1. lecture 1 introduction to manufacturing processes

INME 4055 – Pedro Quintero, Ph.D.

Introduction to Manufacturing Processes

INME 4055

Manufacturing Processes


• Course number: INME 4055• Course title: Manufacturing Processes• Credit hours: 3• Instructor: Pedro O. Quintero Aguiló• Office: L-100 B• Office hours: Tue and Thu12:30-2:00, Wed 12:30-2:30

• E-mail: [email protected]

General Information


The course will be assessed in the following manner:

� Partial Exams (3) 60%� Class Attendance / Participation 10% (*) �Quizzes / Homework 5%� Final Exam 25%* After the second absence one (1) point will be deducted for each non-

authorized absence.

Assessment


Grades

F59 - 0

D69 – 60

C79 – 70

B89 – 80

A100 – 90

Final letter gradeFinal grade range


Attendance

• Attendance and participation in the lecture are mandatory and will be considered in the grading process. Students should bring all the required materials to be used during the lectures. Students are expected to keep up with the assigned reading and be prepared to answer questions on these readings during lectures.


ReferencesTextbook:

Manufacturing Processes for Engineering Materials, SeroweKalpakjian and Steven R. Schmid, Prentice Hall, 5th ed. 2007.

Other References:Manufacturing Engineering and Technology, Serowe Kalpakjian and

Steven R. Schmid, Prentice Hall, 2001.Manufacturing Processes and Equipment, George Tlusty, Prentice

Hall, 2000.Introduction to Manufacturing Processes, John A. Schey, McGraw

Hill, 3rd ed., 2000.Introduction to Manufacturing Processes and Materials, Robert C.

Creese, Marcel Dekker, 1999.Principles of Manufacturing Processes, J. Beddoes and M.J. Bibby,

Arnold Publishers, 1999. SME Tool and Manufacturing Engineering Handbook, SME Press,

1989 Volumes 1-7


Exams

• Exam will be conducted during lectures periods at the assigned classroom on the date specified by the lecturer with at least two weeks in advance.

• The only items allowed for use during the exams are calculators, pencils, pen, and ruler.

• Neatness and order will be taken into consideration and may affect your grade.


Tentative Course Schedule

4Microfabrication and interconnections

4Introduction to polymer processing

2Sheet metal forming

2Extrusion

2Forging

3Rolling

3Bulk deformation

2Fluid flow

2Heat transfer on molds

2Solidification and structures

3Casting

2Process capability

2Statistical process control

2Surfaces and tribology

4Review of behavior of materials and deformation

4Review of materials science

2Introduction to manufacturing

Contact HoursOutline


What is Manufacturing?

• Manufacturing is the processof convertingraw material into products; it encompasses the designand fabricationof goods by means of various production methods and techniques. – from Latin, manu factus, meaning made by hand

• Manufacturing represents ~ 20% to 30% of the value of all goods and services produced in industrialized countries.

• Because a manufactured item has undergone a number of changes during which the raw material has become an useful product, it has added value ($$$).


Manufacturing Processes• Processing operation:

– raw material is transformed into individual parts

• Assembly operation:– individual parts are combined together to form an

specific product

• Manufacturing may produce:– Discrete products: individual parts or pieces (nails,

gears, steel balls, engine blocks)– Continuous products: may be cut into individual

pieces, becoming discrete products (wire, metal sheet, pipe)


Manufacturing activities must…• Meet design requirements and specifications• Use the most economical and environmentally friendly

methods• Incorporate quality into each stage• Be flexible to respond to changing market demands• Keep updated with state of the art materials and production

methods• Be viewed as a large system in which all components are

interrelated• Work with customers to get timely feedback for

continuous improvement• Constantly strive for higher productivity


Product Design and Concurrent Engineering• Product design is critical because ~ 70 to 80% of the cost of

product development and manufacture is set at the initial design stages.

• Design requires a clear understanding of functions and performance of the product.

• Traditionally, design and manufacturing have taken place sequentially rather than concurrently or simultaneously.

• Concurrent engineering is a systematic approach integratingthe design and manufacture of products with the view toward optimizing all elements involved in the life cycle of the product.

• Goal is to minimize design and changes as well as the time and costs involved in taking the product from design concept to production and introduction to market.


