Faculty of Mechanical Engineering, University Technology MARA

Content

Faculty of Mechanical Engineering, University Technology MARA

 Introduction
Manufacturing
• Defined as the conversion process of raw materials(input) into
products(output) which conform to design specification, or the
transformation of materials and information into goods for the
satisfaction of human needs.

“The science of planning, designing and managing people and machinery to

produce usable products”_SME

“The making of goods or wares by manual labour or machinery, especially on a

large scale”_Webster Dictionary

“The creation and integration of informational and physical processes to create

economic wealth through the production of artifacts”_NSF, USA

Faculty of Mechanical Engineering, University Technology MARA

 History of Manufacturing
Evidences of manufacturing activities :

Before the middle ages

• Bricks to build the Mesopotamian city of Uruk
• Clay pots to store grain in ancient Greece
• Bronze weapons used during Roman Empire

In the middle ages

• Silk factories operated in Syria and textile mills were established
in Europe (Italy, Belgium, France and England)
• Factories were built to produce gunpowder, clothing, cast iron and
paper
• Using machines powered by water together with simple tools

Faculty of Mechanical Engineering, University Technology MARA

 History of Manufacturing
Evolution of manufacturing:

In the Middle Ages

• Manufacture was an individual activity practiced by artisans and apprentices
• Power was in the form of water and wind power

First Industrial Revolution (1750 A.D.)

• Power produced using steam
• Introduction of mechanized machinery

Second Industrial Revolution (1900 A.D.)

• Mechanized machines powered by electric

Third Industrial Revolution (1970 A.D)

• Electronic circuitry was introduced
• Invention of transistor which gave rise of computers

Faculty of Mechanical Engineering, University Technology MARA

 Future Technologies

Today
Recycling of components, e.g. ;
• In automotive industry, excess steel and aluminum can become
scrap stock for new metal
• Rubber tires can be chopped and mixed with asphalt for new
roadways
• Engine starters can be remanufactured and sold again
Producing of new material, e.g. ;
• Composite material – combination of material designed with
superior physical and mechanical properties.

Faculty of Mechanical Engineering, University Technology MARA

 Contd.
Environmental control, e.g. ;
• Smoke scrubbers to remove dangerous gases and particulate from
plant dischargers.
• Develop methods of eliminating or reusing dump chemical
products.

Advanced manufacturing technology, e.g. ;

• Using sophisticated robotic tools and handling system such as in

automobile and semiconductor industries.
• adaptation of computer control system in controlling the
manufacturing operation.
• Towards full automation or unmanned factory by combining and
integrating CAD, CAM, CNC, TQM, MIS, MRP etc.

Faculty of Mechanical Engineering, University Technology MARA

 Manufacturing Processes
• Manufacturing process is the manufacturing activities that are used to
make products. Many manufacturing processes are used to
manufacture, transform or produce parts and shapes.
Casting
• Refers to a metal forming process that delivers a liquid molten
metal into die or mould.

Forming and shaping

• Metal forming processes in which the shape of workpieces such as
sheets, rods or tubes is changed to a desired configuration.
• Examples are rolling, forging, extrusion etc.

Rapid prototyping
• Refers to a solid free-form manufacturing processes
• The process of producing a physical prototype directly from CAD
3D surface or solid modeling

Faculty of Mechanical Engineering, University Technology MARA

 Contd.
Joining processes
• A process of joining or assembling two or more materials or
parts together.
• Examples are welding, brazing, soldering, diffusion bonding,
adhesive bonding and mechanical joining.

Machining
• Refers to a broad term used to describe removal of material
from a workpiece, in which the size or surface properties of a
part or workpiece are changed.
• Examples are cutting, turning, boring, drilling, milling etc.

Finishing operations
• An operation used for final finishing of part, to remove any
remaining stock and creates the desired surface finish.
• Examples are honing, lapping, polishing, burnishing, deburring
etc.

Faculty of Mechanical Engineering, University Technology MARA

 Classification of Manufacturing
Casting processes
Forming processes
Shaping processes Particulate processes
Material removal processes

Adhesive joining processes

Welding processes
Assembly processes Brazing & soldering
Mechanical fastening
Manufacturing
Processes Cleaning & surface treatment
Coating & deposition
Finishing processes processes
Misc processes

Misc. processes Property enhancing (heat

treatment processes,
surfaces, treatment), QC etc.

Faculty of Mechanical Engineering, University Technology MARA

 Traditional Metalworking Processes

Metal Working
Processes

Hot Working Cold Working

Processes Processes

Extrusion Sheetmetal working

Forging Drawing etc.
Rolling etc.

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 Material and Processes
Melt Solidification

Billet
Bulk
Bar
Deformation
Section
Starting
Materials Plate
Sheet
Sheet
Forming
Strip

Particulate Particulate
Materials Processing

Faculty of Mechanical Engineering, University Technology MARA

 Groups of Manufacturing Techniques

Manufacturing
Techniques

Original forming Forming Machining Joining

Casting Turning Fastening

Forging
Powder technology Drilling Welding
Extrusion
Plastic Technology etc. Milling Soldering, brazing
Rolling
Grinding Gluing etc.
Sheetmetal working etc.
EDM/USM etc.

