MM 323 MANUFACTURING SYSTEMS

INTRODUCTION

What is Manufacturing?
The word manufacture is derived from two Latin words
manus (hand) and factus (make); the combination
means made by hand
Made by hand accurately described the fabrication
methods that were used when the English word
manufacture was first coined around 1567 A.D.
Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers

Manufacturing System Defined

A collection of integrated equipment and human resources,
whose function is to perform one or more processing
and/or assembly operations on a starting raw material,
part, or set of parts
Equipment includes
Production machines and tools
Material handling and work positioning devices
Computer systems

Human resources are required either full-time or periodically

to keep the system running

Manufacturing Systems in the Production

System

Components of a Manufacturing System

1. Production machines
2. Material handling system
3. Computer system to coordinate and/or control the
preceding components
4. Human workers to operate and manage the system

Examples of Manufacturing Systems

Single-station cells
Machine clusters
Manual assembly lines
Automated transfer lines
Automated assembly systems
Machine cells (cellular manufacturing)
Flexible manufacturing systems

Example for Single-station cells

Manufacturing - Technologically
Application of physical and chemical processes to
alter the geometry, properties, and/or appearance
of a starting material to make parts or products
Manufacturing also includes assembly
Almost always carried out as a sequence of
operations
Manufacturing
as a technical
process

Manufacturing - Economically
Transformation of materials into items of greater
value by means of one or more processing and/or
assembly operations
Manufacturing adds value to the material by
changing its shape or properties, or by combining
it with other materials
Manufacturing
as an economic
process

Manufacturing Capability
A manufacturing plant consists of processes and
systems (and people, of course) designed to
transform a certain limited range of materials
into products of increased value
The three building blocks - materials,
processes, and systems - are the subject of
modern manufacturing
Manufacturing capability includes:
1. Technological processing capability
2. Physical product limitations
3. Production capacity

Limitations and Capabilities of a

Manufacturing Plant
Manufacturing capability - the technical and physical
limitations of a manufacturing firm and each of its plants
Three dimensions of manufacturing capability:
1. Technological processing capability - the available set of
manufacturing processes
2. Physical size and weight of product
3. Production capacity (plant capacity) max production
quantity that can be made in a given time under assumed
operating conditions

1. Technological Processing Capability

The available set of manufacturing processes in
the plant (or company)
Certain manufacturing processes are suited to
certain materials
By specializing in certain processes, the
plant is also specializing in certain materials
Includes not only the physical processes, but
also the expertise of the plant personnel
Examples:
A machine shop cannot roll steel
A steel mill cannot build cars

2. Physical Product Limitations

Given a plant with a certain set of processes,
there are size and weight limitations on the
parts or products that can be made in the plant
Product size and weight affect:
Production equipment
Material handling equipment
Production, material handling equipment, and
plant size must be planned for products that lie
within a certain size and weight range

3. Production Capacity
Defined as the maximum quantity that a plant
can produce in a given time period (e.g.,
month or year) under assumed operating
conditions
Operating conditions refer to number of
shifts per week, hours per shift, direct labor
manning levels in the plant, and so on
Usually measured in terms of output units,
such as tons of steel or number of cars
produced by the plant
Also called plant capacity

There are certain basic activities that must be carried out

in a factory to convert raw materials into finished
products
For discrete products:
1.
2.
3.
4.

Processing and assembly operations

Material handling
Inspection and testing
Coordination and control

A processing operation transforms a work material from one state of

completion to a more advanced state using energy to alter its shape,
properties or appearance to add value to the material.

Manufacturing Processes
Manufacturing processes
Converts unfinished materials to finished products
Often is a set of steps

Machine tool is an assembly that produces a desired result

Two basic types:

1. Processing operations - transform a work material from one
state of completion to a more advanced state
Operations that change the geometry, properties, or
appearance of the starting material
2. Assembly operations - join two or more components to
create a new entity

Classification of manufacturing processes

Processing Operations
Alters a materials shape, physical properties, or
appearance in order to add value

Three categories of processing operations:

1. Shaping operations - alter the geometry of the
starting work material
2. Property-enhancing operations - improve
physical properties without changing shape
3. Surface processing operations - to clean,
treat, coat, or deposit material on exterior
surface of the work

Shaping Processes Four Categories

1.
2.
3.
4.

