Instructor : Prof. Dr.

Omar Badran

Prepared by:
Dr. Naseer Ahmed
Department of Mechanical Engineering
College of Engineering, Taibah University
Department of Mechanical Engineering

ME-321 Manufacturing Process I

ME 321
Manufacturing
Process I

Manufacturing Processes

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Manufacturing Processes can be divided into two

basic types
Processing Operations
Assembly Operation

Processing Operations

Department of Mechanical Engineering

ME-321 Manufacturing Process I

They transform a work material from one state of

completion to a more advanced state that is closer
to the final desired product.
It add values by changing the geometry, properties,
or appearance of the starting material.
These operations are mostly applied to discrete
work parts, but some processing operations are
also applicable to assembled items.

Processing
Operations

Property
Enhancing
Processes

Surface
Processing
operations

Casting,
Molding, etc.

Heat
Treatment

Cleaning and
Surface
Treatments

Particulate
Processing
Deformation
Processes
Material
Removal
Department of Mechanical Engineering

Coating and
Deposition
processes

ME-321 Manufacturing Process I

Shaping
Processes

Assembly Operations

Department of Mechanical Engineering

ME-321 Manufacturing Process I

These operations join two or more components in

order to create a new entity.
The new entity is called an assembly, or subassembly.

Assembly
Operations

Welding

Threaded
fasteners

Brazing and
soldering

Permanent
Fastening
methods

Adhesive
bonding

Department of Mechanical Engineering

Mechanical
Fastening

ME-321 Manufacturing Process I

Permanent
Joining
Processes

1. Processing Operations

Department of Mechanical Engineering

ME-321 Manufacturing Process I

A processing operation uses energy to alter a workparts

shape, physical properties, or appearance in order to add
value to the material.
The forms of energy include mechanical, thermal, electrical,
and chemical.
The energy is applied in a controlled way by means of
machinery and tooling.
Human energy may also be required, but human workers are
generally employed to control the machines, to oversee the
operations, and to load and unload parts.
More than one processing operation is required to transform
the starting material into final form.

1. Processing Operations (contd)

The categories of processing operations are distinguished.
Shaping operations
Property-enhancing operations
Surface processing operations

Department of Mechanical Engineering

ME-321 Manufacturing Process I

1.
2.
3.

1.1 Shaping Processes

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Most shaping processes apply heat or mechanical forces or a

combinations of these to effect a change in geometry.
Classification is as under
Solidification processes: Casting (of metals), molding (of plastics)
Particulate processing: the starting material is a powder, and the
powders are formed and heated into the desired geometry
(processing, and sintering).
Deformation processes: the starting material is a ductile solid
(commonly metal), which is deformed to shape the part.
Material removal processes: the starting material is a solid
(ductile or brittle) from which material is removed so that the
resulting part has the desired geometry.

1.1.1 Casting, Molding

ME-321 Manufacturing Process I

Department of Mechanical Engineering

1.1.2 Particulate Processing

ME-321 Manufacturing Process I

Department of Mechanical Engineering

1.1.3 Deformation Process

ME-321 Manufacturing Process I

Department of Mechanical Engineering

1.1.4 Metal removal Process

ME-321 Manufacturing Process I

Department of Mechanical Engineering

1.2 Property Enhancing Process

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Improving Mechanical or physical properties

Do not alter the shape of the part, except unintentionally in
some cases.
Involves heat treatment, which include various annealing and
strengthening processes for metal and glasses.

1.3 Surface Processing Operations

Department of Mechanical Engineering

ME-321 Manufacturing Process I

These operations includes

Cleaning
Surface treatment
Coating and thin film deposition
Surface coating can benefit in
Corrosion protection
Color and appearance
Wear resistance
Preparation for subsequent processing

2. Assembly Operations

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Two or more separate parts are joined to form a new entity

either permanently or semi permanently.
Examples are welding, brazing, soldering, and adhesive
bonding.

Production Machines
Presses for stamping operations
Forge hammers for forging
Rolling mills for rolling sheet metal
Welding machines
Insertion machines for inserting electronic components into
printed circuit boards
These machines can be of two purposes
General-purpose equipment is more flexible and adaptable to
a variety of jobs
Special-purpose equipment is usually designed to produce a
specific part or product in large quantities

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Tooling

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Tooling customizes the equipment for the particular part or

product
Can be fixed to a machine and can be interchangeable
The shape is specific for the kind of job, it is going to perform

List of production equipment and tooling used for

various Manufacturing processes
Equipment

Special Tooling (function)

Casting

Various

Mold (Cavity for molten metal)

Molding

Molding machine

Mold (Cavity for hot polymer)

