BMCG 2312

BMCU 1323
BMCG 2323
Manufacturing Process
 WHAT IS
MANUFACTURING?
WHAT IS MANUFACTURING

Machinery

Tooling

Power

Labor
TECHNICAL PROCESS

Conversion of raw
material into Product
products by using Raw materials
machines, tooling, Manufacturing
power, labour etc Process Profit
according to a
detailed plan.
Raw Material(s)

1) Technology – manufacturing is the 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 assembly of multiple parts to make products.
WHAT IS MANUFACTURING
Manufacturing
ECONOMIC PROCESS Process
2) Economic – manufacturing is the
transformation of materials into items of Value
greater value by means one or more added
processing involve. Therefore,
manufacturing is “added value” to the
material.
Starting Material in Processed
material processing material
Raw Material(s) Products
WHAT WILL YOU LEARN?

Raw Material(s) Process(es) Products

STEEL SUBTRACTIVE PROCESSES

TYPE OF PROCESSES
MANUFACTURING FORMING AND SHAPING CONTINOUS PROCESS
OPERATION AND
LAYOUT NET SHAPE PROCESS
ADDITIVE PROCESS
JOINING PROCESS
QUALITY AND METROLOGY

SUSTAINABLE MANUFACTURING
 DEVELOPMENT
PRODUCT
INPUT FROM COMMENTS
CUSTOMERS INPUT FROM FROM
SUPPLIERS CUSTOMER

PROJECT PROJECT PRODUCT PRODUCT PROJECT

DESIGN
PROPOSAL PLANNING MANUFACTURE LAUNCH CLOSE

HOW MANUFACTURING STARTS

 PLANNING
TEAM

PRODUCT
DESIGN TEAM
ENGINEERING/
PRODUCTION
TEAM
WHO INVOLVE IN MANUFACTURING
HOW DISCUSSION TAKE PLACE?

CUSTOMERS PLANNING ENGINEERING/

SUPPLIERS
PRODUCTIO N
New feature
Quantity to produce Does the design can
Destination market fit the current
Production location equipment
Product life Need new machine?
Similar competitor
model

Translate planning
design Into
manufacturable
Design
WHY CONCURRENT ENGINEERING IS IMPORTANT?
PLANNING TEAM PRODUCT DESIGN ENGINEERING/
TEAM PRODUCTION
TEAM

SEQUENTIAL/OVER THE WALL ENGINEERING

HOW TO SELECT THE RIGHT PROCESSES
DESIGN
• Size and shape of the final
product and raw material
• Geometry complexity
• parts with thin cross-sections
cannot be cast properly;
complex parts cannot be
formed easily.
COST
• Economics (cost) of tooling,
capital,scrap rate etc
• Operational and Cost
considerations:
• Design and cost of tooling
TIME FRAME
Lead time required to
begin production
EXTERNAL REGULATIONS
MATERIAL • Environment and
• Material to be used (type and • safety
basic properties)
• Castability/
weldability/Machinability QUANTITY
• Number of parts or products
required and
• desired production rate
QUALITY
• Dimensional accuracy
(tolerances) required
• Surface finish required - MACHINES AND TOOLS
additional operations: grinding, • Availability of
polishing (better finish but more machines and
expensive!) equipment
• Flexibility to change
the design at any time
Additional reading
https://writepass.com/journal/2016/08/factors-that-
affect-selection-of-manufacturing-process-design-
at-apple-inc/
 bulk deformation process -forming and shaping (F&S)
 F&S (Sheet Metal)
 Casting
 Machining
 F&S (Polymer)
 Joining
 Casting
 forming and shaping (F&S) (bulk deformation process)
 F&S (Polymer)
 F&S (Sheet Metal)
 Machining
 Joining

PROCESS AVAILABLE
 Forming and shaping (general)
 Additive
 Net Shape
 Subtractive
 Continouos

OTHERS CLASSIFICATION
TYPE OF INDUSTRIES

Industries can be classified as:

@jurie 2007 – Lecture 1

 Take the outputs of the
primary industries and
Those that CULTIVATE CONVERT them into
AND EXPLOIT natural consumer and
resources; capital goods.
•Aerospace Constitute with
•Automotive SERVICE SECTOR of
PRIMARY INDUSTRY

•Agriculture •Banking
•Beverages the economy.
•Forestry

INDUSTRY
SECONDARY

TERTIARY INDUSTRY
•Building materials •Communications
•Fishing •Education
•Chemicals
•Livestock •Entertainment
•Computers
•Quarries •Financial services
•Consumer appliances
•Mining •Health and medical
•Electronics
•Petroleum •Government
•Equipment
•Food processing •Hotel
•Glass, ceramic •Insurance
•Paper •Restaurant
•Pharmaceuticals •Retail trade
•Plastics (shaping) •Tourism
•Textiles •Transportation
•Tire and rubber •Real estate
•Wood and furniture
WHICH INDUSTRIES INVOLVE WITH SPOON AND FORK?
 11

