ME144 - INDUSTRIAL PROCESSES

Prepared By:
Engr. Estelito V. Mamuyac
11 June 2014
Week-1.0 Introduction
2014-2015 / 1T
INDUSTRIAL PROCESSES
Industrial processes are procedures involving chemical or
mechanical steps to aid in the manufacture of an item or
items, usually carried out on a very large scale.
Industrial processes are the key components of heavy
industry.
An industrial process alters materials or substances.
Some processes make the production of a rare material
vastly cheaper, thus changing it into a commodity; i.e. the
process makes it economically feasible for society to use the
material on a large scale.
COTTAGE INDUSTRY
Some industries which are usually operated from large centralized
factories were cottage industries before the Industrial Revolution*.
A cottage industry (also called the domestic system) is an industry
- primarily manufacturing which includes many producers,
working from their homes, typically part time.
The term originally referred to home workers who were engaged in
a task such as sewing, lace-making or household manufacturing.
Business operators would travel around, buying raw materials,
delivering them to people who would work on them, and then
collecting the finished goods to sell, or typically to ship to another
market.
COTTAGE INDUSTRY
One of the factors which allowed the Industrial Revolution to take
place in Western Europe was the presence of these business people
who had the ability to expand the scale of their operations.
Cottage industries were very common in the time when a large
proportion of the population was engaged in agriculture, because
the farmers (and their families) often had both the time and the
desire to earn additional income during the part of the year (winter)
when there was little farming work to do.
The use of the term has expanded, and is used to refer to any event
which allows a large number of people to work part time.
For example, eBay is said to have spawned a cottage industry of people who
buy surplus merchandise, and sell it on their auction system.

HISTORY OF COTTAGE INDUSTRY
Current applications of the term "cottage industry" include: A program,
process or practice that takes up lengthy and/or inordinate amounts of
time while detracting from the main task at hand.
Cottage industries were the precursor to the factories that would
characterize the Industrial Revolution.
Their formation was prompted largely by the enclosing of the common
lands.
Common lands were lands set aside for the common people on which to
garden or graze their livestock.
Over time the rich aristocrats enclosed the common lands, largely
without censure or punishment of any kind, leaving the poor people in a
major predicament.

HISTORY OF COTTAGE INDUSTRY
Bear in mind that if one was not a land owner, highly skilled, or
highly educated there were few opportunities to make a good
living.
Cottage industries were the solution that solved this problem and
saved many of the common people.
Most of the work was carried out in the home and was often
combined with farming.
The process of the cottage industry involved the entire family as
most work performed in the 18th century did.
In fact the entire process moved from child to the mother then to
the father.

HISTORY OF COTTAGE INDUSTRY
A good example for this type of cottage industry is the making of
cloth. There were three main stages to making cloth: carding,
spinning and weaving.
Most cloth was made from either wool or cotton, but other
materials such as silk and flax were also used.
The woven cloth was sold to merchants called clothiers who visited
the village with their trains of pack-horses.
Some of the cloth was made into clothes for people living in the
same area.
However, a large amount of cloth was exported.
HISTORY OF COTTAGE INDUSTRY
The first process is called carding which was
usually done by children.
This involved using a hand-card that removed and
untangled the short fibers from the mass.
Hand cards were essentially wooden blocks fitted
with handles and covered with short metal spikes.
The spikes were angled and set in leather.
The fibers were worked between the spikes and, by
reversing the cards, scrapped off in rolls (cardings)
about 12 inches long and just under an inch thick.

