1-DMCU 1323 Introduction to Manufacturing (1)

DMCU 1323 – Manufacturing Process

Chapter 1 - Introduction to
Manufacturing

Overview

Example of an Engineering Product
1. Aeroplanes – what are they made of?

2. Twin Tower Petronas – What is this building
composed of?





What is manufacturing?

Source: Automotive manufacturing solutions

WHAT IS MANUFACTURING
Machinery
Tooling
Power
Labor

Raw materials Manufacturing Product
Process Profit

1) Technology – manufacturing is 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 also includes the assembly of multiple parts to make products.

WHAT IS MANUFACTURING

2) Economic – manufacturing is the Starting Manufacturing Processed
transformation of materials into items of material Process material
greater value by means one or more
processing involve. Therefore, Value
manufacturing is “added value” to the added
material.
Material in
processing

WHAT WILL YOU LEARN?

Raw Material(s) Process(es) Products
• SUBTRACTIVE PROCESSES
• STEEL • TYPE OF • PROCESSES • CONTINOUS PROCESS
MANUFACTURING • FORMING AND SHAPING • NET SHAPE PROCESS
OPERATION AND
LAYOUT • ADDITIVE PROCESS

• JOINING PROCESS

QUALITY AND METROLOGY
SUSTAINABLE MANUFACTURING

INPUT FROM PRODUCT INPUT FROM COMMENTS
CUSTOMERS DEVELOPMENT SUPPLIERS FROM

CUSTOMER

PROJECT PROPOSAL PROJECT PLANNING DESIGN PRODUCT PRODUCT
MANUFACTURE LAUNCH

How manufacturing starts ?

PLANNING
TEAM

PRODUCT
DESIGN TEAM

ENGINEERING/PRODUCTION
TEAM

Who ARE involve in manufacturing PROCESS?

HOW DISCUSSION TAKE PLACE?

CUSTOMERS PLANNING ENGINEERING/ SUPPLIERS
PRODUCTION
New feature
Quantity to produce Does the design can fit the
Destination market current equipment
Production location Need new machine?
Product life
Similar competitor model

Translate planning design
Into manufacturable
design

Why concurrent engineering is important?

Traditional “waterfall” or sequential development vs. Iterative
development method in Concurrent Engineering

PLANNING TEAM PRODUCT DESIGN ENGINEERING/PR
TEAM ODUCTION TEAM

Sequential/over the wall engineering

How to select the right processes

DESIGN MATERIAL EXTERNAL REGULATIONS
• Size and shape of the final product • Material to be used (type and basic • Environment and
• safety
and raw material properties)
• Geometry complexity • Castability/ weldability/Machinability MACHINES AND TOOLS
• parts with thin cross-sections • Availability of machines
QUALITY
cannot be cast properly; complex • Dimensional accuracy (tolerances) and equipment
• Flexibility to change the
parts cannot be formed easily. required
design at any time
• Surface finish required -additional

COST operations: grinding, polishing

• Economics (cost) of tooling, (better finish but more expensive!)

capital, scrap rate etc

• Operational and Cost QUANTITY
considerations: • Number of parts or products required

• Design and cost of tooling and
• desired production rate

TIME FRAME Additional reading
• Lead time required to https://writepass.com/journal/2016/08/factors-that-affect-
selection-of-manufacturing-process-design-at-apple-inc/
begin production

Type of Process

Extrusion





Type of Industries

TYPE OF INDUSTRIES

Industries can be classified as:

Those that CULTIVATE Take the outputs of the Constitute with
AND EXPLOIT natural primary industries and SERVICE SECTOR of
resources; CONVERT them into •tBhaenkeicngonomy.
consumer and
•Agriculture capital goods. •Communications
•Forestry •Education
•Fishing •Aerospace •Entertainment
•Livestock •Automotive •Financial services
•Quarries •Beverages •Health and medical
•Mining •Building materials •Government
•Petroleum •Chemicals •Hotel
PRIMARY INDUSTRY •Computers •Insurance
SECONDARY•Consumer appliances •Restaurant
INDUSTRY•Electronics •Retail trade
•Equipment •Tourism
TERTIARY INDUSTRY•Food processing•Transportation
•Glass, ceramic •Real estate
•Paper
•Pharmaceuticals
•Plastics (shaping)
•Textiles
•Tire and rubber
•Wood and furniture

WHICH INDUSTRIES ARE INVOLVED IN THE EXAMPLES BELOW?

