Week 1 –

General
Introduction
Prof. Dian-Ru Li
02/22/2023
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What can you learn?

This class will introduce various manufacturing processes
including the fundamental theories, working principles,
process uniqueness/features, and applications.

Source: Online figures

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What is Manufacturing?
Material Processes Products

Source: Online figures 3

Manufacturing Example Join at [Link] with
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Apple Watch Manufacturing (2016)

Source: [1:48 – 3:43]

[Link]
111s&ab_channel=RandomVids
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Today’s Learning Goals Join at [Link] with
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• General Introduction

• Manufacturing
• Material Selection
• Manufacturing Process Selection
• Lean Manufacturing
• Green Manufacturing
• Smart Manufacturing

Source: Online figures 5

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The vast majority of objects around us consist of

numerous individual pieces that are built and assembled
by a combination of processes called manufacturing.

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
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• Design and manufacturing activities

take place sequentially but with
iterations

• Acquire design requirements from

the market to create design
specifications

• Use various manufacturing methods

to accomplish the design
specifications

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
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Manufacturing Approaches
• _____________________
o Initial design phase
o Need a fast and/or easy way to
efficiently perform design
iterations and refinement
o Cost factor is not heavily
considered
• _____________________
o Production phase with large part
quantities
o Need a robust and precise way to
make consistent parts Source: Online figures

o Cost per part is an important factor

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Prototypes
• A prototype is a physical model of an individual component
or product
• Prototypes developed can allow for multiple modifications to
the original design, materials, or production methods

Virtual Prototyping
• It is a software-based method
that uses advanced graphics and
virtual-reality environments
• To allow designers to view and
examine a part in detail
• Also known as simulation-
based design Source: Online figures

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
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Production Join at [Link] with
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Product Design Source: Online figures

• Design for manufacture (DFM) integrate

the design process with production
methods, materials, process planning,
assembly, testing, and quality assurance

• Design for assembly (DFA), Design for

manufacture and assembly (DFMA), and
Design for disassembly (DFD) are all
important for manufacturing

• Assembly requires a consideration of the

ease, speed, and cost of individual
components of a product
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
10
Production Join at [Link] with
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Design Change Consideration

Source: [Link]
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What is Manufacturing?
Material Processes Products

Source: Online figures 12

Material Selection Join at [Link] with
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General types of materials used:

1. Ferrous metals 鐵材料

2. Nonferrous metals 非鐵材料
3. Plastics (polymers) 塑膠/塑化物
4. Ceramics, glasses 陶瓷、玻璃
5. Composite materials 複合材料
6. Nanomaterials 奈米材料
7. Shape-memory alloys,
semiconductors and
superconductors 記憶合金、半導
體、超導體材料

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
13
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Properties of Materials – Important Selection Criteria

1. _____________ properties
2. _____________ properties
3. _____________ properties
4. _____________ properties
5. _____________

Select the
material that can
withstand the
forces!

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
14
Material Selection Join at [Link] with
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If you don’t carefully consider the material properties

during designing, terrible things could happen!

Source: [Link]
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Availability
• If materials are not available Supply chain shortage
in the desired quantities, due to COVID-19
shapes, dimensions, and
surface texture, substitute
materials can be considered

• Reliability of supply is
important in order to meet
production schedules

• A country’s self-reliance on
resources is a political goal
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
16
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Manufacturing Process Selection

• Selection of process depends on
1) ___________________________________
2) ____________________________________
3) ____________________________________

• A design can be done by various manufacturing

methods

• Each manufacturing method has its pros and cons

for a design
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
17
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Forming

If we want to make a Subtractive Manufacturing (Machining)

part as shown below,
what manufacturing
method can we use?

Additive Manufacturing (3D Printing)

Source: [Link] 18
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Examples of common manufacturing methods are:

1. __________________
2. __________________
3. __________________
4. __________________
5. __________________
6. __________________
Learning goals
Fundamental theories, Working principles,
Process uniqueness/features, and Applications
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
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Casting 鑄造
• Material:______________
(usually metal)

• Process: Molten metal is

poured into a __________
with the shape of the
finished part, and then
_________________
inside the mold

• Application: Large or
structural part with less
dimensional requirements
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd 20
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Source:
[Link]
=CastingDesign
21
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Bulk-Deformation 體積變形
• Material: Metal
(usually heated)

• Process: Heated
metal is __________
_________________
_________________
to form the desired
shape

• Application: Any part

that requires huge
geometry change
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd 22
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Source:
[Link]
_channel=CustomAluminumProducts
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Sheet Metal Forming 金屬板材成形

• Material: Sheet metal
(small thickness)

• Process: A sheet
metal is plastically
deformed under
mechanical forces
into the desired shape

• Application:
Commonly seen in
automotive and
aerospace industries
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd 24
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Source:
[Link]
=219s&ab_channel=WIRED 25
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Polymer Processing 聚合物處理