75% of the recurring manufacturing cost is determined by the design

Material CostPurchase Part Cost

Process Cost

75%

Design

Production Setup – 13%Material Management – 6%Process Management – 6%

25%

Fabrication

… and within the design process …


80% of the cost and performance is committed in the first 20% of the design cycle

Specification

Simulation

Partitioning& Tradeoff

0

20

40

80

100

Decided within first20% of Design Cycle

LogicDesign

VerificationPhysicalDesign

Prototype0

20

40

80

100

80% ofProduct Cost / PerformanceCommitted

Start

End

60

60

Specification

Simulation

Partitioning& Tradeoff

0

20

40

80

100

Decided within first20% of Design Cycle

LogicDesign

VerificationPhysicalDesign

Prototype0

20

40

80

100

80% ofProduct Cost / PerformanceCommitted

Start

End

60

60


RequirementsCapture

ConceptualDesign

(Trade-Off analysis)

Design

Verificationand Qualification

BidSpecification Bid = Cost estimate against the specification

Specification = Engineering’s response to requirements

Does the design fulfill specification and requirements?

Customer

• A customer gives you the requirements, or

• Marketing determines the requirements through interactions in the market place with customers and competitors

Product Design - Life Cycle


Production

Marketing

Sustainment

End of Life

Manufacturing

• Marketing• Sales

• Redesign• Maintenance• Training

When customer is finished with theproduct, what happens to it?

• Service•Warranty


Product Development Life

Cycle

http://www.williamson-labs.com/design.htm

Conceptual Design and Specification

Requirements Capture


Verification

Design Implementation

Conceptual Design and Specification


Product Flow and Development

Process


DFX: X=Manufacture, Assembly, Disassembly, and Service

• Design and manufacturing should never be viewed as separate disciplines.

• DFM is a comprehensive approach to production of goods that integrates the product design process with materials, manufacturing methods, process planning, assembly, testing, and quality assurance.

• Engineers must acquire a fundamental understanding of the characteristics, capabilities, and limitations of materials, production methods, and machinery/equipment.– Variability in machine performance, dimensional accuracy, surface

finish, processing time, effect of processing method on quality


Product Assembly

• After individual parts have been manufactured, they are assembled into a product.

• Assembly is an important phase of the overall manufacturing operation and requires consideration of the ease, speed, and costof putting parts together.

• Products must be designed so that disassembly is possible with relative ease and little time.

• DFMA recognizes the inherent and important interrelationships among design, manufacturing, and assembly.


Product Design for Assembly


Design Principles for Economic Production

• Designs should be as simple as possible to manufacture, assemble, disassemble, service, and recycle.

• Materials should be chosen for their appropriate design and manufacturing characteristics as well as for their service life.

• Dimensional accuracy and surface finish specified should be as broad as permissible.

• Secondary and finishing operations should be minimized.


Sustainable Manufacturing and Product Life Cycle

• The present and potential adverse effects of manufacturing activities, their damage to the environment, and their effect onthe quality of human life are now well recognize.– In response a wide range of laws and regulations have been and

continue to be promulgated by governments and international organizations.

• Efforts have been more successful when there is value added, such as reducing energy requirements or substituting materials that have cost and environmental design benefits (DFR and DFE).

• Sustainable Manufacturing is the realization that natural resources are vital to economic activity and that energy and materials management are essential to ensure that resources are available for future generations.


Guidelines for Sustainable Manufacturing

• Reducing waste of materials at their source by refinements in product design and the amount of materials used.

• Reducing the use of hazardous materials in product and processes.

• Ensuring proper handling and disposal of all waste.

• Making improvements in waste treatment and in recycling and reuse of materials.

• Cradle-to-Cradle philosophy which encourages the use of environmentally friendly materials and designs. By considering the entire life cycle of a product, materials can beselected and employed that have a minimal real waste.


Product Life Cycle (PLC)• PLC consists of the stages that a product goes through, from

design, development, productions, distribution, and use; to its ultimate disposal and recycling.

• A product typically goes through five stages:– Development, involving much time and high costs

– Market introduction

– Growth, with increasing sales volume and lower manufacturing cost per unit

– Maturation, volume peaks and competitive products begin to appear

– Decline

• Product Life Cycle Management (PLCM) is defined as the strategiesemployed by the manufacturer as the product goes through its life cycle.


Selecting Materials• The types of materials generally used in manufacturing are:

– Ferrous metals: carbon steels, alloy steels, stainless steels– Nonferrous metals: aluminum, magnesium, copper, nickel, titanium,

low-melting alloys (lead, zinc, and tin), and precious metals– Plastics: thermoplastics, thermosets, and elastomers– Ceramics: glass ceramics, glasses, graphite– Composite materials: reinforced plastics, metal-matrix and ceramic

matrix, honeycomb structures; (these are known as engineered materials).– Nanomaterials, shape-memory alloys, metal foams, amorphous alloys,

semiconductors.

• Material Properties:– Mechanical properties: strength, toughness, ductility, hardness,

elasticity, fatigue, creep– Physical properties: density, specific heat, CTE, conductivity, melting

point– Manufacturing properties: determine whether they can be processed

(cast, formed, shaped, machined) with relative ease.


Selecting Manufacturing Processes• A wide range of manufacturing processes are used to produce a

variety of parts, shapes, and sizes.

