LESSON 1:

COURSE OVERVIEW

INTRODUCTION TO
MANUFACTURING


DR HERBERT MAPFAIRA 27/01/2014
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DR HERBERT MAPFAIRA

B.ENG. INDUSTRIAL ENGINEERING

MSC. MANUF. SYSTEMS ENG.

PHD. MANUF. ENG. & OPERATIONS MANAGEMENT

12 YEARS WORKING FOR PUBLIC SECTOR UK

1 YEAR WORKING FOR TOYOTA UK

2 YEARS MANAGEMENT CONSULTING - UK
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TODAYS AGENDA
Information on syllabus
Office hours
Text
Grading
Exams & Homework
Class format
Start course material
Lesson 1 Overview of Manufacturing
OFFICE HOURS
By appointment.
Office 248/181
Phone: 355-4301
E-mail: herbert.mapfaira@mopipi.ub.bw

COURSE INFORMATION
Course homepage: Blackboard
Syllabus
Handouts
This introductory presentation
Some lecture material
Homework assignments
Project information
Announcements
Check the page for course information and
announcements
TEXTBOOK
Course Textbook:
M. P. Groover, Principles of Modern Manufacturing: SI
Version [Paperback]


ASSESSMENT CRITERIA
Component Percentage %
Assignments (2 x 5%)
Quizzes
Lab experiments
10 %
Mini-project (Workshop) 10 %
Tests (2 x 10%) 20 %
Final Examination 60 %
CLASSROOM RULES
Turn off cell phones and other communication devices
No completing homework or other assignments
Use common sense and be considerate of others
Notify instructor when absent from class as soon as possible
Before or after the fact
Justifiable reason
LECTURE FORMAT
The first part of class will be devoted to
questions.
Unreasonably long questions will be handled one on one.
If I dont know the answer, Ill get it for the class by the next
lecture.
Lecture
Ask questions
End of Class Will try to leave time for
questions

LECTURE FORMAT
Most material will be delivered
There will be periodic in-class problem solving
sessions.

Any Questions ?
LESSON OUTLINE
1. What is manufacturing?
2. Importance of manufacturing
3. Manufacturing Industries and Products
4. Materials in Manufacturing
5. Manufacturing Operations
6. Production Facilities
7. Product/Production Relationships
8. Lean Production



O
Ok, shall we start now!

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

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 can be defined in two ways, one
technological, and the other economic.

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Manufacturing - Technological
Application of physical and chemical processes to alter
the geometry, properties, and/or appearance of a
starting material to make parts or products
The processes to accomplish manufacturing involve a combination of
machinery, tools, and manual labor.
Manufacturing is always carried out in a sequence of operations. Each
operation bringing the material closer to the desired final stage.



2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Manufacturing - Economic
Transformation of materials into items of greater value by
one or more processing and/or assembly operations
Manufacturing adds value to the material by changing is
shape or properties or by combining it with other materials
that have been similarly altered.
Materials are made more valuable through manufacturing
operations performed on them:

When iron is converted to steel, value
is added;
When sand is converted to glass,
value is added.
When petroleum is converted to
plastic, value is added; and when
plastic is converted to more complex
shapes, even more value is added
Why do you think manufacturing is important?

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Manufacturing is Important
Making things has been an essential human activity
since before recorded history
Today, the term manufacturing is used for this
activity
Manufacturing is important:
Technologically
Economically
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Technological Importance
Technology - the application of science to provide
society and its members with those things that are
needed or desired
Technology provides the products that help our
society and its members live better
What do these products have in common?
They are all manufactured
Manufacturing is the essential factor that makes
technology possible

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Economic Importance
U.S. Economy
Sector: %GDP
Agriculture and natural resources 5
Construction and public utilities 5
Manufacturing 15
Service industries* 75
100
* includes retail, transportation, banking,
communication, education, and government
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Manufacturing Industries
The type of manufacturing done by a company depends on the
kind of product it makes.
Industry consists of enterprises and organizations that produce or
supply goods and services
Let us explore this relationship by first examining the types of
industries in manufacturing and then identifying the products they
make
Industries can be classified as:
1. Primary industries - cultivate and exploit natural resources, e.g.,
agriculture, mining
2. Secondary industries - take the outputs of primary industries and
convert them into consumer and capital goods
3. Tertiary industries - service sector
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 22/37
More Industry Classifications
Process industries, e.g., chemicals, petroleum, basic
metals, foods and beverages, power generation
Continuous production
Batch production
Discrete product (and part) industries, e.g., cars, aircraft,
appliances, machinery, and their component parts
Continuous production
Batch production
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 23/37
Process Industries and
Discrete Manufacturing Industries
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Specific Industries in Each Category
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e

Manufactured Products
Final products divide into two major classes:
1. Consumer goods - products purchased directly by
consumers
Cars, clothes, TVs, tennis rackets
2. Capital goods - those purchased by companies to
produce goods and/or provide services
Aircraft, computers, communication
equipment, medical apparatus, trucks,
machine tools, construction equipment
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Materials in Manufacturing
Most engineering materials can be classified into
one of three basic categories:
1. Metals
2. Ceramics
3. Polymers
Their chemistries are different
Their mechanical and physical properties are
dissimilar
These differences affect the manufacturing
processes that can be used to produce products
from them
What typical operations are you likely to find in
manufacturing?

