ch01 M.P. Groover

8/9/2019 ch01 M.P. Groover

1/56

INTRODUCTION AND

OVERVIEW OF MANUFACTURING

1. What is Manufacturing?

2. Matria!s in Manufacturing

". Manufacturing #r$csss


2/56

Manufacturing is I%&$rtant

Tchn$!$gica!!'

Ec$n$%ica!!'

(ist$rica!!'


3/56

Manufacturing ) Tchn$!$gica!!' I%&$rtant

Tchn$!$g' ) th a&&!icati$n $f scinc t$ &r$*i+s$cit' an+ its %%,rs -ith th$s things thatar n++ $r +sir+

Tchn$!$g' &r$*i+s th &r$+ucts that h!& $ur

s$cit' an+ its %%,rs !i* ,ttr What +$ ths &r$+ucts ha* in c$%%$n?

Th' ar a!! %anufactur+

Manufacturing is th ssntia! fact$r that

%as tchn$!$g' &$ssi,!


4/56

Manufacturing ) Ec$n$%ica!!' I%&$rtant

Manufacturing is $n

-a' ,' -hich nati$ns

crat %atria! -a!th

U.S. economy:

Sector % ofGNP

Manufacturing 2/0

Agricu!tur %inra!s tc. 0

C$nstructi$n 3 uti!itis 0

4r*ic sct$r 5 rtai!trans&$rtati$n ,aningc$%%unicati$n +ucati$n an+g$*rn%nt

6/0


5/56

Manufacturing ) (ist$rica!!' I%&$rtant

Thr$ugh$ut hist$r' hu%an cu!turs that -r,ttr at %aing things -r %$r

succssfu!

Maing ,ttr t$$!s %ant ,ttr crafts 3

-a&$ns 7ttr crafts a!!$-+ &$&! t$ !i* ,ttr

7ttr -a&$ns a!!$-+ th% t$ c$n8ur

$thr cu!turs in ti%s $f c$nf!ict

T$ a significant +gr th hist$r' $f

ci*i!i9ati$n is th hist$r' $f hu%ans: a,i!it' t$

%a things


6/56

What is Manufacturing?

Th -$r+ manufacture is +ri*+ fr$% t-$ ;atin-$r+s manus


7/56

Manufacturing ) Tchn$!$gica!!'

Figur 1.1


8/56

Manufacturing ) Ec$n$%ica!!'

Figur 1.1


9/56

Manufacturing In+ustris

In+ustr' c$nsists $f ntr&riss an+ $rgani9ati$nsthat &r$+uc $r su&&!' g$$+s an+ sr*ics

In+ustris can , c!assifi+ as

1. #ri%ar' in+ustris ) th$s that cu!ti*at

an+ &!$it natura! rs$urcs .g.far%ing %ining

2. 4c$n+ar' in+ustris ) ta th $ut&uts $f

&ri%ar' in+ustris an+ c$n*rt th% int$

c$nsu%r an+ ca&ita! g$$+s )%anufacturing is th &rinci&a! acti*it'

". Trtiar' in+ustris ) sr*ic sct$r


10/56

Manufacturing In+ustris ) c$ntinu+

4c$n+ar' in+ustris inc!u+ %anufacturingc$nstructi$n an+ !ctric &$-r gnrati$n

Manufacturing inc!u+s s*ra! in+ustris

-h$s &r$+ucts ar n$t c$*r+ in this ,$$>

.g. a&&ar! ,*rags ch%ica!s an+f$$+ &r$cssing

F$r $ur &ur&$ss %anufacturing %ans

&r$+ucti$n $f har+-ar

Nuts an+ ,$!ts f$rgings cars air&!ans+igita! c$%&utrs &!astic &arts an+

cra%ic &r$+ucts


11/56


12/56

#r$+uct Varit' P

#r$+uct *arit' P rfrs t$ +iffrnt &r$+uctt'&s $r %$+!s &r$+uc+ in th &!ant

Diffrnt &r$+ucts ha* +iffrnt faturs

Th' ar intn++ f$r +iffrnt %arts

4$% ha* %$r &arts than $thrs Th nu%,r $f +iffrnt &r$+uct t'&s %a+

ach 'ar in a fact$r' can , c$unt+

Whn th nu%,r $f &r$+uct t'&s %a+ in

th fact$r' is high this in+icats high&r$+uct *arit'


13/56

P *rsus Q in Fact$r' O&rati$ns

Figur 1.2 #) R!ati$nshi&


14/56

M$r A,$ut #r$+uct Varit'

