ME363 Principles and Practice of Manufacturing Processes

Professor Yung C. ShinSchool of Mechanical EngineeringPurdue University

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What is Manufacturing?

• Activities– To convert materials from one form to another form– Add values to materials.

• Origin from Latins (manus=hand, factus=made)– The making of goods and articles by hands, or especially by

machinery, often on a large scale and with division of labor

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History of Manufacturing

• BC 4000– Stone age Stone, clay– Copper, Bronze– …

• 18th Century– The first industrial revolution– Development of steam engine– Made power available

• Middle of 20th century– The second industrial revolution– Computers & advanced materials

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Current State of U.S. Manufacturing

• Manufacturing continues to be a mainstay of the U.S. economic productivity: generating nearly $1.6 trillion (11.2%) in GDP in 2009.

• The $1.1 trillion of manufactured goods shipped abroad, accounting for 86% of all U.S. goods exported in 2010.

• Manufacturing sector employed 11.5 million workers in 2010, or 9% of total employment.

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Manufacturing Share of GDP

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Prices of Manufactured Products

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Manufacturing Output after Price Adjustment

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U.S. Inflation Adjusted ManufacturingOutput and Employment

Source: Bureau of Labor Statistics and Bureau of Economic Analysis

80

90

100

110

120

130

140

150

160

1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

1987

= 1

00

Real Output Employment

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U.S. Manufacturing Sector is the Eight Largest Economy (Apr. 2014)

53% of GDP

11.7% of GDP

Source(s): International Monetary Fund and U.S. Bureau of Economic Analysis and MAPI

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Why does manufacturing matter?

• Manufacturing has high paying jobs

• Manufacturing funds much of R&D (70% of private R&D spending)

• Greater impact on the rest of economy

• Innovation spurs growth in economy (manufacturing accounts for 70% of all U.S. patents)

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Manufacturing Pays Premium Compensation

SOURCE: Department of Commerce, NAM

0

10000

20000

30000

40000

50000

60000

70000

Manufacturing Rest of Workforce

2005

Ann

ual c

ompe

nsat

ion

(per

full-

time

wor

ker)

BenefitsWages

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Manufacturing Pays Premium Compensation (Apr. 2014)

Source(s): Left – U.S. Bureau of Labor StatisticsRight – U.S. Bureau of Economic Analysis

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Role of Manufacturing

• Manufacturing companies account for $123 billion of the nation’s $278 billion spent on R&D in year 2003—a 45% national share.

• This compares to a 13% share of manufacturing sector output in overall gross domestic product, or GDP.

• Midwestern manufacturing companies have a strong orientation toward knowledge-intensive manufacturing. The region’s manufacturing companies account for 66% of the region’s R&D versus 19% of the region’s total output.

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Manufacturing Drives Productivity Growth

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Manufacturing Drives the Economic Recovery

• Manufacturing has a higher multiplier effect on economy than any other sector. For every $1 in manufacturing value added, $1.33 in additional value is created in other sectors.

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Manufacturers are Technology Leaders

• Manufacturing accounts for 70 percent of U.S. industrial R&D, 70% of U.S. patents and 47% of U.S. exports despite only 10% of employment.

• Employ over a third of all engineers.• Manufacturing equals Technology.

– Robotics, CAD, RFID, JIT, nanotechnology, etc.– New materials: composites, nanomaterials– Biomanufacturing: pharmaceuticals, fuels, food, biomaterials, etc.

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The Congress finds and declares … 

• The future well‐being of the United States economy depends on a strong manufacturing base and requires continual improvements in manufacturing technology, quality control, and techniques for ensuring product reliability and cost‐effectiveness. 

• Improvements in manufacturing and product technology depend on fundamental scientific and engineering research to develop a)  the precise and accurate measurement methods and measurement standards needed to improve quality and reliability, and b)  new technological processes by which such improved methods may be used in practice to improve manufacturing and to assist industry to transfer important laboratory discoveries into commercial products. 

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PCAST Advanced Manufacturing Report

1) Launch a Federal Advanced Manufacturing Initiative – Concerted, whole-of-government effort – Report to President on Federal priority needs, including:

• Coordinated Federal support to academia and industry for applied research on new technologies and design methodologies

• Shared facilities and infrastructure to help SME’s compete globally • Public/Private Partnerships (PPPs) to advance such technologies through pre-

competitive consortia

2) Improve Tax Policy 3) Support Research

– Strengthen research of three key science agencies: NSF, DOE Office of Science, NIST

4) Strengthen the Workforce – Strengthen STEM education

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Current Manufacturing

1. World wide competition

2. Advanced technologyex) CNC, Robotics, CAPP, CAD, CAM, New processes, IT

3. New manufacturing systems structure,strategies and management

– total integrated manufacturing, concurrent manufacturing, total quality management (TQM), just in time (JIT), Flexible Manufacturing Systems (FMS), Intelligent Manufacturing Systems (IMS), agile manufacturing, lean manufacturing– Top down or bottom up

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Important Technology Areas of Advanced Manufacturing: examples

• Advanced robotics

• Nanoelectronics

• Materials by design

• Biomanufacturing

• Energy manufacturing

• Additive manufacturing

• Digital manufacturingSource:Report to the President on ensuring American leadership in advanced manufacturing, June 2011

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Objectives In Manufacturing

• Productivity

• Low manufacturing cost

• Quality

• Flexibility

• Low initial Costs

• ________________

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An Example of Manufacturing Cost

Remarks: The direct labor cost constitutes a small portion of manufacturing cost. Therefore, a system approach must be adopted, taking all aspects into consideration.

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Evolution of Machining Accuracy

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Example: Evolution of Computer Chips

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Process Capabilities

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Manufacturing Costs vs. Quality

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How Can We Achieve These Goals?

• Analysis and Simulation

• Process Monitoring

• Control & Automation

• System Integration (man + machine + software)

• Improved Equipment

• Supply chain Management

• Improved design

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Role of Engineers in Manufacturing

• Designer must understand manufacturing processes– Certain dimensional sizes + materials dictate manufacturing

processes• “design for manufacture”• “design for assembly”• “design for inspection”

• Manufacturing engineers– Select & coordinate specific processes and equipment to be used.

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Business Driver

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Definitions

PRODUCTION SYSTEMS

– MANUFACTURING PRODUCTION SYSTEMS (MPS)manufacturing system + information, design, analysis

– SERVICE PRODUCTION SYSTEMS (SPS)

ex) transportation, banking, insurance, utilities, education, entertainment

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Manufacturing Systems

Def: A collection of operations and processes used to obtain a desired product or component(s).

Types of Manufacturing Systems– JOB SHOP

– FLOW SHOP

– CELL SHOP

– PROJECT SHOP

– CONTINUOUS PROCESS

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Cell Shop

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Manufacturing Processes

An action or actions to convert unfinished materials or products to semi-finished or finished products.

Basic Manufacturing Processes

casting or molding forming or metal/working processes machining joining and assembly surface treatment (finishing) heat treating others

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Operation

1. MATERIAL HANDLING/TRANSPORTING

2. PROCESSING

3. PACKAGING

4. INSPECTION/TESTING

5. STORING