2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 32/37
Manufacturing Operations
There are certain basic activities that must be carried out
in a factory to convert raw materials into finished products
For discrete products:
1. Processing
2. Assembly operations
3. Material handling
4. Inspection and testing
5. 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.
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 33/37
Fig. 2.3
Classification of
manufacturing
processes
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Shaping Processes Four Categories
1. Solidification processes - starting material is a
heated liquid or semifluid
2. Particulate processing - starting material consists of
powders
3. Deformation processes - starting material is a
ductile solid (commonly metal)
4. Material removal processes - starting material is a
ductile or brittle solid
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
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

2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 39/37
Assembly Operations
Joining processes
Welding
Brazing and soldering
Adhesive bonding
Mechanical assembly
Threaded fasteners (e.g., bolts and nuts, screws)
Rivets
Interference fits (e.g., press fitting, shrink fits)
Other
An assembly operation joins two or more components to create
a new entity which is called an assembly, subassembly, etc.
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 40/37
Other Factory Operations
Material handling and storage
Inspection and testing
Coordination and control
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 41/37
Material Handling
A means of moving and storing materials between processing
and/or assembly operations

Material transport
Vehicles, e.g., forklift trucks, AGVs, monorails
Conveyors
Hoists and cranes
Storage systems
Unitizing equipment
Automatic identification and data capture (AIDC)
Bar codes
RFID
Other AIDC equipment
In manufacturing a product, how much time in percentage
do you think is spend in actual processing of the product?

2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 43/37
Time Spent in Material Handling
Fig. 2.4
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 44/37
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
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 45/37
Coordination and Control
Regulation of the individual processing and assembly
operations
Process control
Quality control
Management of plant level activities
Production planning and control
Quality control
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Production Systems
People, equipment, and procedures used for the
combination of materials and processes that
constitute a firm's manufacturing operations
A manufacturing firm must have systems and
procedures to efficiently accomplish its type of
production
Two categories of production systems:
Production facilities
Manufacturing support systems
Both categories include people (people make the
systems work)
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 47/37
Production Facilities
A manufacturing company attempts to organize its
facilities in the most efficient way to serve the particular
mission of the plant
Certain types of plants are recognized as the most
appropriate way to organize for a given type of
manufacturing
The most appropriate type depends on:
Types of products made
Production quantity
Product variety
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 48/37
Production Quantity
Number of units of a given part or product produced
annually by the plant
Three quantity ranges:
1. Low production 1 to 100 units
2. Medium production 100 to 10,000 units
3. High production 10,000 to millions of units
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 49/37
Product Variety
Refers to the number of different product or part
designs or types produced in the plant
Inverse relationship between production quantity and
product variety in factory operations
Product variety is more complicated than a number
Hard product variety products differ greatly
Few common components in an assembly
Soft product variety small differences between
products
Many common components in an assembly
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 50/37
Product Variety vs.
Production Quantity
Fig. 2.5
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 51/37
Low Production Quantity
Job shop makes low quantities of specialized and
customized products
Also includes production of components for these
products
Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
Equipment is general purpose
Plant layouts:
Fixed position
Process layout
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 52/37
Fixed-Position Layout
Fig. 2.6 (a)
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 53/37
Process Layout
Fig. 2.6 (b)
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 54/37
Medium Production Quantities
1. Batch production A batch of a given product is
produced, and then the facility is changed over to
produce another product
Changeover takes time setup time
Typical layout process layout
Hard product variety
2. Cellular manufacturing A mixture of products is made
without significant changeover time between products
Typical layout cellular layout
Soft product variety
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 55/37
Cellular Layout
Fig. 2.6 (c)
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 56/37
High Production (mass production)
1. Quantity production Equipment is dedicated to the
manufacture of one product
Standard machines tooled for high production (e.g.,
stamping presses, molding machines)
Typical layout process layout
2. Flow line production Multiple workstations arranged in
sequence
Product requires multiple processing or assembly
steps
Product layout is most common
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 57/37
Product Layout
Fig. 2.6 (d)
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 58/37
Relationships between Plant Layout
and Type of Production Facility
Fig. 2.7
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Example of Processes
A spectacular scene in
steelmaking is charging of
a basic oxygen furnace,
in which molten pig iron
produced in a blast
furnace is poured into the
BOF. Temperatures are
around 1650C (3000
F).
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
A machining cell consisting of two horizontal machining
centers supplied by an in-line pallet shuttle (photo courtesy of
Cincinnati Milacron).

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

A robotic arm performs
unloading and loading
operation in a turning
center using a dual gripper
(photo courtesy of
Cincinnati Milacron).
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Metal chips fly in a high
speed turning operation
performed on a computer
numerical control turning
center (photo courtesy of
Cincinnati Milacron).
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Photomicrograph of the cross section of multiple coatings of
titanium nitride and aluminum oxide on a cemented carbide
substrate (photo courtesy of Kennametal Inc.).

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
A batch of silicon wafers enters a furnace heated to 1000C
(1800F) during fabrication of integrated circuits under clean
room conditions (photo courtesy of Intel Corporation).

2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Two welders perform arc
welding on a large steel
pipe section (photo
courtesy of Lincoln
Electric Company).
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Automated dispensing of
adhesive onto component
parts prior to assembly
(photo courtesy of EFD,
Inc.).
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Assembly workers on an
engine assembly line
(photo courtesy of Ford
Motor Company).
2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Assembly operations
on the Boeing 777
(photo courtesy of
Boeing Commercial
Airplane Co.).