• There are more than one method of manufacturing a part from a given material.

• Each process has its own advantages, limitations, production rates, and cost.

Various methods of making a simple part: (a) casting or powder metallurgy, (b) forging or upsetting, (c) extrusion, (d) machining, (e) joining two pieces.


Broad Categories of Processing Methods• Casting: Expendable molding and permanent molding• Forming and shaping: Rolling, forging, extrusion, drawing,

sheet forming, powder metallurgy• Machining: Turning, boring, drilling, milling, shaping, grinding• Joining: Welding, brazing, soldering, diffusion bonding,

adhesive bonding, mechanical bonding• Micromanufacturing and nanomanufacturing: Surface

micromachining, dry and wet etching, electroforming• Finishing: lapping, polishing, deburring, surface treating,

coating, plating

Manufacturing engineers are constantly challenged to find new solutions to production problems as well as finding means for significant cost reduction.


Part Size and Dimensional Accuracy

• Size, thickness, and shape complexity of a part have a major bearing on the process selected.

• The size and shape of manufactured products vary widely.


Lean Manufacturing• Major assessment of each activity of a company regarding the

efficiency and effectiveness of its operation.

• Efficiency of the machinery and equipment used in the operation while maintaining and improving quality.

• Number of personnel involved in a particular operation.

• A thorough analysis in order to reduce the cost of each activity.

• Lean aims at continuously improving the efficiency and profitability by removing all types of waste from its operation.

• Agile manufacturing indicate the use of the principles of lean production in a broader scale.– ensure flexibility so that it can quickly respond to changes

– reconfigurable machines and modular components


Total Quality Management• Tradition: inspection of part after manufacturing = quality

assurance– Inspect to insure parts conform to specifications and standards

(dimensional tolerances, surface finish, mechanical and physicalproperties.

• Modern approach: Quality cannot be inspected into the product; it must be built into it from the early stages through all subsequent stages.

• We need to control processes not products!

• Ultimately, the major goal is to prevent defects from occurring rather than to detect defects in products.– SPC, Control Charts

– DOE


Manufacturing Costs and Total Competitiveness• Manufacturing costs represent ~40% of a product’s selling

price.

• Total cost of manufacturing consists of: cost of materials, tooling, labor, fixed and capitals costs.

• Wide disparity in manufacturing labor costs.

• Outsourcing is the practice of taking internal company activities and paying an outside firm to perform them.


General Trends in Manufacturing• Materials:

– Better control of material composition, purity, and defects

– Enhancement of overall properties, manufacturing characteristics, reliability

– Semiconductors, nanomaterials, nanopowders, shape-memory alloys

• Processes, Equipment, and Systems:– Computers, controls, robots, automated inspection,

sensors, expert systems

– Simulation and modeling are becoming widely used in design and manufacturing resulting in the optimization of processes with better prediction of the effects of relevant variables.


Manufacturing Activities• Product design (conceptual, requirements,

specifications)

• Selecting materials

• Selecting manufacturing processes

• Process design

• Customer satisfaction

• Quality control

• Regulations (EPA, OSHA, ISO)

• Lean Manufacturing


Top Down Design

–A complex problem is decomposed into simpler problems… and so on until each of the problems is solvable

–Then we integrate the solutions together


• The first was never to accept anything for true which I did not clearly know to be such; that is to say, carefully to avoid precipitancy and prejudice, and to comprise nothing more in my judgment than whatwas presented to my mind so clearly and distinctly as to exclude all ground of doubt.

• The second, to divide each of the difficulties under examinationinto as many parts as possible, and as might be necessary for its adequate solution.

• The third, to conduct my thoughts in such order that, by commencing with objects the simplest and easiest to know, I might ascend by little and little, and, as it were, step by step, to the knowledge of the more complex; assigning in thought a certain order even to those objects which in their own nature do not stand in a relation of antecedence and sequence.

Discourse on the Method of Rightly Conducting the Reason, and Seeking Truth in the Sciences

Rene Descartes, 1637


Summary• Manufacturing is the process of converting raw materials into

products be means of a variety of processes and methods.• Product design is an integral part of manufacturing, as

evidenced by trends in in concurrent engineering and DFX.• A key task is to select appropriate materials and optimal

manufacturing methods, given product design goals, process capabilities, and cost considerations.

• Ensuring product quality is a concurrent engineering process rather than a last step in the manufacturing of a product.

• Lean production and agile manufacturing are approaches that focus on the efficiency and flexibility of the organization.

• Manufacturing engineers have the major responsibilities regarding all the above aspects.

1. lecture 1 introduction to manufacturing processes

Documents

product life cycle

life cycle

concurrent engineering

raw material

prentice hall

serowe kalpakjian

surface finish

dimensional accuracy