A!th$ugh P is a 8uantitati* &ara%tr it is%uch !ss act than Q ,caus +tai!s $n

h$- %uch th +signs +iffr is n$t ca&tur+

si%&!' ,' th nu%,r $f +iffrnt +signs

Soft product variety ) s%a!! +iffrncs

,t-n &r$+ucts .g. ,t-n car %$+!s

%a+ $n th sa% &r$+ucti$n !in -ith %an'

c$%%$n &arts a%$ng %$+!s

Hard product variety ) &r$+ucts +iffr

su,stantia!!' .g. ,t-n a s%a!! car an+ a!arg truc -ith f- c$%%$n &arts


15/56

Manufacturing Ca&a,i!it'

A %anufacturing &!ant c$nsists $f processes an+systems


16/56

1. Tchn$!$gica! #r$cssing Ca&a,i!it'

Th a*ai!a,! st $f %anufacturing &r$csss inth &!ant


17/56

2. #h'sica! #r$+uct ;i%itati$ns

Gi*n a &!ant -ith a crtain st $f &r$csssthr ar si9 an+ -ight !i%itati$ns $n th

&arts $r &r$+ucts that can , %a+ in th &!ant

#r$+uct si9 an+ -ight affct

#r$+ucti$n 8ui&%nt

Matria! han+!ing 8ui&%nt

#r$+ucti$n %atria! han+!ing 8ui&%nt an+

&!ant si9 %ust , &!ann+ f$r &r$+ucts that !i

-ithin a crtain si9 an+ -ight rang


18/56

". #r$+ucti$n Ca&acit'

Dfin+ as th %ai%u% 8uantit' that a &!antcan &r$+uc in a gi*n ti% &ri$+


19/56

Matria!s in Manufacturing

M$st nginring %atria!s can , c!assifi+int$ $n $f thr ,asic catg$ris

1. Mta!s

2. Cra%ics

". #$!'%rs

Thir ch%istris ar +iffrnt

Thir %chanica! an+ &h'sica! &r$&rtis

ar +issi%i!ar

Ths +iffrncs affct th %anufacturing

&r$csss that can , us+ t$ &r$+uc

&r$+ucts fr$% th%


20/56

In A++iti$n C$%&$sits

Figur 1." Vnn

+iagra% $f thr

,asic %atria! t'&s

&!us c$%&$sits

N$nh$%$gn$us %iturs $f th $thr thr,asic t'&s rathr than a uni8u catg$r'


21/56

1. Mta!s

Usua!!' alloys -hich ar c$%&$s+ $f t-$ $r %$r!%nts at !ast $n $f -hich is %ta!!ic

T-$ ,asic gr$u&s

1. Frr$us %ta!s ) ,as+ $n ir$n c$%&riss

a,$ut 60 $f %ta! t$nnag in th -$r!+ 4t! F C a!!$'


22/56

2. Cra%ics

C$%&$un+s c$ntaining %ta!!ic


23/56

". #$!'%rs

C$%&$un+ f$r%+ $f r&ating structura! unitsca!!+ mers -h$s at$%s shar !ctr$ns t$

f$r% *r' !arg %$!cu!s

Thr catg$ris

1. Thr%$&!astic &$!'%rs ) can , su,ct+t$ %u!ti&! hating an+ c$$!ing c'c!s

-ith$ut a!tring %$!cu!ar structur

2. Thr%$stting &$!'%rs ) %$!cu!s

ch%ica!!' transf$r%


24/56

H. C$%&$sits

Matria! c$nsisting $f t-$ $r %$r &hass thatar &r$css+ s&arat!' an+ thn ,$n++

t$gthr t$ achi* &r$&rtis su&ri$r t$ its

c$nstitunts

Phase ) h$%$gn$us %ass $f %atria!such as grains $f i+ntica! unit c!! structur

in a s$!i+ %ta!

Usua! structur c$nsists $f &artic!s $r fi,rs

$f $n &has %i+ in a sc$n+ &has

#r$&rtis +&n+ $n c$%&$nnts &h'sica!

sha&s $f c$%&$nnts an+ th -a' th' ar

c$%,in+ t$ f$r% th fina! %atria!


25/56

Manufacturing #r$csss

T-$ ,asic t'&s

1. #r$cssing $&rati$ns ) transf$r% a -$r

%atria! fr$% $n stat $f c$%&!ti$n t$ a

%$r a+*anc+ stat

O&rati$ns that chang th g$%tr'&r$&rtis $r a&&aranc $f th starting

%atria!

