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OVERVIEW OF MANUFACTURING
Chapters:
2. Manufacturing Operations
3. Manufacturing Models and Metrics
2008 Pearson Education, Inc., Upper Saddle River, NJ. All
rights reserved. This material is protected under all copyright laws
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
1
Ch 2 Manufacturing Operations
Sections:
1. Manufacturing Industries and Products
2. Manufacturing Operations
3. Production Facilities
2008
Pearson Education, Relationships
Inc., Upper Saddle River, NJ. All
4. Product/Production
rights
reserved.
This material is protected under all copyright laws
5. Lean
Production
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
2
Classification of Industries
1. Primary industries cultivate and exploit natural
resources
Examples: agriculture, mining
2. Secondary industries convert output of primary
industries
into products
2008
Pearson Education,
Inc., Upper Saddle River, NJ. All
rights reserved.
This material
is protected
under
all copyright laws
Examples:
manufacturing,
power
generation,
as they currently
exist.
construction
No3.portion
of this
materialmay
be reproduced,
Tertiary
industries
service
sector in any form or by
any means, without permission in writing from the publisher. For
Examples: banking, education, government, legal
the exclusive
use of adopters of the book
services,
retailSystems,
trade, transportation
Automation,
Production
and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
7
Manufacturing Industries
ISIC Code
Food, beverages, tobacco
31
Textiles, apparel, leather and fur products
32
Wood and wood products, cork
33
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Education,
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Saddle River, NJ. All
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publishing,
bookbinding
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rights
reserved. This
material
is protected
under
all copyright
Chemicals,
coal,
petroleum
and their
products
35 laws
as they currently exist.
Ceramics, glass, mineral products
36
No portion of this material may be reproduced, in any form or by
Basic without
metals,permission
e.g., steel,inaluminum
37 For
any means,
writing from the publisher.
theexclusive
use of
adopterse.g.,
of thecars,
bookmachines, etc. 38
Fabricated
products,
Automation,
Productione.g.,
Systems,
andtoys
Computer-Integrated39
Other products,
jewelry,
Manufacturing, Third Edition, by Mikell P. Groover.
8
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 Inc., Upper Saddle River, NJ. All
2008
Pearson Education,
rights
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material
is protected under all copyright laws
3. reserved.
Inspection
and
testing
as they
currently exist.and control
4. Coordination
No portion
of this material may be reproduced, in any form or by
A processing operation transforms a work material from one state of
any means, without permission in writing from the publisher. For
completion to a more advanced state using energy to alter its shape,
the exclusive use of adopters of the book
properties or appearance to add value to the material.
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
11
Fig. 2.3
Classification of
manufacturing
processes
Processing Operations
Shaping operations
1. Solidification processes
2. Particulate processing
3. Deformation processes
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Education,
Upper Saddle River, NJ. All
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Material
removalInc.,
processes
rights reserved. This material is protected under all copyright laws
Property-enhancing operations (heat treatments)
as they currently exist.
Surface
processing
operations
Noportion
of this
material may
be reproduced, in any form or by
Cleaning
any means,
without permission
and surface
in treatments
writing from the publisher. For
the exclusive
use ofand
adopters
of the
book
Coating
thin-film
deposition
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
13
Assembly Operations
Joining processes
Welding
Brazing and soldering
Adhesive bonding
Mechanical assembly
2008
Inc.,bolts
Upper
River, NJ. All
Pearson
ThreadedEducation,
fasteners (e.g.,
andSaddle
nuts, screws)
rights reserved.
Rivets This material is protected under all copyright laws
as they currently
exist.
Interference
fits (e.g., press fitting, shrink fits)
No portion
of this material may be reproduced, in any form or by
Other
Material Handling
A means of moving and storing materials between processing and/or
assembly operations
Material transport
Vehicles, e.g., forklift trucks, AGVs, monorails
Conveyors
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cranes Inc., Upper Saddle River, NJ. All
rights
reserved.
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Storage
systems
Unitizing
equipment
as they
currently
exist.
Automatic
identification
and data
capture (AIDC)
No portion
of this
material may
be reproduced,
in any form or by
Bar codes
any means,
without permission in writing from the publisher. For
RFID
the exclusive
ofequipment
adopters of the book
Otheruse
AIDC
Production Facilities
A manufacturing company attempts to organize its
facilities in the most efficient way to serve the particular
mission of the plant
Certain types of plants are recognized as the most
appropriate way to organize for a given type of
2008 Pearson Education, Inc., Upper Saddle River, NJ. All
manufacturing
rights reserved. This material is protected under all copyright laws
Thecurrently
most appropriate
type depends on:
as they
exist.
Types
of products
made
No portion
of this
material may
be reproduced, in any form or by
any means,
without quantity
permission in writing from the publisher. For
Production
the exclusive
usevariety
of adopters of the book
Product
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
20
Production Quantity
Number of units of a given part or product produced
annually by the plant
Three quantity ranges:
1. Low production 1 to 100 units
2. Medium
productionInc.,
100
to 10,000
units NJ. All
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Upper
Saddle River,
rights
This material
is protected
underofallunits
copyright laws
3. reserved.
High production
10,000
to millions
as they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
21
Product Variety
Refers to the number of different product or part
designs or types produced in the plant
Inverse relationship between production quantity and
product variety in factory operations
2008
Pearson
Education,
Inc.,complicated
Upper Saddlethan
River,
NJ. All
Product
variety
is more
a number
rights reserved.
This material
copyright laws
Hard product
varietyisprotected
productsunder
differall
greatly
as they currently exist.
Few common components in an assembly
No portion of this material may be reproduced, in any form or by
Softwithout
product
variety insmall
differences
between For
any means,
permission
writing
from the publisher.
products
the exclusive
use of adopters of the book
Many
Automation,
Production
Systems,
and Computer-Integrated
common
components
in an assembly
Manufacturing, Third Edition, by Mikell P. Groover.
22
Fixed-Position Layout
Fig. 2.6 (a)
Process Layout
Fig. 2.6 (b)
Cellular Layout
Fig. 2.6 (c)
Product Layout
Fig. 2.6 (d)
Product/Production Relationships
P
Lean Production
Operating the factory with the minimum possible
resources and yet maximizing the amount of work
accomplished
Resources include workers, equipment, time, space,
materials
2008
Pearson Education, Inc., Upper Saddle River, NJ. All
rights
reserved.
materialproducts
is protected
under
all copyright
laws
Also
implies This
completing
in the
minimum
possible
as they
exist. a very high quality level to completely
time currently
and achieving
Nosatisfy
portionthe
of this
material may be reproduced, in any form or by
customer
any
permissionmeans
in writing
from
the publisher.
Inmeans,
short,without
lean production
doing
more
with less, For
and
thedoing
exclusive
use of adopters of the book
it better
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
35