Faculty of Mechanical Engineering, University Technology MARA

 Classification of Manufacturing(SIC)

1. Food & Beverages

2. Textile

3. Wood production

4. Petroleum and coal production

5. Plastic and rubber product

6. Computer and electronic product etc.

Faculty of Mechanical Engineering, University Technology MARA

 Summary

Almost all products used by people are dependent on manufacturing.

The constant improvements to/and efficient use of the manufacturing
tools affect the standard of living of any nation and the quality of life of
the people. Only with manufacturing tools we be able to enjoy such
pleasures as the automobiles, aeroplanes, televisions, home appliances
and many more items on which we rely upon in our daily life.

Faculty of Mechanical Engineering, University Technology MARA

 Thank you
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Role of Manufacturing
in Nation's Economy

Refer to Video TOYOTA

Faculty of Mechanical Engineering, University Technology MARA

Faculty of Mechanical Engineering, University Technology MARA
In competitiveness market :

• Manufacturing company survives if they produce high quality

product at low cost, at the right time, place and quantity to
the market.
• Thus, the harmonization, interaction and integration of many
elements, i.e. design, material selection, manufacturing
processes etc. must be emphasized from the very beginning.

Faculty of Mechanical Engineering, University Technology MARA

 Goal of Manufacturing

Manufacturing Goal

Product
At the right time, place and
High Quality Lower Cost
quantity

To achieve
Manufacturing process
Product design Material selection
selection

Main challenges
Selecting the best Selecting the best Improve the quality
To minimize the cost
material processes & productivity

Faculty of Mechanical Engineering, University Technology MARA

 Manufacturing Costs
Total cost of a product consists of :
• Material cost – cost of raw materials
• Tooling cost – cost of making the tools, i.e. die, mold, pattern, jigs
and fixtures – ex: cost for die casting is higher than sand casting
• Fixed cost – e.g. electric power fuel, rent, insurance etc.
• Direct labour cost – labour cost from initial stage(raw material) to
end product
• Indirect labour cost – involves activities such as repair,
maintenance, quality, control, research etc.
• Capital cost – investment in building, land, machinery, tooling and
equipments

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 Breakdown of cost

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 Costs Reduction

Material cost
• Substitution of materials
• Identify and use least expensive material

Production quantity
• Large production quantity requires high production rate
• Reduces the cost per piece

Product design
• Simplifying part design and the number of subassemblies
• Applying design for Y (manufacture, assembly, disassembly, service)
• Reducing the amount of material (high strength to weight ratio)

Faculty of Mechanical Engineering, University Technology MARA

 Cont’d
Dimensional tolerance and surface finish
• Closer dimensional tolerance and better surface finish
• Use high quality machinery and costly finishing operations

Machines and equipment

• Reduce the labour cost by using automated and computer
controlled machinery
• Improve product quality

Methods of manufacturing
• Use alternative methods such as software
• Optimizing manufacturing process

Faculty of Mechanical Engineering, University Technology MARA

 Major factors in process selection

Properties of the workpiece material

• Working temperature (room or elevated temperature, etc.)

• Material properties (ductility, hardness, etc.)
• Manufacturing characteristics (machinability, castability, etc.)

Geometric features

• Part, shape, size, thickness, dimensional tolerances, surface

finish requirements etc.

Part produced at or near final shape

• Eliminate secondary process and hence reduce manufacturing

cost

Faculty of Mechanical Engineering, University Technology MARA

 Cont’d

Option of other possible methods

Cost of raw material

• e.g. per unit weight of square bar is more expensive

than round bar

Quantity and rate of production

• e.g. machining is for few parts and extrusion for large

quantity

Faculty of Mechanical Engineering, University Technology MARA

Awareness of Value Analysis
Value analysis

• System that evaluates each step in design,

material, processes and operations applied to the
product according to its intended functions or
performance at the lowest cost.

Benefits

• Cost reduction
• Reduced lead times
• Better product quality and performance

Faculty of Mechanical Engineering, University Technology MARA

 Value Analysis Phases

Information phase
• To gather data and determine costs

Analysis phase
• To define function and identify problem areas as well as opportunities

Creative phase
• To seek ideas to respond to problem areas as well as opportunities

Evaluation phase
• To select ideas to be developed and to identify cost involved

Faculty of Mechanical Engineering, University Technology MARA

 Value Analysis Phases
Implementation phase
• To present facts, cost and values to the company
• To develop a plan
• To motivate positive action

Review phase
• The overall value analysis process is reviewed and
necessary adjustments are made.

Faculty of Mechanical Engineering, University Technology MARA

 Trends of Manufacturing

Relocate the company • To take advantage of low labour cost

Redesign • Become lean production and make better product

manufacturing systems • Cheaper, faster, flexible

Increase product
• Provide optional for customers
variation

Towards better quality • Towards zero defects and continuous

and reliability improvement

Faculty of Mechanical Engineering, University Technology MARA

 Cont’d

• Apply concurrent engineering efforts

Reduce time to
• Bring product design and manufacturing closer to
market customer

• Conversion of materials into products

Value added activity • Using the least amount of time, material, money, space
and labour.

Faculty of Mechanical Engineering, University Technology MARA

 Thank you
32
Faculty of Mechanical Engineering, University Technology MARA
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