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What is Manufacturing? Technological and Economic

Considerations
The word manufacture is derived from two Latin words
manus (hand) and factus (make); the combination manufacturing can be defined in the two ways; one is the
means “made by hand” technological way and another is economical way

Manufacturing ▪ “Made by hand” accurately described the

fabrication methods that were used when the Manufacturing

Processes English word “manufacture” was first coined around

1567 A.D.
Technological Economical
▪ Most modern manufacturing operations are Considerations Considerations
UNIT-1 DR. KAPIL KUMAR GOYAL
accomplished by mechanized and automated
ASSISTANT PROFESSOR
INTRODUCTION
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
equipment that is supervised by human workers
Physical and chemical processes used for changing shape
Manufacturing processes add value to the product and
size and properties of raw materials to convert in the usable
ultimately results in the value creation
product

Manufacturing Technological Considerations Manufacturing Economical Consideration

Manufacturing - Technologically
Manufacturing Defined (Mikell P Important Manufacturing Defined: (Mikell P Groover)
Groover) :
Technology - the application of science to provide society and its
“Technologically, manufacturing is the members Newer methods/processes and materials for improved “Economically, manufacturing is
application of physical and chemical products and services transformation of materials into items of
processes to alter the geometry, greater value by means of one or more
properties, and/or appearance of a ▪ Manufacturing is the application of technology to produce processing and/or assembly operations
starting material to make parts or products of increased value
products  Manufacturing adds value to the
▪ Manufacturing also includes ▪ Manufacturing provides the products that help our society and its material by
assembly members live better
 changing its shape or properties, or by
▪ Almost always carried out as a ▪ What do these products have in common?
sequence of  combining it with other materials”
operations”  They are all manufactured

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Manufacturing - Economically Need of Manufacturing

Materials in an Automotive
Engine
Important Need of manufacturing is to satisfy the needs of human beings through offering the
improved products and services for the facility of mankind.

 To produce goods to support the living and improve the standard of living

Manufacturing is one way  To take advantage of the economies of scale and produce large quantities in low
by which nations create cost
material wealth
 As resources are limited, we need to optimize the use of resources to increase the
productivity

“More goods are produced using less resources” or “Reduce Wastages”

Six Sigma, TQM, TPM, Kaizen, Quality Circles, lean and Agile Manufacturing
Figure I.1 Section of an automotive engine - the Duratec V-6 - showing
various components and the materials used in making them.

Materials Selection for Paper Clips Materials Selection for Automobile Manufacture of Light Bulbs
Edison’s first successful lamp had a carbon filament, no other material has strength, resistance to
Common to paper clips is the utilization of torsion and elasticity in ➢ Steel was chosen for much of high temperature, and long life as has tungsten, which is now the most commonly used filament
the wire, and friction between wire and paper. When a moderate the body because it is strong, material.
number of sheets are inserted between the two "tongues" of the The wire diameter for a 60-WL 120-V bulb is 0.045 mm or 0.0018 in. The diameter
easy to shape and inexpensive, must be controlled precisely, because if it is only 1 % less than the diameter specified, the life of the
clip, the tongues will be forced apart and cause torsion in the bend
of the wire to grip the sheets together. ➢ Plastics were used in many bulb would be reduced by as much as 25% (because of the increased heat due to the higher
components because of electrical resistance of the wire).
Questions for consideration:
characteristics such as light
• What material properties are required? weight, resistance to corrosion,
• What manufacturing attributes are a wide selection of colours and
required? ease of manufacturing into
• Would the material and processing complex shapes and at low
strategy change if the desired quantity cost.
was 10,000 vs. 1 million per day? ➢ Glass was chosen for all the
windows not only because it is
transparent but also it is hard
(hence scratch resistant), easy Figure I.3a Components of a common Figure I.3b Manufacturing steps in
Examples of the wide variety of materials and geometries for paper clips. to shape, and easy to clean. incandescent light bulb. making an incandescent light bulb.