Manufacturing system can be defined as a

transformation system in which a product or service is
created by working upon a set of inputs. Inputs are
usually in the form of men, machine, money,
materials etc. Production systems are usually
classified on the basis of the following:
Intermittent
Product quantity
Product variety PROJECT
BATCH
The system can be divided into JOBSHOP
two categories;

Intermittent and Continuous Continuous

system
MASS
RELATIONSHIP BETWEEN PRODUCT QUANTITY AND PRODUCT VARIETY
Above 10,000 units

Mass 100 to 10,000 units

High Batch 10 to 100 units

QUANTITY/VOLU
Product

Job shop 1 to 10 units

ME

Medium
Project

Low

Product VARIETY
Production quantity: number of unit produced annually of a particular product
type.
Product variety: different product designs or types that are produced in the plant.
 TYPE OF MANUFACTURING OPERATIONS

- Product position – remains stationary during the manufacturing process – size,

weight, location of the product.
- Materials, people, machinery are brought to the product or product site.
- Based on customer specifications.
- Example: bridge, building construction, aircraft, ships, locomotive.
 A job shop is a type of manufacturing process in which small
batches of a variety of custom products are made. In the job shop
process flow, most of the products produced require a unique set-up
and sequencing of process steps.

- Low volume and production quantities called lot sizes with high product variety.
- Satisfies a market for nonstandard or unique product.
- Layout – different machines with similar functional or processing capabilities
are grouped together as department.
- Require high skill levels labor – to operate a variety of equipments.
- A short duration activities to provide custom goods.
- Example: space vehicles, reactor vessels, turbines, aircraft components.
- Batch production produce or process any product in groups which is called
“batches”.
- Can produce a variety of products – opposed to a continuous production
process, or a one time production.
- Useful for industries that makes seasonal items/products for which it is
difficult to forecast the demand.
- Example: Similar standard items made periodically in batches: bakery, paint,
hand tools.
- Same facilities used to manufacture all the different items.
- Layout of machine – functional layout (based on its function to be performed –
from section to another section).
Batch Production Examples:
Baked goods Flat-pack furniture
Clothing Jet engine production
Computer software Machine tool manufacturing
Die- or mold-making Material coating
Electrical goods Newspapers/magazines
 INTRODUCTION TO MANUFACTURING 17

Advantages
- Reduce initial capital outlay – due to a single production line can be used to
several products – machines can be used more effectively, materials can be
bought in bulk, workers can specialize in that task.
Disadvantages
- Requires very careful production planning & control – next batches; when, types.
- When switching to another batches – takes time (“down time”) – can cause
loss of output (low yield).
- Resulted “WIP” or create inventory/stock – increases costs such as inventory
cost, cost because of damage to stock.
The example production line (shown below) is that of an engineering company, manufacturing small steel
products such as hinges and locks. They manufacture batches of five hundred at a time. The workers are
unskilled and semi skilled. As each task is completed the item being manufactured is passed down the
production line to the next worker, until it is complete.
 Mass production often involves the assembly of a
number of sub-assemblies of individual components.
Parts may be bought from other companies.

- Also known as flow production, repetitive flow production, series production.

- Producing goods in large quantities at low cost per unit and produce in a short
period of time.
- Machinery (eg: robots, machine press) that is needed to set up the mass
production line is so expensive.
- Involved fewer labor cost and a faster rate of production.
- Plant and equipments are arranged in a flow line layout.
- Operation is done base on specific product and thus make the production
control easily.
- Work piece is transfer automatically from one machine to another.
- Example: light bulbs, refrigerator, tv.
The concepts of mass production
are applied to various kinds of
products, from fluids and
particulates handled in bulk (such
as food, fuel, chemical and
mined mineral) to discrete solid
parts (such as fasteners) to
assemblies of such parts (such as
household appliances and
automobiles)
MANUFACTURING PLANT LAYOUT
Plant layout refers to an
optimum arrangement of
facilities including
personnel, operating
equipment, storage
space, material handling
equipment and all other
supporting services along
with the design of best
structure to contain all
these facilities”. Goal of Plant Layout
To maximize the profit by
arrangement of all the plant facilities
to the best advantage of total
manufacturing of the product.
https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
PLANT LAYOUT
Objectives of plant layout
• Streamline the flow of materials through the plant.
Facilitate the manufacturing process.
• Maintain high turnover of in-process inventory.
• Minimize materials handling and cost.
• Effective utilization of men, equipment and space.
• Make effective utilization of cubic space.
• Flexibility of manufacturing operations and
arrangements.
• Provide for employee convenience, safety and
comfort.
• Minimize investment in equipment.
• Minimize overall production time.
• Maintain flexibility of arrangement and operation.
https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
Principles of Plant Layout
Principle of integration: A good layout is one that
integrates men, materials, machines and supporting
services and others in order to get the optimum
utilization of resources and maximum effectiveness.
Principle of minimum distance: This principle is
concerned with the minimum travel (or movement)
of man and materials. The facilities should be
arranged such that, the total distance travelled by
the men and materials should be minimum and as
far as possible straight line movement should be
preferred.
Principle of safety, security and
satisfaction: A good layout is one that
gives due consideration to workers
safety and satisfaction and safeguards
the plant and machinery against fire,
theft, etc.
Principle of minimum handling: A good
layout is one that reduces the material
handling to the minimum
Principle of cubic space utilization: The good
layout is one that utilizes both horizontal and
vertical space. It is not only enough if only the
floor space is utilized optimally but the third
dimension, i.e., the height is also to be utilized
effectively.
Principle of flow: A good layout is one that
makes the materials to move in forward
direction towards the completion stage, i.e.,
there should not be any backtracking.
Principle of maximum flexibility: The good
layout is one that can be altered without
much cost and time, i.e., future requirements
should be taken into account while designing
the present layout.
Fixed position layoutproject
Product LayoutMass Pro
Process Layoutbatch/jobshop
Cellular Layout??

