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Introduction to Manufacturing
What important role does manufacturing play in society? How do we define manufacturing?
Manufacturing is the ability to make goods and services to satisfy societal needs
Manufacturing processes are strung together to create a manufacturing system (MS)
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1930s
1920s
1910s
1900s
1940s
1990s
1950s
1960s
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Types of Goods
Consumer Goods
Items which are purchased directly by consumers
Consumer electronics Clothing
Producer Goods
Items which are manufactured for other companies to produce products from
Steel Mills - coil stock Machine tool builders - Milling Machines Automotive suppliers - Taillight assemblies
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Products
Fabricating - Manufacturing of products from components, pieces, or sub-assemblies. Separate discrete items such as machined parts, bolts, nuts etc. are fabricated. Processing - Manufacturing a product in a continuous series of operation . Examples include wire, beverages, chemicals etc.
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Manufacturing a Product
Manufacturing a Product
Figure 1-4 The functions and systems of the production system, which includes (and services) the manufacturing system. The functional departments are connected by formal and informal information systems designed to service the manufacturing system that produces the goods.
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Manufacturing a Product
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Materials engineers
Specify ideal materials Develop new and better materials
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Technicians
QC, machine set-up, machine maintenance, machine repair, and system integration
Operators
Running production parts and quality
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Mfg. Processes
The method (s) used to convert a product from one form to another- example metal removal. A process typically involves a sequence of steps or operations.
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Mechanics Economics or costs Time Spans Constraints Uncertainties and process reliability Skills Flexibility Process capability
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Operations
Distinct action to produce a desired result or effect Categories of operations
Materials handling and transport Processing Drilling, tapping, turning, milling, injecting Packaging Inspecting and testing Storing
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Figure 1-6 The component called a pinion shaft is manufactured by a sequence of operations to produce various geometric surfaces.
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Factory Layouts
Job Shop Flow Shop Linked-Cell Shop Project Shop Continuous Process
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Factory Layouts
Figure 1-15 Different manufacturing system designs produce goods at different production rates.
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Casting Forming Machining Joining and Assembly Surface Treatment Heat Treatment Other
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Casting
Molten metal fills a cavity in a mold. Quick method to transform a raw material into a desired shape. Two types of casting methods:
Expendable mold
Sand casting
Permanent mold
Die casting
Utilizes Materials that have been previously cast or molded Performed at cold or hot temperatures
cold = room temp to .3 of the melt temperature material hot = above .3 of the melt temperature of the material
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Joining
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Surface Treatment
Aesthetic requirements
Painting
Product requirements
Safety
Burrs
Surface treatment
chemical plating to resist rust
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Heat Treatment
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Other
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Definition of a need Conceptual design Review of initial design Design Prototype Production plan Resource specifications Manufacturing Prototype Manufacturing Inspection--quality checks Packaging - shipping Customer response
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