast, durable, and cost-
efficient. According to the latest manufacturing environment, these
technologies may be divided into three fundamental categories as following
Subtractive manufacturing technology
In Subtractive manufacturing technology, the desired geometry is obtained by
the defined removal of material. These are the most convenient method of
manufacturing. Material removal is done by machining tools such as Lathe-
machine, CNC turning, Milling Machine, Honing machine, etc. for example, all
the machining processes such as by turning, milling, stamping, etc.
Formative manufacturing technology
Formative manufacturing means to alter the geometry in a defined way by
applying external forces or heat, for example, by injection moulding, forging, or
casting.
Additive manufacturing technology
Additive manufacturing creates 3-dimensional objects by depositional
materials such as proper polymers, ceramics, or metals in multiple layers of
equal thickness. These objects are built layer by layer which is in contrast to
traditional manufacturing that often requires machining or other techniques to
remove surplus material. Therefore, it is also called layer technology and this
process called the 3D printing process.
Broad classification of Manufacturing Processes
Manufacturing Processes may be classified into two following categories:
Primary Processing Operations
A processing operation uses energy to Obtain the desired shape. The forms of
energy include mechanical, chemical, electrical, and other energy. The energy
is applied in a controlled way by means of machinery, tooling & Humans.
Human energy may also be required, but the workers generally control the
machines, take care of the operations, and load and unload parts before and
after every cycle of operation.
Three categories of processing operations are distinguished:
• Shaping Operations
• Property Operations
• Surface Operations
Shaping operations:
Shaping Operations change the geometry or shape of the starting work
material by various procedures. Common shaping processes are Casting,
Forging, Machining, Stamping. Most shape processing operations required
heat, mechanical force, or a combination of these to effect a change in the
shape of the material. There are various ways to classify the shaping processes
as follows.
• Solidification Processes
• Deformation Processes
• Machining Processes
Solidification Processes:
In these processes, the Material is heated to liquidity or highly plastic
(semifluid) state. Materials in a liquid or semifluid form, they can be poured or
otherwise forced to flow into a mould cavity. As temperature decreased, metal
taking a complex solid shape the same as the cavity, most processes are called
casting or moulding. Casting is used for metals, and moulding for plastics.
Deformation Processes:
In deformation processes, the shape of the metal is altered by the application
of forces that exceed the material’s yield strength. Deformation processes
include Stamping, Rolling, Extrusion, and Forging operation to alter the shape
of the material. During deformation, Materials must be sufficiently ductile to
avoid fracture. Material is often heated to increase ductility before
MACHINING PROCESSES:
Machining is a manufacturing process where the desired shape is created by
removing material from a larger piece. It is used for making finished products
and for raw material processing. Machining processes are also known as
subtractive manufacturing processes. Complex parts often require the use of
multiple machining processes in conjunction with each other.
Most machining processes have high control over the material removal for
utmost accuracy. Almost all materials, including metals, wood, glass, plastics,
ceramics, and more, support machining operations.
HISTORY OF MACHINING PROCESSES:
Machining is not a recent manufacturing process. Early machining tools went
as far back as 1200 BC. These tools used handicraft operations for making
weapons and basic utilities. Primitive versions of manual lathes date to Ancient
Egypt. With time, the machining processes progressed to include higher
production speed, more complexity, and a degree of automation
Different Stages of Machining Processes
Machining processes go through multiple stages to complete the part
production. These different stages are:
• Designing Part: For automated manufacturing using a CNC machine, a
graphical design of the part is made. The design is saved as a Computer
Aided Design (CAD) file. Minor adjustments and manual machining might
not require designs.
• Creating CAM File: The CAM file contains the G-code that the machine
can understand. The programmer converts the CAD file to a CAM
version. The operator then loads this file to the machine. For machines
without CNC, the CAM file is not needed.
• Machine Setup: Every machine requires setup before executing the
machining process. Setup includes loading the workpiece, adjusting the
settings, and ensuring tight connections.
• Machining: The machine begins execution once the setup is complete.
The execution is done in the presence of the operator.
• Unloading: The finished product is removed from the machine. It is then
sent for secondary assembly or additional machining processes as
needed
Different types of Machining Processes: -
• Turning
Turning is a machining process where a lathe rotates the workpiece while the
cutting tool moves linearly, removing material to shape the part.
• Milling
Milling is another versatile machining operation that utilizes a rotating multi-
point cutter to remove material from the workpiece. It is widely used for
creation parts with complex shapes and features, such as slots and pockets.
• Drilling
Drilling is a cutting process where a drill bit is spun to cut a hole of circular cross-
section in solid materials. The drill bit is usually a rotary cutting tool, often multi-
point. The bit is pressed against the work-piece and rotated at rates from
hundreds to thousands of revolutions per minute.