TYPE OF LAYOUT

http://slideplayer.com/slide/3715352/
 PROJECT
Fixed Position Layout This is also called
the project type of layout. In this type of
layout, the material, or major
components remain in a fixed location
and tools, machinery, men and other
materials are brought to this location.
This type of layout is suitable when one
or a few pieces of identical heavy
products (huge) are to be
manufactured and when the assembly
consists of large number of heavy parts,
the cost of transportation of these parts is
very high and take a long time to
produce.

1. FIXED POSITION LAYOUT

Process layout is recommended for batch
production. All machines performing similar 2. FUNCTIONAL (PROCESS)
type of operations are grouped at one location LAYOUT
in the process layout e.g., all lathes, milling
machines, etc. are grouped in the shop will be
clustered in like groups.
Thus, in process layout the arrangement of
facilities are grouped together according to
their functions. A typical process layout is shown
in the following figure. The flow paths of
material through the facilities from one
functional area to another vary from product to
product. Usually the paths are long and there
will be possibility of backtracking.
Process layout is normally used when the
production volume is not sufficient to justify a
product layout. Typically, job shops employ
process layouts due to the variety of products BATCH
manufactured and their low production
volumes.
 L L M M G G D D

L L M M G G D D

APPLICABLE TO MACHINE SHOP


Product Layout
In this type of layout, machines and
auxiliary services are located
according to the processing sequence
of the product.
Plant arrangement to facilitate material
processing in the same order.
Suitable for mass production system as ,
the facilities can be arranged to
achieve efficient flow of materials and
lower cost per unit.
3 FLOW LINE (PRODUCT LAYOUT)
MASS
• Machines and equipment are
positioned along a flow line.
• Several flow lines may come together
to feed the final assembly line.
• Product passes from workstation to
another workstation along the flow line.
• Special purpose machines are used
which perform the required function
quickly and reliably.
• High level of machine and manpower
utilization
• Need to categorize operations to
ensure equal processing time at all
work stations (line balancing).
When Applicable FLOW LINE (PRODUCT) LAYOUT
The product layout is Product A
selected when the volume L L M D
of production of a product
is high such that a Product B
L M M D
separate production line
to manufacture it can be
justified. In a strict product Product C
L G G D
layout, machines are not
shared by different
products. Therefore, the
production volume must
be sufficient to achieve
satisfactory utilization of
the equipment. A typical
product layout is shown in
the following figure.
Advantages
• Reduced work handling leads to short cycle time/piece.
• Less WIP
• Simple planning and control.
• Reduced labor skill.
• Good space utilization.

Disadvantages
• Limited flexibility
• Machine breakdown causes major problem
• High setting up cost.
• Uses expensive special purpose machine
- Plant divided into groups or cells in a small unit (individual cell), consisting of one to
several workstations.
- A w/station can contains either one machine (known as a single machine cell), or
several machines (known as a group machine cell) with each machine performing a
different operation on the part.
- Cells can process a complete family of parts – need to form families of products.

- The flow among the equipment in the cells can vary depending on the composition of
parts within the part family.
- Good example for the implementation of the concept of group technology.

- The machines at w/stations can be modified, retooled, and regroup for different
product lines within the same family of parts.

Group technology or GT is a manufacturing

technique in which parts having similarities in
geometry, manufacturing process and/or functions
are manufactured in one location using a small
number of machines or processes.
 Relate to quantity
Plant layout & variety of
product
Type of
Nature of manufac Tech
work operation
involved
Classifica Definition
Definition tion
Intro to
Industry Econ
Manufac
classification
Select
People
process
Example involve
Factors
to
consider Roles