ADVANCED MANUFACTURING PROCESS Ahmad Afiq Tarmeze @ Ghazali Norul Husna BT Ibrahim DJF42012 JABATAN KEJURUTERAAN MEKANIKAL POLITEKNIK KOTA KINABALU
CHAPTER ONE INTRODUCTION TO MANUFACTURING PROCESS Ahmad Afiq Tarmeze @ Ghazali BE (Hons) (Manufacturing Technology) Norul Husna Bt Ibrahim M.Ed (Technical & Vocational) BE (Manufacturing) Department of Mechanical Engineering Politeknik Kota Kinabalu
Published by: POLITEKNIK KOTA KINABALU No. 4, Jalan Politeknik, KKIP Barat Kota Kinabalu Industrial Park 88460 Kota Kinabalu, Sabah Phone : 088-401800 Fax : 088-499960 Website : http://polikk.mypolycc.edu.my Copyright @ Politeknik Kota Kinabalu First Edition, 2023 All rights are reserved. Without the written consent of Politeknik Kota Kinabalu, it is forbidden to reproduced any portion of the article, illustration, or content of this e-book in any way, including electronically, photocopying, mechanically, recording or in any other form. e ISBN 978-967-2301-79-0
PREFACE The purpose of this E-book is to provide a simple guide to help student understanding on topic one, Introduction to Manufacturing Process for the course DJF42012- Advance Manufacturing Process, Politeknik Malaysia. This ebook provides a foundational overview of the fundamental concepts and principles that underlie the field of manufacturing. It serves as a starting point for understanding the various processes involved in transforming raw materials into finished products. It reviewed the process of transforming raw materials into final products, vital for meeting societal needs and fostering economic growth. Its historical evolution traces the transition from manual methods to today's highly automated processes. Manufacturing processes are classified into categories like casting, forming, machining, joining, and additive manufacturing. It's an interdisciplinary field involving engineering, materials science, design, and management, focusing on efficient and cost-effective production. The product life cycle concept covers development, production, distribution, and disposal stages. Computer-Aided Design and Manufacturing (CAD/CAM) technologies are crucial for process design and optimization. Globalization has intensified competition, necessitating continuous improvement and innovation in manufacturing. Recognizing environmental impact, sustainable practices are paramount. Ahmad Afiq Tarmeze @ Ghazali Norul Husna Ibrahim Politeknik Kota Kinabalu, Sabah September 2023
Explain the basic concept of manufacturing process 01 Summary 38 Organize the design process 10 Expose the trends in manufacturing 25 SUBTOPIC 1.1 1.2 1.3 Pages
The word manufacture is derived from Latin words, manus (hand) and Factus (make); the combination means made by hand. The English word manufacture is several centuries old, and “made by hand’ accurately describe the manual methods used when the word was first coined. Introduction To Manufacturing Process Basic Concept of Manufacturing Process 1.1 Manufacturing Concept 01
Definition and the importance of manufacturing process Design and Planning: This initial stage involves product design, feasibility studies, and determining the production process required to create the product. Engineers and designers work together to develop detailed plans and specifications. Sourcing of Raw Materials: Raw materials, components, or parts needed for the production are sourced from suppliers. The selection of high-quality materials is crucial for the final product's performance and quality. Pre-processing: In some cases, raw materials may require pre-processing before entering the main manufacturing line. For example, cutting, shaping, or treating materials to make them suitable for production. Assembly: This stage involves the actual manufacturing process where various components are assembled to create the final product. It can involve manual labor, automated machinery, or a combination of both. The manufacturing process refers to a series of steps and activities involved in converting raw materials, components, or parts into finished products. It is the systematic way of producing goods on a large scale, and it varies depending on the type of product being manufactured. The manufacturing process typically includes the following stages: Introduction To Manufacturing Process 02
Quality Control: Throughout the manufacturing process, quality control checks are performed to ensure that the products meet the required standards. Defective items are identified and either repaired or discarded. Testing: Once the product is assembled, it undergoes testing to ensure it functions as intended and meets safety and quality standards. Packaging: Finished products are carefully packaged to protect them during transportation and storage. Packaging also includes labeling and adding any necessary documentation. Distribution: The products are then distributed and made available for sale to retailers, wholesalers, or directly to customers. Post-production support: After-sales services such as warranty support, maintenance, and repair are provided to customers to ensure customer satisfaction and product longevity. Continuous Improvement: Manufacturing processes are often subject to continuous improvement efforts to enhance efficiency, reduce costs, and improve quality over time. Introduction To Manufacturing Process 03