• Grinding
Grinding is an abrasive machining process that uses a grinding wheel or abrasive
belt as the cutting tool. It is commonly used to remove material from a
workpiece, to produce a smooth finish on the surface of the workpiece, or to
remove burrs from the surface.
• Boring
In machining, boring is the process of enlarging a hole that has already been
drilled (or cast) by means of a single-point cutting tool (or of a boring head
containing several such tools), such as in boring a gun barrel or an engine cylinder.
• Knurling
Knurling is a manufacturing process, typically conducted on a lathe, whereby a
pattern of straight, angled or crossed lines is rolled into the material. Knurling can
also refer to material that has a knurled pattern.
Surface Operations:
The processes to remove dirt, oil, and other contaminants from the surface.
Surface treatments include mechanical working such as shot peening and
sandblasting, and physical processes such as diffusion and ion implantation.
Coating and thin film deposition processes apply a coating of material to the
exterior surface of the work part. Surface processing operations may be
classified into the following categories:
• Cleaning & Other Surface Treatments
• Coating
Some of the commonly used surface finishing processes are:
Honing, Lapping, Belt Grinding, Polishing, Sanding, deburring, Electroplating,
Buffing, Metal spraying, Painting, Coating, Anodizing, Galvanizing, Plastic
coating, Sandblasting, etc.
Secondary Assembly Operations:
An assembly operation joins two or more separate components to create a
new entity. Components of the new entity are connected either permanently
or semi-permanently.
Permanent joining processes include welding, brazing, soldering, and adhesive
bonding. They form a joint between components that cannot be easily
disconnected.
Some assembly components/ Products are fastened together in a joint that can
be conveniently disassembled. Screws, bolts, and other threaded fasteners are
important traditional methods in this Semi-permanent assembly category.
What is the Manufacturing Support Systems?
The basic required functions for manufacturing processes facilities are the
following:
1. Design the Product & Process, Set-up Equipment & Quality
standards: R&D
2. Production Planning and Control: PRODUCTION
3. Maintain product quality standards: QA & QC
These functions are accomplished by procedures and peoples who manage the
production operations.
Research and development (R&D) Department
R&D is responsible for the activities companies undertake to innovate and
introduce new products, planning the manufacturing processes—deciding
what processes should be used to make the parts and assemble the products,
Stay ahead of manufacturing trends. R&D is also involved in Advanced Product
Quality Planning (APQP) and Production Part Approval Process (PPAP). It is
often the first stage in the development process and plays an integral role in
the life cycle of a product.
Production Department
A production department is a group of following functions within a
manufacturing facility.
Production planning and Control: Schedule the production plan for each
product, manage inventory & take corrective measures if necessary.
Production execution: Execute the production plan, Inventory management,
Management of equipment, machinery, and manpower as per the situation.
Maintenance: Takes Corrective action if the machine breaks down.
Preventive & Predictive maintenance to reduce the breakdown of machinery
and equipment. Manage all necessary spares parts of machinery.
Purchase & Store: Purchase & Store department is responsible for procuring all
necessary materials needed for production or daily operations.
Logistics & dispatch: The primary duty of the logistics department is to ensure
geographical repositioning of finished products, raw materials, equipment &
machinery, or scrap.
Quality Assurance / Quality Control
Every industry must pay sufficient attention to maintaining quality because it is
another important requirement or function of a Manufacturing unit. The key
responsibility of QA/QC is to ensure the quality of products manufactured by
their company.
• Perform and coordinate inspections and determine quality assurance
testing models of raw materials and finished products.
• Prepare, document, and execute detailed test plans, test cases, and
defect reports as per ISO standards.
• Review and approve quality requirements for manufacturing planning,
supplier purchase orders, and engineering specifications.
• To perform training to workers for producing good quality products.
CONCLUSION
Manufacturing processes form the backbone of industrial development,
enabling the transformation of raw materials into finished goods that drive
economic progress and innovation. Over centuries, these processes have
evolved from manual craftsmanship to highly advanced systems like CNC
machining and additive manufacturing, revolutionizing the way products are
designed and produced. The classification of manufacturing technologies into
subtractive, formative, and additive approaches highlights the diverse methods
available to meet varying industrial demands.
The historical milestones, such as the Industrial Revolution and the introduction
of assembly lines, have shaped the modern manufacturing landscape. These
advancements have not only increased efficiency and precision but also
expanded the scope of what can be produced, from everyday consumer goods to
sophisticated industrial equipment.
Today, with the integration of automation, artificial intelligence, and sustainable
practices, manufacturing continues to break new ground. These innovations
promise to reduce waste, improve energy efficiency, and enhance productivity.
Understanding the fundamental principles of manufacturing processes is
essential for leveraging these modern advancements effectively.
As industries move toward a future driven by smart technologies, embracing
innovation while maintaining a focus on sustainability will be critical.
Manufacturing will remain a cornerstone of progress, adapting to the dynamic
needs of an ever-evolving world.