11

• Manufacturing system can be defined as a transformation system in which a
product or service is created by working upon a set of inputs.

• Inputs are usually in the form of men, machine, money, materials etc. Production
systems are usually classified on the basis of product quantity and variety.

Intermittent Continuous
Project Mass
Batch
Jobshop

1) Project – 1 to 10 units. [Low production]
2) Job shop – 10 to 100 units.
3) Batch – 100 to 10,000 units. [Medium production]
4) Mass – Above 10,000 units. [High production]

@jurie 2007 – Lecture 1

RELATIONSHIP BETWEEN PRODUCT QUANTITY AND PRODUCT VARIETY

Above 10,000 units Continuous Production
System

Mass 100 to 10,000 units Intermitted Production
System
Product
QUANTITY/VOLUME High Batch 10 to 100 units

Job shop 1 to 10 units
Project
Medium

Low

Product VARIETY

Production quantity: number of unit produced annually of a particular product type.
Product variety: different product designs or types that are produced in the plant.

Type of
Manufacturing
Operations

TYPE OF MANUFACTURING OPERATIONS

• Position – remains stationary
during the manufacturing
process

• Materials, people, machinery
are brought to the product
site.

• Based on customer
specifications.

• Example: bridge, building
construction, aircraft, ships,
locomotive.

2) JOB SHOP A job shop is a type of manufacturing process in which small batches of a variety
of custom products are made. In the job shop process flow, most of the products
produced require a unique set-up and sequencing of process steps.

 Low volume. Make-to-order
 Satisfies a market for nonstandard or

unique product.
 Layout – different machines with similar

functional are grouped together as

department.
 Require high skill levels labor – to

operate a variety of equipment
 A short duration activities to provide

custom goods.
 Example: Car workshop.

 Batch production produce or process any product in groups
called “batches”.

 Can produce a variety of products – opposed to a
continuous production process, or a one time production.

 Useful for industries that makes seasonal items/products
 Example: Similar standard items made periodically in

batches: bakery, paint, hand tools.
 Same facilities used to manufacture all the different items.

Batch Production Examples:
Baked goods
Clothing
Computer software
Die- or mold-making
Electrical goods

- Reduce initial capital outlay
- due to a single production line can be used to several products
- machines can be used more effectively, materials can be bought in bulk
- workers can specialize in that task.

DISADVANTAGES

- Requires very careful production planning & control – next batches; when, types.
- When switching to another batches – takes time (“down time”) – can cause loss of
output (low yield).
- Resulted “WIP” or create inventory/stock – increases costs such as inventory
cost, cost because of damage to stock.

The example production line (shown below) is that of an engineering company, manufacturing small steel
products such as hinges and locks. They manufacture batches of five hundred at a time. The workers are
unskilled and semi skilled. As each task is completed the item being manufactured is passed down the
production line to the next worker, until it is complete.

Mass production often involves the assembly of a number of
sub-assemblies of individual components. Parts may be bought
from other companies.

 A.k.a flow production, repetitive flow
production

 Producing goods in large quantities at low cost
per unit and produce in a short period of time.

 Involved fewer labor cost and a faster rate of
production.

 Work piece is transfer automatically from one
machine to another.

 Example: Cola-cola drinks, light bulbs,
refrigerator, tv.

Type of Plant
Layout

Manufacturing Plant Layout

Plant layout refers to an Goal of Plant Layout
optimum arrangement of To maximize the profit by arrangement of all the plant
facilities including facilities to the best advantage of total manufacturing of
personnel, operating the product.
equipment, storage space,
material handling
equipment and all other
supporting services along
with the design of best
structure to contain all
these facilities”.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html

Plant Layout - Objectives

• Streamline the flow of materials through the plant.
Facilitate the manufacturing process.