Introduction To Manufacturing Process The manufacturing process is of paramount importance for various reasons, and its significance extends to different stakeholders, including businesses, economies, consumers, and society as a whole. Here are some key aspects highlighting the importance of the manufacturing process: Importance of the manufacturing process 4. Product Availability: Manufacturing ensures a steady supply of goods to meet consumer demands. Without efficient manufacturing processes, there would be shortages of essential products, affecting everyday life and industries. 3. Supply Chain and Trade: Manufacturing involves sourcing raw materials, components, and equipment from various suppliers, which contributes to a robust supply chain network. Efficient manufacturing processes enable countries to engage in global trade and export their products, boosting international commerce. 2. Innovation and Technological Advancement: The manufacturing process fosters innovation and technological advancements. Companies continually seek ways to improve production efficiency, product quality, and develop new products, leading to progress and competitiveness. 1. Economic Growth: Manufacturing plays a vital role in driving economic growth and development. It contributes significantly to a nation's gross domestic product (GDP) and creates job opportunities at various skill levels, supporting a wide range of industries and sectors. 04
Introduction To Manufacturing Process 5. Customization and Mass Production: Modern manufacturing processes allow for both mass production of standardized goods and customization to meet individual preferences. This ability to cater to diverse needs enhances customer satisfaction. 6. Cost Efficiency: Manufacturing at scale allows companies to benefit from economies of scale, reducing production costs. Cost-efficient production leads to competitive pricing and accessible products for consumers. 05 7. Job Creation: The manufacturing sector provides employment opportunities to a wide range of individuals, including engineers, technicians, operators, and support staff. A strong manufacturing industry helps reduce unemployment and boost local economies. 8. Knowledge and Skill Transfer: Manufacturing involves a wide range of specialized skills and knowledge. As individuals work in the industry, they acquire valuable expertise, which can be passed on to future generations, helping to build a skilled workforce. 9. Technological Spillover: Advances in manufacturing technology often lead to spillover effects in other industries. For example, developments in robotics and automation used in manufacturing have also influenced fields like medicine and transportation.
Introduction To Manufacturing Process In summary, the manufacturing process is not just about making products; it is a driving force behind economic growth, technological advancement, job creation, and social progress. Emphasizing efficient and sustainable manufacturing practices can lead to a stronger and more prosperous society. 10. National Security: A robust domestic manufacturing sector is crucial for national security. Relying heavily on foreign countries for essential goods can pose risks during times of geopolitical instability or supply chain disruptions. 11. Sustainable Development: The manufacturing process plays a pivotal role in promoting sustainable development. It involves optimizing resource usage, reducing waste, and adopting eco-friendly practices to minimize environmental impacts. 12. Social Impact: Manufacturing jobs provide stability and income to individuals and families, improving their quality of life. A thriving manufacturing sector can revitalize communities and contribute to social well-being. 06
Manufacturing Processes Processing Operations Shaping Processes Solidification Processes Particulate Processing Deformation Processes Material Removal Heat Treatment Cleaning and Surface Treatment Welding Brazing and Soldering Adhesive Bonding Coating and Deposition Processes Threaded Fasteners Permanent Fastening Methods Surface Processes Operation Property enhancing Processes Permanent Joining Processes Mechanical Fastening Assembly Operations Introduction To Manufacturing Process Classification of manufacturing Process PROCESSING OPERATIONS A processing operation transforms a work material from one state of completion to a more advanced state that is closer to the final desired product. It adds value by changing the geometry, properties, or appearance of the starting material. In general, processing operations are performed on discrete workparts, but certain processing operations are also applicable to assembled items (e.g., painting a spot-welded car body). ASSEMBLY OPERATIONS An assembly operation joins two or more components to create a new entity, called an assembly, subassembly, or some other term that refers to the joining process (e.g., a welded assembly is called a weldment). 07
