Ch 2: Manufacturing Operations
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1 Ch 2: Manufacturing Operations Learning Objectives: By the end of the lecture the student should be able to: Explain the difference between technological and economical definition of manufacturing. Properly classify manufacturing industry with respect to size, processes used, product produced. Outline and explain four main manufacturing operations for desecrate product production. Explain processing operations. Explain the relationship between product quantity and product variety. Explain the relationships between plant layout and type of production facility. Explain the relationships between product quantity/variety and type of production facility. NOTE: Materials used to create this presentation were supplied from: Lecture notes designed by 2008 Pearson Education Inc. Third Edition by Professor Mikell P. Groover Lecture notes designed by Professor Darek Ceglarek, University of Wisconsin Madison.
2 Manufacturing Operations - Technological Definition Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products Manufacturing also includes the joining of multiple parts to make assembled products Accomplished by a combination of machinery, tools, power, and manual labor. Almost always carried out as a sequence of operations
3 Manufacturing Technological Definition
4 Manufacturing - Economic Definition Transformation of materials into items of greater value by means of one or more processing and/or assembly operations Manufacturing adds value to the material Examples: Converting iron ore to steel adds value Transforming sand into glass adds value Refining petroleum into plastic adds value
5 Manufacturing - Economic Definition
6 Classification of Industries 1. Primary industries cultivate and exploit natural resources Examples: agriculture, mining 2. Secondary industries convert output of primary industries into products Examples: manufacturing, power generation, construction 3. Tertiary industries service sector Examples: banking, education, government, legal services, retail trade, transportation
7 International Standard Industrial Classification (ISIC) ISIC Code Food, beverages, tobacco 31 Textiles, apparel, leather and fur products 32 Wood and wood products, cork 33 Paper, printing, publishing, bookbinding 34 Chemicals, coal, petroleum, & their products 35 Ceramics, glass, mineral products 36 Basic metals, e.g., steel, aluminum 37 Fabricated products, e.g., cars, machines, etc. 38 Other products, e.g., jewelry, toys 39
8 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
9 Process Industries and Discrete Manufacturing Industries
10 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 and assembly operations 2. Material handling 3. Inspection and testing 4. Coordination and control
11 1. Processing and assembly operations
12 Processing Operations Shaping operations 1. Solidification processes 2. Particulate processing 3. Deformation processes 4. Material removal processes Property-enhancing operations (heat treatments) Surface processing operations Cleaning and surface treatments Coating and thin-film deposition
13 Material Removal Processes - Turning A single point cutting tool removes material from a rotating workpiece to generate a cylindrical shape Performed on a machine tool called a lathe Variations of turning that are performed on a lathe: Facing Contour turning Chamfering Cutoff Threading
14 Turning Operations - Examples a) Facing c) Contour turning e) Chamfering f) Cutoff g) Threading
15 Cutting Tools and Inserts - Turning
16 Turning vs. Boring Difference between boring and turning: Boring is performed on the inside diameter of an existing hole Turning is performed on the outside diameter of an existing cylinder In effect, boring is an internal turning operation
17 Reaming, Drilling, Tapping Reaming Drilling Tapping Counterboring
18 Milling Slab Milling Slotting Face Milling End Milling Profile Milling Pocket Milling Surface Contouring
19 Tools - End and Face Mills From top: slot, roughing and ball nose end mills End Mill cutter with two flutes Face Mill Source:
20 Material Removal Rate (MRR) and Chip Formation Achieving the correct size of chip is of critical importance. The size of this chip depends on several variables. Surface cutting speed (V): This is the speed at which each tooth cuts through the material as the tool spins. Spindle speed (N): This is the rotation speed of the tool, and is measured in revolutions per minute (RPM). Feed per tooth (f): This is the distance the material is fed into the cutter as each tooth rotates. Feed rate (fr): This is the speed at which the material is fed into the cutter. Diameter of the tool (D) Depth of cut (d) Width of cut (w)
21 MRR Calculations Source:
22 MRR Calculations Source:
23 Example We want to face mill the top of aluminum block (1.5 by 9 inches) at the cutting depth of 0.1 inch. We will use a 0.2 inch wide face mill with 5 cutting inserts. The manufacturer recommends the cutting speed (V) = 350 feet/min and feed per tooth (f) = 0.01 (inch per tooth). What is MRR? Source:
24 Assembly Operations Joining processes Welding Brazing and soldering (joining two materials using the third; soldering uses lower melting temperature filler metal) Adhesive bonding Mechanical assembly Threaded fasteners (e.g., bolts and nuts, screws) Rivets Interference fits (e.g., press fitting, shrink fits) Other
25 Joining Technology in Automobile
26 Material Handling Material transport Vehicles, e.g., forklift trucks, AGVs, monorails Conveyors Hoists and cranes Storage systems Unitizing equipment Automatic identification and data capture Bar codes RFID Other AIDC
27 Time Spent in Material Handling
28 Inspection and Testing Inspection examination of the product and its components to determine whether they conform to design specifications Testing observing the product (or part, material, subassembly) during actual operation or under conditions that might occur during operation
29 Coordination and Control Regulation of the individual processing and assembly operations Process control Management of plant level activities Production planning and control
30 Plant Layout
31 Relationships between Plant Layout and Type of Production Facility
32 Limitations and Capabilities of a Manufacturing Plant Manufacturing capability - the technical and physical limitations of a manufacturing firm and each of its plants Three dimensions of manufacturing capability: 1. Technological processing capability - the available set of manufacturing processes 2. Physical size and weight of product 3. Production capacity (plant capacity) - production quantity that can be made in a given time
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