• Minimize materials handling and cost.
• Effective utilization of men, equipment and space.
• Flexibility of manufacturing operations and

arrangements.
• Provide for employee convenience, safety and

comfort.
• Minimize investment in equipment.
• Minimize overall production time.
• Maintain flexibility of arrangement and operation.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html

Principles of
Plant Layout

Integration Minimum Safety, Minimum Cubic space Flow Maximum
Distance security, and handling utilization flexibility
A good satisfaction Materials to
layout The total Reduces A good move in Can be
integrates distance Workers the layout is forward altered
men, travelled by safety and material one that direction without much
materials, the men and satisfaction handling to utilizes both towards the cost and
and materials and the horizontal completion time, i.e.,
machines in should be safeguards minimum and vertical stage future
order to get minimum the plant space. Also requirements
the optimum and as far as and the height
utilization of possible machinery
resources straight line against fire,
and movement theft, etc.
maximum should be
effectiveness. preferred

Type of
Layout

Fixed Position Flow Line Functional Cellular
(Product) (Process)

 Fixed position Layoutproject
 Product LayoutMass Production
 Process LayoutBatch/jobshop
 Cellular LayoutHybrid

Extra Notes: http://slideplayer.com/slide/3715352/

PROJECT

1. Fixed position layout

Fixed Position Layout This is also called the project type of layout.
• The material, or major components remain in a fixed location and tools, machinery, men and other

materials are brought to this location.
• Suitable when one or a few pieces of identical heavy products (huge) are to be manufactured and when

the assembly consists of large number of heavy parts, the cost of transportation of these parts is very high
and take a long time to produce.

Process layout is recommended for batch production. 2. Functional (process) layout
• Machines performing similar type of operations are
BATCH
grouped at one location in the process layout e.g., all
lathes, milling machines, etc. are grouped in the shop
will be clustered in like groups (according to
functions)

• The flow paths of material through the facilities from
one functional area to another vary from product to
product.

• Usually the paths are long and there will be
possibility of backtracking.

• Process layout is normally used when the production
volume is not sufficient to justify a product layout.

• Typically, job shops employ process layouts due to
the variety of products manufactured and their low
production volumes.



MASS

3. Flow line (product layout)

In this type of layout, machines and • Machines and equipment are positioned
auxiliary services are located
according to the processing along a flow line.
sequence of the product. • Several flow lines may come together to

Plant arrangement to facilitate feed the final assembly line.
material processing in the same • Product passes from workstation to
order.
another workstation along the flow line.
Suitable for mass production system • Special purpose machines are used which
as , the facilities can be arranged to
achieve efficient flow of materials perform the required function quickly and
and lower cost per unit.
reliably.
• High level of machine and manpower

utilization
• Need to categorize operations to ensure

equal processing time at all work stations

(line balancing).

When Applicable FLOW LINE (PRODUCT) LAYOUT
When the volume of production
of a product is high such that a Product A L LMD
separate production line to
manufacture it can be justified. Product B L MM D

In a strict product layout, Product C L GG D
machines are not shared by
different products. Therefore,
the production volume must be
sufficient to achieve satisfactory
utilization of the equipment.

A typical product layout is
shown in the following figure.

Advantages
• Reduced work handling leads to short

cycle time/piece.
• Less WIP
• Simple planning and control.
• Reduced labor skill.
• Good space utilization.

Disadvantages
• Limited flexibility
• Machine breakdown causes major

problem
• High setting up cost.
• Uses expensive special purpose machine

Difference between Process vs. Product Layout

4. Hybrid Layout (Cellular)

 Plant divided into groups or cells in a small unit (individual cell), consisting of one to several
workstations.

 A w/station can contains either one machine (known as a single machine cell), or several machines
(known as a group machine cell) with each machine performing a different operation on the part.

 Cells can process a complete family of parts – need to form families of products.

 The flow among the equipment in the cells can vary depending on the composition of parts within
the part family.

 Good example for the implementation of the concept of group technology.

 The machines at w/stations can be modified, retooled, and regroup for different product lines
within the same family of parts.

 Consist of two subsections which is Just-in-Time (JIT) and Lean Manufacturing

Group technology or GT is a manufacturing technique in which
parts having similarities in geometry, manufacturing process
and/or functions are manufactured in one location using a small
number of machines or processes.

Plant layout Relate to quantity &
variety of product

Nature of Type of Tech
work manufac
operation
involved
Definition
Classificati
Definition on

Industry Intro to Econ
classification Manufac
People
Example Select involve
process

Factors to Roles
consider