Introduction To Manufacturing Process Factor to be considered for selecting manufacturing process The product design is one of the most important factors to consider when selecting a manufacturing process. The shape, size, and complexity of the product will all affect the type of process that is best suited for it. For example, a complex product with intricate features may require a more specialized process, such as CNC machining, than a simple product with few features. Product design: The production volume is another important factor to consider when selecting a manufacturing process. High-volume production typically requires a more automated process, such as injection molding, than low-volume production. This is because automated processes are more efficient and can produce products at a faster rate. Production volume: The cost of the manufacturing process is also an important factor to consider. Some processes are more expensive than others, and the cost of the process will need to be weighed against the cost of the product. For example, additive manufacturing is a relatively new process that is still in development. It is a very versatile process that can be used to create complex parts, but it is also very expensive. Cost The quality of the product is another important factor to consider when selecting a manufacturing process. Some processes are better suited for producing high-quality products than others. For example, CNC machining is a very precise process that can produce high-quality parts. Quality 08
Introduction To Manufacturing Process The skill level of the workforce is another important factor to consider when selecting a manufacturing process. Some processes require a highly skilled workforce, while others can be operated by less skilled workers. For example, CNC machining requires a highly skilled operator, while injection molding can be operated by a less skilled worker. Skill level of the workforce The environmental impact of the manufacturing process is also an important factor to consider. Some processes have a greater environmental impact than others. For example, casting is a relatively low-impact process, while forging has a higher environmental impact. Environmental impact The time to market is the time it takes to bring a product to market. Some processes are faster than others, and the time to market will need to be considered when selecting a process. For example, injection molding is a relatively fast process that can be used to produce products quickly. Time to market 09
The design process is essential to manufacturing since it serves as the basis for the entire production cycle. To guarantee product quality, cost-effectiveness, and timely delivery, a well-organized design process is essential. This sub-topic offers a thorough method for structuring the design process that incorporates knowledge from current techniques in manufacturing engineering and technology. Manufacturers can optimise processes, reduce errors, and promote innovation by implementing an organised and effective design methodology. Understanding the Requirements: The first step in organizing the design process involves a thorough understanding of the project's requirements. Effective communication between stakeholders, including designers, engineers, and clients, is essential to gather all necessary information. This helps in setting clear objectives, defining specifications, and identifying potential challenges early on. By outlining the scope and constraints, the design team can proceed with a well-defined plan. Introduction To Manufacturing Process Organize the design process 1.2 10
Introduction To Manufacturing Process Cross-Functional Collaboration: To organize the design process effectively, it is vital to encourage cross-functional collaboration among different departments. Encouraging teamwork and communication between design, engineering, manufacturing, and other teams results in smarter decisions and ensures every stage of the product's life is taken into account. This collaborative approach fosters innovation and allows for comprehensive problem-solving. Iterative Design: Organizing the design process necessitates adopting an iterative approach. This involves creating prototypes and conducting rigorous testing and analysis at each stage of the design. Feedback loops between design, engineering, and testing teams help in identifying potential issues early, reducing costly redesigns and rework. Iterative design also allows for continuous improvements and ensures that the final product meets or exceeds the required standards. 11
Integrating advanced computer-aided design (CAD) and simulation tools can significantly enhance the organization of the design process. These tools facilitate the creation of detailed 3D models, enabling designers to visualize products accurately before production. Moreover, simulation tools can evaluate the performance of the design under different conditions, leading to betterinformed decisions. Utilizing Computer-Aided Design (CAD) and Simulation Tools: Design for Manufacturability (DFM) and Design for Assembly (DFA): Adhering to Design for Manufacturability (DFM) and Design for Assembly (DFA) principles further streamlines the design process. DFM ensures that the product can be manufactured efficiently, reducing production costs and time. DFA, on the other hand, focuses on simplifying the assembly process, leading to improved productivity and quality. Emphasizing these principles from the initial stages of design optimizes the entire manufacturing process. Introduction To Manufacturing Process 12