• Material: Plastic
polymer with solid
or liquid format

• Process: _________
________________
polymer is poured
into the mold to
______, or ____by
chemical reactions

• Application: Any
plastic parts
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd 26
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Source:
[Link]
hannel=MpactLimited 27
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Joining 接合
• Material: Metal or
plastic materials

• Process: Two or more

parts are assembled
together permanently
by _______________
_______________,
or temporarily by
________________

• Application: Creating
an assembly
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd 28
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Source:
[Link]
Stickwelder
29
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Machining 加工
• Material: Metal or
plastic materials

• Process: A process of
_________________
from the workpiece
(raw material) into
the desired shape

• Application: Parts
requiring _________
_________________

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd 30
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Source: [Link]
eM&ab_channel=BeijingJingdiaoGroupCo.%2CLtd.
31
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Additive Manufacturing 積層製造(3D列印)

• Material: Metal or plastic materials
• Process: A process of __________________________
to form the desired shape

• Application: Prototyping, complex or delicate parts

Source: Dilberoglu, U. M., Gharehpapagh, B., Yaman, U. & Dolen, M. The Role of Additive
Manufacturing in the Era of Industry 4.0. Procedia Manuf 11, 545–554 (2017).
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Source:
[Link]
hannel=WildRoseBuilds
33
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• Lean manufacturing refers to

a production process with
1) _____________________
2) _____________________
• Lean production focuses on:
1. Efficiency and effectiveness
of each and every
manufacturing operation,
2. Efficiency of the machinery
and equipment used
3. Activities of the personnel Source: [Link]

involved in each operation

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
34
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Lean Principles
• ___________: customer-related
factors including requirements Source: [Link]

and expectations.

• ___________: values in each step

of the processes

• _________: process efficiency

and established workflow

• _________: companies only make

enough parts to meet demands

• _________: continuous
improvement by incorporating
Lean thinking
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Green Manufacturing
• Workers use ______ natural
resources, ______ pollution
and waste, _____________
__________ materials, and
__________ emissions in
their processes.

• Green manufacturers
research, develop, or utilize
technologies and practices
to lessen their impact on the
environment
Source: [Link]
manufacturing/#:~:text=Essentially%2C%20it%20is%20the%20%E2%80%9Cgreening,their%20impact%20on%20the%20environment.
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Waste in Manufacturing Operations

1. Chips from machining and
trimmed materials
2. Slag from foundries and
welding
3. Additives in sand used in
sand-casting
4. Hazardous waste and toxic
materials
5. Lubricants and coolants
6. Liquids from heat treating
7. Smoke and pollutants from
furnaces
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
37
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Guidelines for Green Design and Manufacturing

1. Reduce waste of materials

2. Reduce hazardous materials products and processes
3. Investigate environmental-friendly manufacturing
technologies
4. Improvements in methods of recycling and reusing
5. Minimize energy use
6. Encourage recycling

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
38
Computers in Manufacturing Join at [Link] with
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Role of Computers in Product Design

• Product models are
simplified through ________
____________________ and
_______________________
_______________techniques

• CAD systems are capable of

rapid and complete analysis
of designs (paperless design)

• Performance of structures
can be analyzed via CAE
simulations
Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
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Role of Computers in Product Design

• ______________________
______________involves
all phases of manufacturing

• Performing tasks such as:

programming for numerical
control machines, designing
tools, dies, molds, fixtures,
and work-holding devices

• Maintaining quality control

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd 40
Computers in Manufacturing Join at [Link] with
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Manufacturing Technologies Enabled by Computers

• Computer numerical
control (CNC)
machines
• Industrial robots
• Automated materials
handling
• Automated assembly
systems
• Artificial intelligence
(AI)

Source: Manufacturing Engineering and Technology, Seventh Edition, Serope Kalpakjian and Steven R. Schmid
Copyright © 2014 Pearson Education South Asia Pte Ltd
41
Digital Manufacturing Join at [Link] with
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• Digital manufacturing
describes the transition
away from older
manufacturing models
towards a new, integrated
approach incorporating
internet of things (IoT),
automation, robotics,
virtual reality, cloud
computing and data
analytics to improve
productivity
Source: [Link]
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Source: [Link]

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Smart Manufacturing Join at [Link] with
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• Smart manufacturing refers to

fully integrated, collaborative
manufacturing systems that
respond in real time to meet
changing demands and
conditions in the factory, in
the supply network and in
customer needs

• Data analysis and artificial

intelligence are the key factors
enabling smart manufacturing
Source: [Link]

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Source:
[Link]
nel=DeloitteUS
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Course Wrap-Up Join at [Link] with
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• General Introduction

• Manufacturing
• Material Selection
• Manufacturing Process Selection
• Lean Manufacturing
• Green Manufacturing
• Smart Manufacturing

46
Reminder Join at [Link] with
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• No class next Monday

• We may change classroom. Please check

email or NTU COOL before next Wed

• Always check NTU COOL before the

class to download the slides for taking
notes

• Any questions?
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