2. Ass%,!' $&rati$ns ) $in t-$ $r %$r

c$%&$nnts t$ crat a n- ntit'


26/56

Figur 1.H C!assificati$n $f %anufacturing &r$csss


27/56

#r$cssing O&rati$ns

A!trs a %atria!s sha& &h'sica! &r$&rtis$r a&&aranc in $r+r t$ a++ *a!u

Thr catg$ris $f &r$cssing $&rati$ns

1. 4ha&ing $&rati$ns ) a!tr th g$%tr'

$f th starting -$r %atria!2. #r$&rt' nhancing $&rati$ns )‑

i%&r$* &h'sica! &r$&rtis -ith$ut

changing sha&

". 4urfac &r$cssing $&rati$ns ) t$c!an trat c$at $r +&$sit %atria! $n

tri$r surfac $f th -$r


28/56

4ha&ing #r$csss 5 F$ur Catg$ris

1. 4$!i+ificati$n &r$csss ) starting %atria!is a hat+ !i8ui+ $r s%if!ui+

2. #articu!at &r$cssing ) starting %atria!

c$nsists $f &$-+rs

". Df$r%ati$n &r$csss ) starting %atria!is a +ucti! s$!i+


29/56

4$!i+ificati$n #r$csss

4tarting %atria! is hat+ sufficint!' t$transf$r% it int$ a !i8ui+ $r high!' &!astic stat

Ea%&!s %ta! casting &!astic %$!+ing


30/56

#articu!at #r$cssing

4tarting %atria!s ar &$-+rs $f %ta!s $rcra%ics

Usua!!' in*$!*s &rssing an+ sintring in

-hich &$-+rs ar first c$%&rss+ an+ thn

hat+ t$ ,$n+ th in+i*i+ua! &artic!s


31/56

Df$r%ati$n #r$csss

4tarting -$r&art is sha&+ ,' a&&!icati$n $ff$rcs that c+ th 'i!+ strngth $f th

%atria!

Ea%&!s


32/56

Matria! R%$*a! #r$csss

Ecss %atria! r%$*+ fr$% th starting &ics$ -hat r%ains is th +sir+ g$%tr'

Ea%&!s %achining such as turning +ri!!ing

an+ %i!!ing> a!s$ grin+ing an+ n$ntra+iti$na!

&r$csss


33/56

Wast in 4ha&ing #r$csss

Dsira,! t$ %ini%i9 -ast in &art sha&ing Matria! r%$*a! &r$csss ar -astfu! in

unit $&rati$ns si%&!' ,' th -a' th' -$r

M$st casting %$!+ing an+ &articu!at

&r$cssing $&rati$ns -ast !itt! %atria! Tr%in$!$g' f$r %ini%u% -ast &r$csss

Net shape &r$csss ) -hn %$st $f th

starting %atria! is us+ an+ n$

su,s8unt %achining is r8uir+ Near net shape &r$csss ) -hn

%ini%u% a%$unt $f %achining is r8uir+


34/56

#r$&rt' Enhancing #r$csss‑

#rf$r%+ t$ i%&r$* %chanica! $r &h'sica!&r$&rtis $f -$r %atria!

#art sha& is n$t a!tr+ c&t

unintnti$na!!'

Ea%&! unintnti$na! -ar&ing $f a hattrat+ &art

Ea%&!s

(at trat%nt $f %ta!s an+ g!asss

4intring $f &$-+r+ %ta!s an+ cra%ics


35/56

4urfac #r$cssing O&rati$ns

C!aning ) ch%ica! an+ %chanica!&r$csss t$ r%$* +irt $i! an+ $thr

c$nta%inants fr$% th surfac

4urfac trat%nts ) %chanica! -$ring

such as san+ ,!asting an+ &h'sica!&r$csss !i +iffusi$n

C$ating an+ thin fi!% +&$siti$n ) c$ating

tri$r surfac $f th -$r&art


36/56

Ass%,!' O&rati$ns

T-$ $r %$r s&arat &arts ar $in+ t$ f$r% an- ntit'

T'&s $f ass%,!' $&rati$ns

1. J$ining &r$csss 5 crat a &r%annt

$int W!+ing ,ra9ing s$!+ring an+

a+hsi* ,$n+ing

2. Mchanica! ass%,!' 5 fastning ,'

%chanica! %th$+s Thra++ fastnrs &rss fitting &ansi$n fits


37/56

#r$+ucti$n 4'st%s

#$&! 8ui&%nt an+ &r$c+urs us+ f$r thc$%,inati$n $f %atria!s an+ &r$csss that

c$nstitut a fir%:s %anufacturing $&rati$ns

A %anufacturing fir% %ust ha* s'st%s an+

&r$c+urs t$ fficint!' acc$%&!ish its t'&$f &r$+ucti$n

T-$ catg$ris $f &r$+ucti$n s'st%s

#r$+ucti$n faci!itis

Manufacturing su&&$rt s'st%s

7$th catg$ris inc!u+ &$&!