An organized design process is the backbone of successful manufacturing engineering and technology. By understanding requirements, fostering crossfunctional collaboration, embracing iterative design, utilizing CAD and simulation tools, implementing DFM and DFA principles, and maintaining thorough documentation, manufacturers can ensure the efficiency, quality, and innovation of their products. This holistic approach not only enhances the design process but also sets the stage for sustainable growth and competitiveness in the dynamic manufacturing industry. Introduction To Manufacturing Process Documenting the Design Process: A well-organized design process requires comprehensive documentation. All design decisions, changes, and iterations should be recorded, ensuring that the entire team is on the same page. Proper documentation also aids in knowledge transfer, making it easier for new team members to join the project. This organized record-keeping is essential for future reference and continuous improvement. 13
Product design is a crucial and complex process that involves creatively and systematically determining the shape and features of a product to achieve specific objectives while considering various limitations. It holds significant importance as it impacts a substantial portion, about 80%, of the total cost associated with product development and manufacturing. Consequently, decisions made during the initial design stages profoundly influence the overall success of the product. Innovation is essential to successful product design because it makes it possible to develop original, one-of-a-kind solutions. It is crucial to specify the intended uses of the product, its purpose, and how useful it will be to users. To guarantee that the product meets or exceeds specified criteria, it is also essential to articulate the intended performance of the product. Product design Introduction To Manufacturing Process Step involved in design and manufacturer product 14
The design process also considers whether the product is entirely new or a modification of an existing one. In both cases, a comprehensive understanding of the target market becomes indispensable. Valuable input from market analysts and sales personnel, who study market trends and consumer needs, helps define the product's intended market and uses. Tailoring the design to cater to specific demands and aligning it with consumer expectations becomes possible through this understanding. Creating successful products necessitates close collaboration between manufacturing and design activities. The seamless interaction between these two aspects is critical to producing high-quality, costeffective, and innovative products. Product design is an important process that requires a combination of creative thinking, systematic planning, and a deep understanding of market demands. Embracing innovative approaches, specifying clear functions and performance expectations, and considering market trends enable manufacturers to develop products that not only meet consumer needs but also gain a competitive advantage in the market. The effective coordination between manufacturing and design activities further enhances the likelihood of producing successful and marketable products. Introduction To Manufacturing Process 15
Traditionally, design and production processes have been carried out in the order even though this process may initially seem simple and logical, it actually wastes resources. Consider a manufacturing engineer who, for a variety of reasons, decides that it would be preferable to use (a) a different material, such as a polymer or a ceramic, instead of a metal, or (b) the same material in a different condition, such as a softer rather than a harder material. The traditional sequential approach to product design involved distinct phases, where design decisions were made before manufacturing commenced. This approach often led to challenges when design changes or improvements were required during or after production. For example, altering materials or adjusting certain specifications after design completion would be difficult and costly. Concurrent Engineering, also known as Integrated Product and Process Development (IPPD), introduced a paradigm shift by promoting simultaneous collaboration between various disciplines during product development. This approach breaks down silos between design, engineering, manufacturing, and other departments, allowing them to work together from the early stages. The aim is to leverage their expertise and address potential issues proactively, reducing the need for late-stage changes and minimizing project delays. Product design and concurrent engineering Introduction To Manufacturing Process 16
Benefits of Concurrent Engineering: Introduction To Manufacturing Process Faster Product Development Concurrent Engineering speeds up the process of creating a product by allowing different teams to work on various aspects simultaneously. This leads to quicker iterations and reduces the time it takes to bring the product to market. Cost Savings Involving manufacturing experts early in the design phase enables the integration of Design for Manufacturability (DFM) principles. As a result, the designs are more cost-effective to produce and assemble, leading to savings in manufacturing expenses. Better Collaboration Concurrent Engineering promotes a culture of collaboration among different departments. This fosters better communication and problem-solving skills, as teams work together to find innovative solutions through brainstorming. Flexibility for Improvements Concurrent Engineering offers the flexibility to make design changes and improvements at any stage of the process. This adaptability allows manufacturers to respond quickly to market demands and customer feedback, making necessary adjustments as needed. Improved Product Quality By involving diverse perspectives and expertise from the beginning, Concurrent Engineering helps identify and address potential design flaws early on. This focus on quality leads to better overall product performance and higher customer satisfaction. 17