HISTORY OF COTTAGE INDUSTRY
CARDING MACHINE
HISTORY OF COTTAGE INDUSTRY
The second process was known as spinning and this was
performed by the mothers.
The spinning of wool, cotton or flax was originally done by the spindle
and distaff.
The distaff, a stick about 3 ft long, was held under the left arm, and
the fibers of wool drawn from it were twisted spirally by the forefinger
and thumb of the right hand.
As the thread was spun, it was wound on the spindle.
It consisted of a revolving wheel operated by treadle and a driving
spindle. this slow process of spinning was a tedious process that
remained unaltered until the invention of Spinning Jenny.
The machine used eight spindles onto which the thread was spun
from a corresponding set of rovings. By turning a single wheel, the
operator could now spin eight threads at once.
HISTORY OF COTTAGE INDUSTRY
Modern top-whorl drop spindles
Spinning with a spindle (below) and
distaff (above)
HISTORY OF COTTAGE INDUSTRY
The last process was performed by the fathers or the men of
the household, this process was called the weaving.
The weaving was done on a machine known as the handloom weaver
so weaving was also referred to as hand-looming.
The handloom was devised about 2,000 years ago and was brought to
England by the Romans. The process consisted of interlacing one set
of threads of yarn (the warp) with another (the weft). The warp
threads are stretched lengthwise in the weaving loom. The weft, the
cross-threads, are woven into the warp to make the cloth.
Like the process of spinning, weaving remained unchanged for a great
period of time. Then the twelfth child of a Yeoman farmer, John Kay
invented the flying shuttle, which enabled a weaver to knock the
shuttle across the loom and back again using one hand only.
HISTORY OF COTTAGE INDUSTRY
Weaving in ancient Egypt
An Indian weaver on a pegged
loom
A Jacquard loom
(mechanical loom, 1801)
A hand loom
HISTORY OF COTTAGE INDUSTRY
Recently cottage industries have been encouraged by
environmental groups to preserve areas of the rainforest by aiding
the local tribes in a sustainable way.
e.g., the Maisin tribe and others in Papua New Guinea is a notable
example to sustain the rainforest for future generations.
In the Philippines, cottage industry is very much alive, especially in
the provinces. Typical of this industry are:
Dress making
Handcrafts and artcrafts
Fine jewelry making
Furniture and woodworks

MANUFACTURING
Manufacturing, in its comprehensive sense, is the process of converting raw
materials into products.
It is the production of goods for use or sale using labor and machines, tools,
chemical and biological processing, or formulation. The term may refer to a
range of human activity, from handicraft to high tech, but is most commonly
applied to industrial production, in which raw materials are transformed into
finished goods on a large scale.
Manufacturing also involves activities in which the manufactured product,
itself, is used to make other products.
Examples include large presses to shape sheet metal for appliances and car bodies,
machineries to make fastenerssuch as bolts and nuts, and sewing machines to make
clothing.
Other complex products, such as aircraft, household appliances or automobiles, are sold to
wholesalers, who in turn sell them to retailers, who then sell them to end users the
"consumers".
MANUFACTURING
The word manufacturing is derived from the Latin manu
factus, meaning made by hand. The word manufacture
first appeared in 1567, and the word manufacturing
appeared in 1683.
The word product means something that is produced, and
the words product and production first appeared
sometimes during the 15
th
century.
Manufacturing and production often are used
interchangeably.
MANUFACTURING HISTORY &
DEVELOPMENT
In its earliest form, manufacturing was usually carried out by a single
skilled artisan* with assistants. Training was by apprenticeship. In
much of the pre-industrial world the guild system protected the
privileges and trade secrets of urban artisans.
Before the Industrial Revolution, most manufacturing occurred in
rural areas, where household-based manufacturing served as a
supplemental subsistence strategy to agriculture (and continues to
do so in places). Entrepreneurs organized a number of
manufacturing households into a single enterprise through the
putting-out system.
Toll manufacturing is an arrangement whereby a first firm with
specialized equipment processes raw materials or semi-finished
goods for a second firm.

