Title: Manufacturing Engineering
1Manufacturing Engineering Technology
2Manufacturing
- Comes from Latin manu factus made by hand
- Manufacturing is concerned with making products.
Dates back to 5000-4000 BC
3TABLE 1.1 Approximate Number of Parts in
Products
4TABLE 1.2 Historical Development of Materials,
Tools, and Manufacturing Processes
5TABLE 1.2 (continued) Historical Development of
Materials, Tools, and Manufacturing Processes
6TABLE 1.2 (continued) Historical Development of
Materials, Tools, and Manufacturing Processes
7TABLE 1.2 (continued) Historical Development of
Materials, Tools, and Manufacturing Processes
8TABLE 1.2 (continued) Historical Development of
Materials, Tools, and Manufacturing Processes
9Industrial Revolutions
- (First)Industrial revolution England 1750s.
Prior to this good produced in batches and
required much manual labor in all phases of
production - (Second) Industrial revolution mid-1900s
Solid-state electronic devices and computers - Interchangeable parts- early 1800s- American
manufacturer Eli Whitney
10FIGURE 1.2a Components of a common incandescent
light bulb. Source Courtesy of General Electric
Company.
11FIGURE 1.2b Manufacturing steps in making an
incandescent light bulb. Source Courtesy of
General Electric Company.
12Product Design
- Product Design involves the creative and
systematic prescription of the shape and
characteristics of an artifact to achieve
specified objectives while simultaneously
satisfying several constraints (p.8) - Concurrent Engineering (simultaneous
engineering) from the earliest stages of
product design and engineering, all relevant
disciplines are simultaneously involved.
13FIGURE 1.3 (a) Chart showing various steps
involved in traditional design and manufacture of
a product. Depending on the complexity of the
product and the type of materials used, the time
span between the original concept and the
marketing of the product may range from a few
months to several years. (b) Chart showing
general product flow in concurrent engineering,
from market analysis to marketing the product.
Source After S. Pugh.
14Life Cycle
- Life cycle of a product
- Product start-up
- Rapid growth of the product in the marketplace
- Product maturity
- Decline
15Life Cycle Engineering
- Life cycle engineering requires that the entire
life of a product be considered, beginning with
the design stage and on through production,
distribution, product use, and finally recycling
or the disposal of the product.
16Computers
- CAD
- CAM
- Prototype a physical model of an individual
component or product (Rapid prototyping)
17More about Design
- Design for manufacture is a comprehensive
approach to integrating the design process with
production methods, materials, process planning,
assembly, testing and quality assurance. - Design for service products often have to be
disassembled to varying degrees in order to
service and repair.
18Green Design
- Green design and manufacturing considers all
possible adverse environmental impacts of
materials, processes, operations, and products,
so that they can all be taken into account at the
earliest stages of design and production.
19Selection of Materials
- Ferrous metals carbon, alloy, stainless, steel
- Nonferrous metals aluminum, magnesium, copper,
nickel, titanium - Plastics (polymers) Thermoplastics, thermosets,
elastomers - Composite materials reinforced plastics and
metal-matrix and ceramic-matrix composites - Nanomaterial
- Shape-memory alloys
20TABLE 1.3 General Manufacturing Characteristics
of Various Materials
21FIGURE 1.5 Cross sections of baseball bats made
of aluminum (top two) and composite material
(bottom two).
22FIGURE 1.6a Schematic illustrations of various
casting processes.
23FIGURE 1.6b Schematic illustrations of various
bulk-deformation processes.
24FIGURE 1.6c Schematic illustrations of various
sheet-metal-forming processes.
25FIGURE 1.6d Schematic illustrations of various
polymer-processing methods.
26FIGURE 1.6e Schematic illustrations of various
machining and finishing processes.
27FIGURE 1.6f Schematic illustrations of various
joining processes.
28FIGURE 1.9 A saltshaker and pepper mill set.
The two metal pieces (at the bottom) for the
pepper mill are made by powder-metallurgy
techniques. Source Reproduced with permission
from Success Stories on P/M Parts, Metal Powder
Industries Federation, Princeton, NJ, 1998.
29TABLE 1.4 Average Life Expectancy of Various
Products
30Product Quality
- Product quality (p.29) is one of the most
critical aspects of manufacturing because it
directly influences customer satisfaction. The
traditional approach of inspecting products after
they are made had largely been replaced by the
recognition that quality must be built into the
product from its initial design thought all
subsequent stages of manufacture and assembly.
31?????? (Six Sigma)
- The level of defects is identified in terms of
standard deviation and given the symbol sigma
(Greek letter ? upper case or s lower case) - Six sigma (standard deviations) allows only 3.4
defective parts per million parts made
32TABLE 1.5 Relative Cost of Repair at Various
Stages of Product Development and Sale
33TABLE 1.6 Typical Cost Breakdown in
Manufacturing
34TABLE 1.7 Approximate Relative Hourly
Compensation for Workers in Manufacturing in 2006
(United States 100)