Role of Computers in Product Design: The integration of computers into product design has had a profound impact on the manufacturing industry. Computer-Aided Design (CAD) has become a crucial tool for creating detailed and precise 2D and 3D models, improving visualization and design understanding. Rapid Prototyping (RP) technologies, such as 3D printing, enable faster and more cost-effective prototyping, facilitating iterative design improvements. Computers also play a vital role in simulation and analysis during product design. Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) simulations help evaluate product behavior under different conditions, leading to optimized designs. Parametric modeling enables design optimization through variable manipulation, exploring various design possibilities efficiently. Introduction To Manufacturing Process Overall, computers in product design foster greater efficiency, collaboration, and innovation, resulting in higher quality products and increased competitiveness in the manufacturing industry. As technology continues to advance, the role of computers in product design will further evolve, opening new possibilities for design creativity and efficiency. 18
A prototype acts as a physical representation of an individual component or product. These prototypes are carefully examined to discover potential enhancements in the original design, materials, or production methods. One revolutionary and continuously evolving technology in this domain is rapid prototyping. By utilizing Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) in conjunction with specialized technologies, designers can now create prototypes quickly and affordably. These prototypes can be made from a diverse range of materials, including metallic and non-metallic substances like plastics and ceramics. In the past, developing prototypes through conventional methods like casting, forming, and machining incurred exorbitant costs for automotive companies, reaching hundreds of millions of dollars annually, and some components took a year or more to complete. However, rapid prototyping has brought about a transformative change, significantly reducing expenses and shortening productdevelopment schedules Prototypes Introduction To Manufacturing Process 19
Introduction To Manufacturing Process Rapid-prototyping techniques have progressed to an advanced level, making them applicable in the costeffective production of low-volume batches (usually fewer than 100 parts) of actual and fully functional components. These components can then be assembled into final products. The possibilities offered by rapid prototyping have revolutionized the manufacturing landscape, presenting vast potential for innovation, efficiency, and cost-effectiveness in the production process. 20
Design for Manufacture, Assembly, Disassembly, and Service (DFMADS) is a crucial concept in modern manufacturing, aimed at optimizing the entire product life cycle. It involves thoughtful consideration of the manufacturing process, ease of assembly, disassembly, and serviceability right from the early stages of product design. The primary goal of DFMADS is to create products that not only function effectively but also prove cost-effective to produce and maintain. By integrating DFMADS principles, manufacturers can streamline production processes, minimize material waste, and enhance product quality. The first facet of DFMADS, "Design for Manufacture," emphasizes the creation of products that can be easily manufactured using available technologies and processes. This involves prudent material selection, reducing complexity, and avoiding features that could be challenging or expensive to produce. "Design for Assembly" centres on simplifying the assembly process. By designing products with fewer components and assembly steps, manufacturers can reduce both assembly time and cost while bolstering product reliability. Introduction To Manufacturing Process Design for manufacture, assembly, disassembly, and service 21
Conversely, "Design for Disassembly" considers the product's endof-life stage. Products designed with disassembly in mind can be easily taken apart, facilitating efficient recycling or reuse of components, thereby reducing environmental impact, and promoting sustainability. Lastly, "Design for Service" ensures products are easily serviceable throughout their lifecycle. Serviceability features, such as accessible maintenance points and standardized components, expedite costeffective repairs, minimizing downtime and enhancing customer satisfaction. Embracing DFMADS principles can yield numerous benefits, including lower manufacturing costs, improved product quality, enhanced performance, and increased customer satisfaction. Manufacturers can maintain competitiveness by integrating DFMADS as an integral part of their product development process. Introduction To Manufacturing Process 22