Solidification processes - starting material

is a heated liquid or semifluid
Particulate processing - starting material
consists of powders
Deformation processes - starting material
is a ductile solid (commonly metal)
Material removal processes - starting
material is a ductile or brittle solid

Solidification Processes
Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
Examples: metal casting, plastic molding

Particulate Processing
Starting materials are powders of metals or
ceramics
Usually involves pressing and sintering, in
which powders are first compressed and then
heated to bond the individual particles

Deformation Processes
Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
Examples: (a) forging, (b) extrusion

Material Removal Processes

Excess material removed from the starting piece
so what remains is the desired geometry
Examples: machining such as turning, drilling,
and milling; also grinding and nontraditional
processes

Waste in Shaping Processes

Desirable to minimize waste in part shaping
Material removal processes are wasteful in
unit operations, simply by the way they work
Most casting, molding, and particulate
processing operations waste little material
Terminology for minimum waste processes:
Net shape processes - when most of the
starting material is used and no
subsequent machining is required
Near net shape processes - when
minimum amount of machining is required

Property-Enhancing Processes
Performed to improve mechanical or physical
properties of work material
Part shape is not altered, except
unintentionally
Example: unintentional warping of a heat
treated part
Examples:
Heat treatment of metals and glasses
Sintering of powdered metals and ceramics

Surface Processing Operations

Cleaning - chemical and mechanical

processes to remove dirt, oil, and other
contaminants from the surface
Surface treatments - mechanical working
such as sand blasting, and physical
processes like diffusion
Coating and thin film deposition - coating
exterior surface of the workpart

Assembly Operations
Two or more separate parts are joined to form a new entity.
In assembly, the distinguishing feature is that two or more separate
components are joined together. Examples are; 1) mechanical fastening
operations, which make use of screws, nuts, rivets, etc., and 2)joining
processes, such as welding, brazing, and soldering.

Types of assembly operations:

1. Joining processes create a permanent joint

Welding, brazing, soldering, and adhesive bonding

2. Mechanical assembly fastening by mechanical
methods

Threaded fasteners (screws, bolts and nuts); press

fitting, expansion fits

Other Factory Operations that require new sytems

Material Handling and

Storage Systems
Inspection and testing Systems
Coordination and control Systems

Inspection and Testing

Inspection and testing are generally considered part of
quality control. The purpose of inspection is to determine
whether the manufactured product meets the established
design standards and specifications. For example,
inspection examines whether the actual dimensions of a
mechanical part are within the tolerances indicated on the
engineering drawing for the part.
Testing is generally concerned with the functional
specifications of the final product rather than the individual
parts that go into the product. For example, final testing of
the product ensures that it functions and operates in the
manner specified by the product designer.

Inspection and Testing

Inspection examination of the product and its
components to determine whether they conform to
design specifications
Inspection for variables - measuring
Inspection of attributes gaging

Testing observing the product (or part, material,

subassembly) during actual operation or under
conditions that might occur during operation

Hardness testing equipments

Measurement by a gage

A tensile testing machine

An ultrasonic testing device

Computer Control System

The control function in manufacturing includes both the
regulation of individual processing and assembly
operations, and the management of plant-level activities.
Control at the process level involves the achievement of
certain performance objectives by proper manipulation of
the inputs to the process.
Control at the plant level includes effective use of labor,
maintenance of the equipment, moving materials in the
factory, shipping products of good quality on schedule,
and keeping plant operating costs at the minimum level
possible.

Manufacturing control
Manufacturing control is concerned with managing
and controlling the physical operations in the factory to
implement the manufacturing plans. The flow of
information is from planning to control. Information also
flows back and forth between manufacturing control and
the factory operations.
Included with the control function are shop floor control,
inventory control, quality control, and various other
control activities. Process control is also included if the
plant uses automatic process control in its operations.

Shop Floor Control

Shop floor control is concerned with the problem of monitoring the
progress of the product as it is being processed, assembled, moved, and
inspected in the factory. The sections of a traditional production planning
and control department that are involved in shop floor control include
scheduling, dispatching, and expediting. Production scheduling is
concerned with assigning start dates and due dates to the various parts
(and products) that are to be made in the factory. This requires that the
parts be scheduled one by one through the various production machines
listed on the route sheet for each part. Based on the production schedule,
dispatching involves issuing the individual work orders to the machine
operators to accomplish the processing of the parts. The dispatching
function is performed in some plants by the shop foremen, in other plants
by a person called the dispatcher. Even with the best plans and
schedules, things sometimes go wrong (e.g., machine breakdowns,
improper tooling, parts delayed at the vendor). The expediter compares
the actual progress of a production order against the schedule. For orders
that fall behind, the expediter attempts to take the necessary corrective
action to complete the order on time.

Inventory control
Inventory control attempts to strike a proper
balance between the danger of too little inventory (with
possible stock-outs of materials) and the expense of
having too much inventory. Shop floor control is also
concerned with inventory in the sense that the materials
being processed in the factory represent inventory
(called work-in-process).

Quality control
Quality control assures that the quality of the
product and its components meet the standards
specified by the product designer. To accomplish
its mission, quality control depends on the
inspection activities performed in the factory at
various times throughout the manufacture of the
product. Also, raw materials and components from
outside sources must be inspected when they are
received. Final inspection and testing of the
finished product is performed to ensure functional
quality and appearance.

Computer Control System

Typical computer functions in a manufacturing
system:
Communicate instructions to workers
Download part programs to computer-controlled
machines
Control material handling system
Schedule production
Failure diagnosis when malfunctions occur
Safety monitoring
Quality control
Operations management