Introduction to Basic Manufacturing

Process and Workshop Technology

Aung Myo Lwin, [Link], Ph.D

 Introduction
Manufacturing is the backbone of any industrialized nation.
Manufacturing and technical staff in industry must know the
various manufacturing processes, materials being processed,
tools and equipment's for manufacturing different
components or products with optimal process plan using
proper precautions and specified safety rules to avoid
accidents.
Beside above, all kinds of the future engineers must know
the basic requirements of workshop activities in term of
man, machine, material, methods, money and other
infrastructure facilities needed to be positioned properly for
optimal shop layouts or plant layout and other support
services effectively adjusted or located in the industry or
plant within a well planned manufacturing organization.
 Manufacturing Engineering
• Manufacturing is derived from the Latin word
manufactus, means made by hand.
• In modern context, manufacturing involves making
products from raw material by using various
processes, by making use of hand tools, machinery
or even computers.
• It is therefore a study of the processes required to
make parts and to assemble them in machines.
Advance manufacturing engineering involves the following concepts
1. Process planning
2. Process sheets
3. Route sheets
4. Tooling
5. Cutting tools, machine tools (traditional, numerical control (NC),
and computerized numerical control (CNC)
6. Jigs and Fixtures
7. Dies and Moulds
8. Manufacturing Information Generation
9. CNC part programs
10. Robot programmers
11. Flexible Manufacturing Systems (FMS), Group Technology (GT)
and Computer integrated manufacturing (CIM)
 Production Process
• It is the process followed in a plant for converting semi-
finished products or raw materials into finished products or
raw materials into finished products.
• The art of converting raw material into finished goods with
application of different types of tools, equipments, machine
tools, manufacturing set ups and manufacturing processes, is
known as production.
• Generally there are three basic types of production system
that are given as under
1. Job production (Single job)
2. Batch production (200 – 800)
3. Mass production (> 50000)
 Process Planning
Process planning consists of selection of means of
production (machine-tools, cutting tools, presses, jigs,
fixtures, measuring tools etc.), establishing the efficient
sequence of operation, determination of changes in form,
dimension or finish of the machine tools in addition to the
specification of the actions of the operator.
It includes the calculation of the machining time, as well as
the required skill of the operator.
 It also establishes an efficient sequence of manufacturing
steps for minimizing material handling which ensures that
the work will be done at the minimum cost and at maximum
productivity.
Classification of Manufacturing Process
• For producing of products materials are needed. It is
therefore important to know the characteristics of the
available engineering materials.
• Raw materials used manufacturing of products, tools,
machines and equipments in factories or industries are
extracted from ores.
• The ores are suitably converted the metal into a molten form
by reducing or refining processes in foundries. This molten
metal is poured into moulds for providing commercial
castings, called ingots.
• Such ingots are then processed in rolling mills to obtain
market form of material supply in form of bloom, billets,
slabs and rods.
• These forms of material supply are further subjected
to various manufacturing processes for getting
usable metal products of different shapes and sizes
in various manufacturing shops.
• All these processes used in manufacturing concern
for changing the ingots into usable products may be
classified into six major groups as primary shaping
processes, secondary machining processes, metal
forming processes, joining processes, surface
finishing processes and processes effecting change
in properties.
 Product Simplification and
Standardization
• The technique of simplification and standardization of
product is closely inter-related that leads to higher efficiency
in production, better quality and reduced production cost.
• Simplification is a process of determining limited number of
grades, types and sizes of a components or products or parts
in order to achieve better quality control, minimize waste,
simplify production and, thus, reduce cost of production.
• By eliminating unnecessary varieties, sizes and designs,
simplification leads to manufacture identical components or
products for interchangeability and maintenance purposes of
assembly of parts.
• Standardization is the important step towards interchangeable
manufacture, increased output and higher economy.
 Inspection and Quality Control
• A product is manufactured to perform desired functions.
• It must have a specified dimension such as length, width,
height, diameter and surface smoothness to perform or
accomplish its intended function.
• It means that each product requires a defined size, shape
and other characteristics as per the design specifications.
• For manufacturing the product to the specified size, the
dimensions should be measured and checked during and
after the manufacturing process.