Reduced costs for the service provider: DFS can help to reduce the cost of service by making products easier to service, maintain, and repair. This can be achieved by using standardized components, modular designs, and easy-toaccess service points. Improved customer satisfaction: DFS can help to improve customer satisfaction by making products easier to use and maintain. This can be achieved by designing products with clear instructions, providing customer support, and offering training programs. Increased product reliability: DFS can help to increase product reliability by designing products that are less likely to fail. This can be achieved by using high-quality materials, designing products for harsh environments, and using preventive maintenance strategies. Design for Service There are many benefits to using DFS. These include: Introduction To Manufacturing Process 23
The type of product being designed: Some products are more difficult to service than others. For example, complex products with many components may be more difficult to service than simple products with few components. The environment in which the product will be used: Products that will be used in harsh environments, such as extreme temperatures or high vibration, will need to be designed to withstand these conditions. There are several factors to consider when using DFS. These include: Introduction To Manufacturing Process The customer's needs: The customer's needs should be considered when designing a product for service. For example, if the customer needs a product that is easy to maintain, the design should reflect this need. 24
Trends in Manufacturing are the changes that are taking place in the manufacturing industry. These changes are driven by several factors, including advances in technology, globalization, and changing customer demands. Trends in Manufacturing represent the dynamic and ever-evolving landscape of the manufacturing industry. Embracing these trends is crucial for manufacturers to stay competitive and thrive in a rapidly changing global market. The conversation is divided into the following subject matter categories: 1. Globalization and outsourcing 2. Lean manufacturing and six sigma 3. Additive manufacturing 4. Cyber-physical manufacturing systems 5. Sustainable manufacturing Expose the trends in manufacturing. Introduction To Manufacturing Process 1.3 25
Lean manufacturing and six sigma: Lean manufacturing is a set of principles and practices that are designed to improve efficiency and productivity in manufacturing. Lean manufacturing focuses on eliminating waste and improving flow throughout the manufacturing process. Six Sigma is a quality improvement methodology that is designed to reduce defects and improve quality. Six Sigma uses a systematic approach to identify and eliminate causes of variation in manufacturing processes. Introduction To Manufacturing Process Aspect of changing to modern manufacturing Globalization and outsourcing: The global economy is becoming increasingly interconnected, and this is having a major impact on manufacturing. Companies are increasingly outsourcing manufacturing to countries with lower labor costs, which can lead to lower prices for consumers. However, outsourcing can also lead to job losses in developed countries. Additive manufacturing: Additive manufacturing, also known as 3D printing, is a process for creating three-dimensional objects from a digital model. Additive manufacturing is becoming increasingly popular in manufacturing, as it allows for the creation of complex parts that would be difficult or impossible to manufacture using traditional methods. 26
Introduction To Manufacturing Process Cyber-physical manufacturing systems: Cyber-physical manufacturing systems (CPS) are manufacturing systems that are integrated with information technology. CPS use sensors and actuators to monitor and control the manufacturing process, and they use data analytics to improve efficiency and productivity. Sustainable manufacturing: Sustainable manufacturing is the production of goods and services that meet the needs of the present without compromising the ability of future generations to meet their own needs. Sustainable manufacturing focuses on reducing the environmental impact of manufacturing, and it uses resources more efficiently. 27
Environmental sustainability is given top priority, and green design and manufacturing is a fundamental and forward-thinking approach in the manufacturing industry that aims to reduce the environmental impact of products and production methods. Engineers and designers are dedicated to integrating environmentally friendly practices throughout the product life cycle in the framework of green design and manufacturing. This starts with the design stage, where choosing eco-friendly materials, minimising waste, and ensuring energy efficiency are prioritised. Manufacturers may reduce the impact their products have on the environment by using recyclable or biodegradable materials. A crucial component of green design and manufacturing is the manufacturing process itself. Among the steps taken to lessen the environmental impact of manufacturing operations are the use of energy-efficient technologies, workflow optimisation, and water reduction. Manufacturers can cut greenhouse gas emissions and resource use by implementing greener production methods. Product life extension and end-of-life management are two important aspects of green design and manufacturing. Longer product lifespans, fewer replacements, and less waste are all benefits of designing items for strength and repairability. Furthermore, including disassembly capabilities in the product design makes recycling and proper disposal of components when their useful lives are over easier. Introduction To Manufacturing Process Green design in manufacturing 28