38/56


39/56

Faci!itis *rsus #r$+uct uantitis

A c$%&an' +signs its %anufacturing s'st%s

an+ $rgani9s its fact$ris t$ sr* th

&articu!ar %issi$n $f ach &!ant

Crtain t'&s $f &r$+ucti$n faci!itis ar

rc$gni9+ as th %$st a&&r$&riat f$r a

gi*n t'& $f %anufacturing

1. ;$- &r$+ucti$n 5 1 t$ 1//

2. M+iu% &r$+ucti$n 5 1// t$ 1////

". (igh &r$+ucti$n 5 1//// t$ L1//////

Diffrnt faci!itis ar r8uir+ f$r ach $f th

thr 8uantit' rangs


40/56

;$- #r$+ucti$n

Job shop is th tr% us+ f$r this t'& $f&r$+ucti$n faci!it'

A $, sh$& %as !$- 8uantitis $f

s&cia!i9+ an+ cust$%i9+ &r$+ucts

#r$+ucts ar t'&ica!!' c$%&! .g.s&ac ca&su!s &r$t$t'& aircraft s&cia!

%achinr'

E8ui&%nt in a $, sh$& is gnra! &ur&$s

;a,$r f$rc is high!' si!!+ Dsign+ f$r %ai%u% f!i,i!it'


41/56

M+iu% #r$+ucti$n

T-$ +iffrnt t'&s $f faci!it' +&n+ing $n&r$+uct *arit'

Batch production

4uit+ t$ har+ &r$+uct *arit'

4tu&s r8uir+ ,t-n ,atchs

Cellular manufacturing

4uit+ t$ s$ft &r$+uct *arit'

W$rr c!!s $rgani9+ t$ &r$css &arts-ith$ut stu&s ,t-n +iffrnt &art st'!s


42/56

(igh #r$+ucti$n

Oftn rfrr+ t$ as mass production (igh +%an+ f$r &r$+uct

Manufacturing s'st% ++icat+ t$ th

&r$+ucti$n $f that &r$+uct

T-$ catg$ris $f %ass &r$+ucti$n

1. uantit' &r$+ucti$n

2. F!$- !in &r$+ucti$n


43/56

uantit' #r$+ucti$n

Mass &r$+ucti$n $f sing! &arts $n sing!%achin $r s%a!! nu%,rs $f %achins

T'&ica!!' in*$!*s stan+ar+ %achins 8ui&&+

-ith s&cia! t$$!ing

E8ui&%nt is ++icat+ fu!!)ti% t$ th&r$+ucti$n $f $n &art $r &r$+uct t'&

T'&ica! !a'$uts us+ in 8uantit' &r$+ucti$n ar

&r$css !a'$ut an+ c!!u!ar !a'$ut


44/56

F!$- ;in #r$+ucti$n

Mu!ti&! %achins $r -$rstati$ns arrang+ ins8unc .g. &r$+ucti$n !ins

#r$+uct is c$%&!

R8uirs %u!ti&! &r$cssing an+B$r

ass%,!' $&rati$ns W$r units ar &h'sica!!' %$*+ thr$ugh th

s8unc t$ c$%&!t th &r$+uct

W$rstati$ns an+ 8ui&%nt ar +sign+

s&cifica!!' f$r th &r$+uct t$ %ai%i9fficinc'


45/56


46/56

O*r*i- $f Ma$r T$&ics

Figur 1.1/ O*r*i- $f &r$+ucti$n s'st% an+ %a$rt$&ics in Fundamentals of Modern Manufacturing .

A t ! i t ! i i h i f , i


47/56

A s&ctacu!ar scn in st!%aing is charging $f a ,asic $'gn

furnac in -hich %$!tn &ig ir$n &r$+uc+ in a ,!ast furnac is

&$ur+ int$ th 7OF. T%&raturs ar ar$un+ 1/C


48/56

A %achining c!! c$nsisting $f t-$ h$ri9$nta! %achining cntrs

su&&!i+ ,' an in)!in &a!!t shutt!


49/56

A r$,$tic ar% &rf$r%s

un!$a+ing an+ !$a+ing

$&rati$n in a turning

cntr using a +ua! gri&&r


50/56

Mta! chi&s f!' in a high

s&+ turning $&rati$n

&rf$r%+ $n a c$%&utr

nu%rica! c$ntr$! turningcntr


51/56

#h$t$%icr$gra&h $f th cr$ss scti$n $f %u!ti&! c$atings $f

titaniu% nitri+ an+ a!u%inu% $i+ $n a c%nt+ car,i+

su,strat


52/56

A ,atch $f si!ic$n -afrs ntrs a furnac hat+ t$ 1/// C


53/56

T-$ -!+rs &rf$r% arc

-!+ing $n a !arg st!

&i& scti$n


54/56

Aut$%at+ +is&nsing $f

a+hsi* $nt$ c$%&$nnt

&arts &ri$r t$ ass%,!'


55/56

Ass%,!' -$rrs $n an

ngin ass%,!' !in


56/56

Ass%,!' $&rati$ns

$n th 7$ing 666

ch01 M.P. Groover

Documents

Transcript of ch01 M.P. Groover