• It involves measuring the size, smoothness and other
features, in addition to their checking.
• These activities are called measurement and inspection
respectively.
 Mechanization and Automation
• Mechanization means something is done or operated by
machinery and not by hand.
• Mechanization of the manufacturing means is milestone
oriented trend towards minimizing the human efforts to the
extent of its possibility, by adopting mechanical and
electrical means or methods for automating the different
manufacturing processes.
• Such a trend may be in the area of automating and
mechanizing the processes of material handling, loading and
unloading of components, actual operations performed on
the job or transportation, etc.
The reasons why one should go for automation are:
1. Increased productivity
2. Reduced cost of labor and dependence on labor shortages
3. Improved quality
4. Reduced in-process inventory
5. Reduced manufacturing time
6. Reduced dependence on operator skills
7. Increased safety or reduced risk of humans.
Automation can be classified into three categories, viz.
8. Fixed automation
9. Programmable automation
10. Flexible automation.
 Computer Aided Manufacturing
• The computer aided manufacturing implies manufacturing
itself, aided or controlled by computers.
• In a wider sense, it denotes all the activities in the
manufacturing environment like use of computers in
inventory control, project management, material requirement
planning, data acquisition, testing and quality control.
• Computer Numerical Control (CNC) machines used in
production and the part programs being made by the stored
geometry from the design stage, the scrap level would be
reduced to the minimum possible and almost no rework
would be necessary.
 Manufacturing System
• Manufacturing basically implies making of goods or articles
and providing services to meet the needs of mankind.
• It creates value by useful application of physical and mental-
labor in the process.
• It is a chain of interrelated activities of production process
and other support services activities of an manufacturing
environment such as order processing, product design,
design and manufacturing of tools, die, mould, jigs, fixtures
and gauges, selection of material, planning, managing and
maintaining control of the processes, production, and
reliable quality of processed product in a systematic and
sequential manner with proper coordination, cooperation and
integration of the whole manufacturing system that will lead
to economical production and effective marketing of
proposed product in the minimum possible time.
 Product Development
A product development has to go through the following concepts of
product engineering which are given as under.
Product functions
1. Product specifications
2. Conceptual design
3. Ergonomics and aesthetics
4. Standards
5. Detailed design
6. Prototype development
7. Testing
8. Simulation
9. Design for manufacture
10. Design for assembly
11. Drafting.
Computers in Manufacturing Industries
• Factors governing increased productivity, more
accuracy, greater flexibility of shapes, and reduced
manufacturing costs are forcing the manufacturing
concerns to use computers in design, manufacturing
and other allied functions of industrial activities.
• In today’s time, computer applications have
progressed considerably in all areas of design and
manufacturing involving CAD and CAM.
Today, computers are not only used in manufacturing but they
play also an important role in all manufacturing related
activities such as business or financial management, factory
level production management, CIM technologies, CAD,
feature and solid modelling, and CAM, manufacturing
information, manufacturing system.
Business or Financial Management
1. Costing
2. Sales and Marketing
3. Purchase Order Control
4. Vendors
5. Subcontracting
6. Personnel.
Factory Level Production management
1. Planning
2. Production Management
3. Manufacturing production scheduling (MPS)
4. Material requirement planning (MRP)
5. Just in time (JIT)
6. Bill of Materials
7. Capacity Planning
8. Inventory Control.
 CIM Technologies
1. Computer Networks
2. System Design and Analysis
3. Distributed Processing
4. Database Management Manufacturing
5. Modelling and Simulation
6. Expert Systems
7. Quality Engineering.
 Computer Aided Design (CAD)
This area is also known Feature and Solid Modelling.
1. Variational and Parametric
2. Modelling
3. Computer Graphics
4. Graphic Standards
5. Inter-graphics exchange specification (IGES)
6. Data exchange file (DXF)
7. Manufacturing Robot Programming
8. Design Analyses Tools
9. Programming
10. Finite element modelling (FEM)
11. Finite element analysis (FEA)
12. Simulation
13. Mechanisms
14. Test and Analysis
15. Design Tools Mechanical
16. Hydraulic, Electronics, etc.
Computer Aided Manufacturing (CAM)
This involves activities related to manufacturing information
and manufacturing system.
Manufacturing Information
1. Generation
2. Process Planning
3. Production Planning
4. Computer numerical control (CNC) part Programming
5. Robot Programming
6. Coordinate measuring machine (CMM) Programming.
Manufacturing System
1. Production Activity
2. Machining
3. Assembly
4. Material Handling
5. Storage
6. Production Control
7. Loading
8. Scheduling
9. Balancing
10. Capacity Planning
11. Quality Control.