A further basic principle of green design and manufacturing is waste reduction. Manufacturers may optimise resource utilisation and decrease overall waste generation through implementing practises like lean manufacturing into practise, where waste is minimised at every stage of the production process. The use of renewable energy sources in manufacturing facilities is encouraged by green design and manufacturing. Manufacturers may lower their carbon footprint and support international efforts to prevent climate change by switching to renewable energy. In conclusion, "Green Design and Manufacturing" is a cutting-edge strategy that incorporates social responsibility, resource efficiency, and environmental responsibility into every stage of product development and manufacturing. Manufacturers may improve the environment and promote a more sustainable and prosperous future by implementing these ideas. Introduction To Manufacturing Process 29
Chips resulting from machining processes and trimmed materials from sheet forming, casting, and moulding operations. Slag produced in foundries and welding operations. Additives used in sand for sand-casting operations. Hazardous waste and toxic materials used in certain products. Lubricants and coolants used in metalworking and machining processes. Liquids generated from processes such as heat treating and plating. Solvents used in cleaning operations. Smoke and pollutants emitted from furnaces and gases released from burning fossil fuels. The manufacturing process and the operation of machinery can significantly impact the environment. During manufacturing operations, various types of waste are generated, including: Introduction To Manufacturing Process Waste in manufacturing 30
These wastes can have adverse effects on the environment if not properly managed and disposed of. Manufacturers are increasingly adopting sustainable practices to reduce waste generation, minimize environmental impact, and promote responsible resource management throughout the production process. Across all industrial sectors, the term "green design and manufacturing" has become widely used, with a special emphasis on "design for the environment" (DFE). The goal of this strategy, often referred to as environmentally conscious design and manufacturing, is to identify and minimise any potential adverse environmental impacts of materials, processes, operations, and products. The objective is to produce sustainable and environmentally friendly results by taking these factors into account at the commencement of the design and manufacturing processes. The idea of "design for recycling" (DFR) was also inspired by these goals. Recycling might involve the following two basic tasks: Introduction To Manufacturing Process 31
In waste manufacturing, the biological cycle involves natural processes that break down materials, creating new soil to support life. This cycle is integrated into product design, utilizing organic materials that serve their purpose, and after use, safely return to the environment. In waste manufacturing, the natural recycling process, often referred to as "Nature's Recycling," involves the breakdown of materials into reusable components. For example, in the context of food waste, organic materials like fruit peels or vegetable scraps undergo decomposition by microorganisms. This process transforms the waste into nutrient-rich compost, which can then be used to enrich soil and promote plant growth. This activity demonstrates how the biological cycle in waste manufacturing contributes to the sustainable reuse of materials in a way that benefits the environment. 1. Biological cycle: Introduction To Manufacturing Process 32
2. Industrial cycle: In waste manufacturing, the industrial cycle involves how materials are used, reused, and managed. This cycle guides how products are created, used, and eventually handled at the end of their life. One example within the industrial cycle is the recycling of scrap metal generated during machining processes in a factory. Instead of discarding the metal waste, it is collected, sorted, and sent to a recycling facility. There, the scrap metal is melted down and reprocessed to create new metal products or components, reducing the need for virgin raw materials, and minimizing waste. This activity contributes to resource conservation and a more sustainable industrial ecosystem. Introduction To Manufacturing Process 33