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Classification of Manufacturing Primary Shaping (Forming Deforming Processes

Processes Processes) These processes make suitable use of stresses like compression, tensile
and shearing or combined to cause plastic deformation of materials to
Various processes applied in manufacturing to convert raw materials
convert them into the desired shapes:
into finished goods can be classified in the following broad categories: Its an additive manufacturing in which the products are made by
addition. Cohesion is normally among particles  Forging
 Primary Shaping (Forming Processes)
 Casting  Rolling
 Deforming Processes
 Powder Metallurgy  Extrusion
 Machining/ Material Removal Processes
 3D Printers  Drawing
 Surface Machining Processes
 Plastic Technology  Embossing
 Joining Processes
 Sheet Metal Working
 Material Properties Modification Processes

Machining/ Material Removal Surface Finishing Operations Joining Processes

Processes These operations are used to provide good surface finish on the metal surfaces. Small
or negligible amount of material is added or removed:
In these processes two or more metal pieces are united together to make
a final product permanently or temporarily:

In these processes desired surface is produced by providing suitable  Honing  Welding

relative motion between the tool and workpiece. In this case the  Lapping  Riveting
material is removed by shearing so the workpiece is subjected to  Buffing  Soldering
comparatively lower stresses than Deformation processes:
 Tumbling  Brazing
➢ Turning ➢ Slotting  Galvanizing
 Sintering
➢ Drilling ➢ Hobbing
 Pickling
➢ Milling ➢ Boring  Couplings
 Sand blasting
➢ Shaping ➢ Threading  Nuts & Bolts
➢ Grinding ➢ Knurling  Electroplating
 Keys and Cotters
➢ Broaching ➢ Parting  Plastic and metal coating

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Manufacturing Processes: Casting

Manufacturing Processes: Forming and Shaping
Material Properties Modification
Processes
In this process properties of the material are changed to suit the
desirable characteristics without changing the shape

 Heat Treatment

 Shot Peening

 Surface Chemical Treatment

Schematic illustration of various casting processes Schematic illustration of various bulk deformation processes

Manufacturing Processes: Forming and Shaping Manufacturing Processes: Machining Manufacturing Processes: Joining

Schematic illustration of various sheet metal forming processes Schematic illustrations of various machining and finishing processes. Schematic illustration of various joining processes

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Manufacturing Processes: Forming and Shaping

Production Quantity Q Product Variety P

The quantity of products Q made by a factory has an important Product variety P refers to different product types or
influence on the way its people, facilities, and procedures are models produced in the plant
organized
▪ Annual production quantities can be classified into three ranges:
▪ Different products have different features
 They are intended for different markets
Production range Annual Quantity Q
 Some have more parts than others
Low production 1 to 100 units
Medium production 100 to 10,000 units
▪ The number of different product types made each year
in a factory can be counted
High production 10,000 to millions of
▪ When the number of product types made in the factory
is high, this indicates high product variety

Schematic illustration of various polymer processing methods

P versus Q in Factory Operations Production Systems Low Production

People, equipment, and procedures used for the Job shop is the term used for this type of production facility
combination of materials and processes that constitute
a firm's manufacturing operations ▪ A job shop makes low quantities of specialized and
customized products
▪ A manufacturing firm must have systems and
Products are typically complex, e.g., space capsules, prototype aircraft,
procedures to efficiently accomplish its type of 
special machinery
production
▪ Labor force is highly skilled
▪ Two categories of production systems:
 Production facilities ▪ Equipment in a job shop is general purpose
 Manufacturing support systems ▪ Designed for maximum flexibility
▪ Both categories include people (people make the
Figure P-Q Relationship systems work)

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Medium Production High Production Life Cycle

Life cycle of a product

1. Product start-up
Two different types of facility, depending on product Often referred to as mass production
variety:  High demand for product 2. Rapid growth of the product in the
▪ Batch production  Manufacturing system dedicated to the production of that product marketplace
 Suited to hard product variety ▪ Two categories of mass production: 3. Product maturity
 Setups required between batches 1. Quantity production
4. Decline
▪ Cellular manufacturing 2. Flow line production
 Suited to soft product variety
 Worker cells organized to process parts without setups between different
part styles

Life Cycle Engineering Books/References

Life cycle engineering requires that the entire life of a
product be considered, beginning with the design  Fundamental of Modern Manufacturing: Materials,
stage and on through production, distribution, product Processes and Systems: M. P. Groover(John Wiley).
use, and finally recycling or the disposal of the
 Manufacturing Processes for Engineering Materials: S.
product.
Kalpakliamand S. R. Schmid(Prentice Hall).
 Fundamental of Manufacturing Processes: G. K. Laland
S. K. Choudhuary(Narosa).

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