Rolling

Rolling mill

Roll (reduce work thickness)

Forging

Forge hammer

Die (squeeze work to shape)

Extrusion

Press

Extrusion die (reduce cross section)

Stamping

Press

Die (Shearing, forming sheet metal)

Machining

Machine Tool

Cutting tool (Material removal)

Fixture (hold workpart)
Jig (hold part and guide tool)

Grinding

Grinding machine

Grinding wheel (material removal)

Welding

Welding Machine

Electrode (fusion of work metal)

Fixture (hold parts during welding)

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Process

Production Systems

Department of Mechanical Engineering

ME-321 Manufacturing Process I

It consists of people, equipment and procedures designed for the

combination of materials and processes
Can be divided into two
Facilities (physical equipment and the arrangement of
equipment in the factory) (Blue-collar people).
Manufacturing support (procedures used by the company to
manage production and solve the technical and logistics
problems encountered in ordering material, moving work
through factory, and ensuring the quality of the product)
(White-collar people).

Production Facilities

Department of Mechanical Engineering

ME-321 Manufacturing Process I

These consists of
Factory
Production equipment
Material handling equipment
Different facilities are required for different quantity ranges.

For Low-quantity Production (1-100

units/year)

Department of Mechanical Engineering

ME-321 Manufacturing Process I

In low-quantity range, the term Job Shop is often used to describe

the type of production facility.
Job Shop makes low quantities of specialized and customized
products.
Products are typically complex.
The equipment is general purpose and the labor force is highly
skilled.
Job shop must be designed for maximum flexibility.
Larger products typically remains at fix locations while they are
made. This layout is known as the Fixed-position layout.
The individual components of the main products are made in
factories in which the equipment is arranged according to function or
type (Process Layout). The lathes are in one department, the milling
in the other and so on.
Different parts are routed in specific order. This layout is known for its
flexibility.
The disadvantage of the process layout is that machinery and
methods to produce a part are not designed for high efficiency, and
much material handling is required to move parts between
departments.

Fixed-Position Layout
ME-321 Manufacturing Process I

Department of Mechanical Engineering

For Medium-quantity Production (10010,000 units annually)

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Two different kind of facilities can exist

When product variety is hard the usual approach is batch
production. In which a batch of one product is made, after
which the facility is changed over to produce a batch of
next product. Orders for each are frequently repeated.
Normally used for make-to-stock situation. The equipment
is usually arranged in a process layout
If the product variety is soft, cellular manufacturing is used.
It is possible to configure the equipment so that groups of
similar products can be made on the same equipment
without significant time loss. This layout is called cellular
layout.

Process Layout
ME-321 Manufacturing Process I

Department of Mechanical Engineering

Cellular Layout

Cell

Department of Mechanical Engineering

ME-321 Manufacturing Process I

Cell

For High-quantity Production (10,000 to

millions annually)

Department of Mechanical Engineering

ME-321 Manufacturing Process I

This kind is referred to as mass production. The

situation is characterized by high demand rate for
the product. Two main kind occurs
1. Quantity production
2. Flow line production

Quantity production

Department of Mechanical Engineering

ME-321 Manufacturing Process I

It involves the mass production of single part on single pieces

of equipment.
The method of production typically involves standard
machines equipped with special tooling.
Typical layouts used are the process and cellular layouts.

Flow line production

Department of Mechanical Engineering

ME-321 Manufacturing Process I

It involves multiple pieces of equipment or workstations

arranged in sequence, and the work units are physically
moved through the sequence to complete the product.
The workstations and equipment are designed specifically for
the product to maximize efficiency.
This kid of layout is called the Product Layout.
The work is usually moved between by mechanical conveyor
by mechanized conveyor. Normally the product made by a
single flow line are identical and this production line is
therefore called the single-model production line. But Mixedmodel production line applies to those situations where there
is a soft variety in the products made on the line.

Product Layout
ME-321 Manufacturing Process I

Department of Mechanical Engineering

Manufacturing Support Systems

Department of Mechanical Engineering

ME-321 Manufacturing Process I

The people and procedures by which a company manages its

production operations.
Manufacturing support functions are often carried out in the firm by
people organized into departments such as
Manufacturing engineering: responsible for planning the
manufacturing process, designing and ordering the machine tools
and other equipment used by the operating department.
Production planning and control: responsible for solving the
logistics problems in manufacturing: ordering materials and
purchased parts, scheduling production, and making sure that
the operating departments have the necessary capacity to meet
the production schedule.
Quality control: responsible for designing and building products
that confirms to specifications and satisfy or exceed
expectations.