A manufacturing strategy known as "cradle-to-cradle" focuses on using recyclable or reusable materials while making items. By creating goods with components that are simple to disassemble and reuse at the end of their useful lives, it works to reduce waste. This method helps make production more environmentally friendly and sustainable. In this innovative approach, products are designed with the intent of being easily disassembled, reclaimed, and transformed into new products or materials at the end of their useful life. This design philosophy places a strong emphasis on using materials that can be safely and effectively recycled or composted. The goal is to eliminate the concept of waste altogether by ensuring that all components of a product can be used to create new products or returned to nature without harming the environment. Cradle-to-cradle Production Introduction To Manufacturing Process Cradle-to-cradle production can be seen in the recycling of aluminum cans. These cans can be melted down and repurposed multiple times without losing their inherent properties, thereby reducing the need for extracting and processing new aluminum resources. Overall, cradle-to-cradle production represents a visionary shift in manufacturing philosophy, where products are conceived as part of a perpetual cycle of use and regeneration. By embracing this approach, manufacturers contribute to a more sustainable future, minimize waste, and mitigate the environmental impact of their products and operations. 34
35 The term "Guidelines for Green Design and Manufacturing" refers to a collection of rules and procedures that place emphasis on resource conservation and environmental sustainability across the whole product lifecycle. This strategy strives to improve long-term social and environmental well-being while reducing the ecological impact of industrial procedures and end products. Introduction To Manufacturing Process Guidelines for green design and manufacturing
Introduction To Manufacturing Process Using recycled materials can help to reduce the demand for virgin materials, which can conserve natural resources and reduce pollution. For example, recycled paper can be used to make new paper products, and recycled plastic can be used to make new plastic products. Designing products that are easy to repair and remanufacture can help to reduce waste and extend the life of products. This can be achieved by using modular designs and by using standardized components. Using energy-efficient manufacturing processes can help to reduce energy consumption and greenhouse gas emissions. For example, using waterjet cutting instead of laser cutting can reduce energy consumption by up to 80%. Minimizing waste in manufacturing can help to reduce the environmental impact of manufacturing. This can be achieved by using lean manufacturing techniques, by recycling and composting waste materials, and by disposing of waste in an environmentally responsible manner. Using renewable energy sources in manufacturing can help to reduce greenhouse gas emissions and promote a more sustainable future. For example, using solar panels to power manufacturing facilities can reduce the reliance on fossil fuels. Use recycled materials: Design products for easy repair and remanufacture: Use energy-efficient manufacturing processes: Minimize waste: Use renewable energy sources: There are connections between the fundamental ideas of DFMA, DFD, DFE, and DFR. These connections can be summed up as the following rules, which are swiftly gaining acceptance everywhere: 36
“The great differentiator in business is when an organization steps out and creates value from something never tried before. ” -Kerry Baskins, 37
Definition and Importance of Manufacturing: Manufacturing is the process of converting raw materials into final products through various operations and techniques. It plays a crucial role in modern society by producing goods that fulfill our needs and contribute to economic development. Historical Evolution: The topic delves into the historical evolution of manufacturing, from early manual methods to the highly automated and technology-driven processes of today. Classification of Manufacturing Processes: Manufacturing processes are categorized into several types, such as casting, forming, machining, joining, and additive manufacturing. Each category involves specific techniques to shape and assemble materials. Interdisciplinary Nature: Manufacturing is an interdisciplinary field that draws from engineering, materials science, design, and management. It emphasizes the integration of various technologies and disciplines to achieve efficient and cost-effective production. Product Life Cycle: The concept of the product life cycle is introduced, highlighting the stages of product development, production, distribution, and disposal. Role of Computer-Aided Design and Manufacturing (CAD/CAM): The integration of CAD and CAM technologies is discussed, emphasizing their pivotal role in designing and optimizing manufacturing processes. Globalization and Competition: The topic explores how globalization has impacted manufacturing, leading to increased competition and the need for continuous improvement and innovation. Environmental Considerations: The environmental impact of manufacturing processes is acknowledged, and the importance of adopting sustainable practices is emphasized. The topic "Introduction to Manufacturing Process" provides a foundational overview of the fundamental concepts and principles that underlie the field of manufacturing. It serves as a starting point for understanding the various processes involved in transforming raw materials into finished products. The key points covered in this topic include: Overall, the introduction to manufacturing process lays the groundwork for understanding the intricate world of production, setting the stage for exploring the diverse techniques, technologies, and strategies employed in the creation of products that shape our modern world. SUMMARY 0138
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