MANUFACTURING ACTIVITIES
Typical Manufacturing Activities
Product Design
Machinery and Tooling
Process and Planning
Materials
Purchasing/procurement
Manufacturing
Production Control
Support Services
Marketing
Sales
Shipping
Customer Services
MANUFACTURING ACTIVITIES
Manufacturing activities should be responsive to several demands
and trends:
A product must fully meet design requirements, product specs, and standards.
A product must be manufactured by the most economical and environmentally friendly
methods.
Quality must be built into the product at each stage, from design to assembly, rather
than relying on quality testing after the product is manufactured.
In the highly competitive environment of today, production methods must be
sufficiently flexible to respond to changing market demands, types of products,
production rates, production quantities, and to provide on-time delivery to the
customer.
Continuous developments in materials, production methods, and computer integration
of both technological and managerial activities in a manufacturing organization must be
evaluated constantly with a view to their appropriate, timely, and economical
implementation.
MANUFACTURING ACTIVITIES
Manufacturing activities demands and trends (contd.):
Manufacturing activities must be viewed as a large system, all
parts of which are interrelated to varying degrees. Such
systems can now be modeled in order to study the effect of
factors such as changes in the market demands, product design,
materials, and production methods on product quality and cost.
The manufacturer must work with the customer for timely
feedback for continuous product improvement.
A manufacturing organization constantly must strive for higher
levels of productivity, defined as the optimum use of all its
resources such as materials, machines, energy, capital, labor,
and technology; output per employee per hour in all phases
must be maximized.
FLOW SCHEMATIC DIAGRAM
PCB Manufacturing (Fabrication)
MANUFACTURING SCHEMATIC FLOW DIAGRAM
PCB Manufacturing (Fabrication)
MANUFACTURING SCHEMATIC FLOW DIAGRAM
Car Wheels Manufacturing
PROCESS SCHEMATIC FLOW DIAGRAM
Synthetic Fuel from End of Life Plastics
PROCESS SCHEMATIC FLOW DIAGRAM
MANUFACTURING SCHEMATIC FLOW DIAGRAM
HELPFUL INFORMATION
Industrial Revolution
The Industrial Revolution was the transition to new manufacturing processes
that occurred in the period from about 1760 to some time between 1820 and
1840. This transition included going from hand production methods to
machines, new chemical manufacturing and iron production processes,
improved efficiency of water power, the increasing use of steam power and
development of machine tools. The transition also included the change from
wood and other bio-fuels to coal. The Industrial Revolution began in Great
Britain and within a few decades had spread to Western Europe and the United
States.
The Industrial Revolution marks a major turning point in history; almost every
aspect of daily life was influenced in some way. Most notably, average income
and population began to exhibit unprecedented sustained growth. In the words
of Nobel Prize winner Robert E. Lucas, Jr., "For the first time in history, the living
standards of the masses of ordinary people have begun to undergo sustained
growth ... Nothing remotely like this economic behavior is mentioned by the
classical economists, even as a theoretical possibility.
HELPFUL INFORMATION
Artisans
An artisan or artisan (from French: artisan, Italian: artigiano) or craftsman
(craftsperson), is a skilled manual worker who makes items that may be
functional or strictly decorative, including furniture, sculpture, clothing,
jewelry, household items and tools or even machines such as the
handmade devices of a watchmaker.
Artisans practice a craft and may through experience and aptitude reach
the expressive levels of an artist.
Artisans were the dominant producers of consumer products prior to the
Industrial Revolution. According to classical economics theory, the division
of labor occurs with internal market development. However, according to
economist John Hicks merchants and artisans originated as servants to the
rulers.
HOMEWORK
o Read the Industrial Revolution and discuss its
significance in the industrial world.
REFERENCES
Textbook
George T. Austin, (1984), Shreves Chemical Processes Industries, 5
th
Ed. (McGraw-Hill)
Kalpakjian, Serope; Steven Schmid (August 2005). Manufacturing, Engineering & Technology.
Prentice Hall. pp. 2236, 951988.
Web
http://en.wikipedia.org/wiki/List_of_industrial_processes
http://en.wikipedia.org/wiki/Cottage_industry#Cottage_industry
http://en.wikipedia.org/wiki/Manufacturing
www.intelorg.com.sg/Alloy%20Wheel%20Projects.htm
www1.eere.energy.gov