Manufacturing Engineering and Technology

Rapid Prototyping
Allows designers to generate parts quickly, directly from 3D models, for mockup and testing.
Discrete Products
Finished and sold as is items, nothing is added (gears/bolts/nuts)
Concurrent Engineering
Also called simultaneous engineering. Cross functional teamwork in new product development
projects that provides product design, quality engineering, and manufacturing process
engineering all at the same time
Manufacturing
The process in which raw material are changed into a finished product
Continuous Products
Can be turned into something else or sold as it is (pvc/wire)
Steps for Finished Product
-Idea
-Prototype
-Testing
-Manufacturing
Careers Involved in Product Development
-Engineering
-Designers
-Marketing
-Machining
First Production of Steel
Asia 600-800 A.D.
Ironmaking's Beginning
Middle East about 1100 B.C.
First Industrial Revolution
-Began in England in the 1750s till 1851.
-Before it, goods were produced and batches and required much reliance on manual labor in all
phases of production.
-Centered around three new developments
-Coal-powered steam engine
-Textile machines
-Blast furnaces to produce iron
Second Industrial Revolution
Began in the mid-1900s with the development of solid-state electronic devices and computers
Mechanization
Began in England and other countries of Europe, basically with the development of textile
machinery and machine tools for cutting metal; Soon moved to U.S. where it continued to be
further developed.
Interchangeable Parts
-Design, production, and usage of them was a major advance in manufacturing
-Early 1800s
-Conceived by American Manufacturer and Inventor
Manufacturing Engineering and Technology

Eli Whitney
-Prior to Interchangeable Parts, no two parts could be made exactly alike (much hand fitting
necessary)
Product Design
-Involves the creative and systematic prescription of the shape and characteristics of an artifact
of achieve specified objectives while simultaneously satisfying several constraints
-80% of the cost of product development and manufacture is determined by decisions made in
the initial stages of design
What is essential for successful product design?
-Innovative approaches
-Clearly specified functions
-Clear statement of performance expected
-Defined market and anticipated use(s)
Sequential Design (Traditional)
-Wasteful of resources and time
-Changes at material specification stage will necessitate a repeat of the Design Analysis Stage
and subsequent stages
Life Cycle
In concurrent engineering, a view toward optimizing all elements involved in the life cycle of
the product. Consists of four stages:
-Product start-up
-Rapid growth of the product in the marketplace
-Product maturity
-Decline
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 disposal of the product
Paperless Design
No prototypes or mock-ups are built and construction and assembly is done directly from
CAD/CAM software
Computer-aided Manufacturing
Involves all phases of manufacturing, by utilizing and processing the large amount of
information on materials and processes gathered and stored in the organization's database
Prototype
Physical model of an individual component or product
Virtual Prototyping
Software-based method that uses advanced graphics and virtual-reality environments to allow
designers to view and examine a part in detail (AKA simulation-based design)
Design for Manufacture (DFM)
Comprehensive approach to integrating the design process with production methods,
materials, process planning, assembly, testing, and quality assurance
DFM requirements
-Fundamental understanding of the characteristics, capabilities, and limitations of materials,
manufacturing processes, machinery, equipment, and tooling
Manufacturing Engineering and Technology

-Variability in machine performance, dimensional accuracy and surface finish of the workpiece,
processing time, and the effect of processing methods on product quality
DFA, DFMA, and DFD
-Design For Assembly
-Design For Manufacture and Assembly
-Design for Disassembly
Assembly
-Important phase of manufacturing and requires a consideration of the ease, speed, and cost of
putting together the numerous individual components of a product
-Assembly costs can be substantial, typically ranging from 20-60% of the total product cost
Design for Service
Design should take into account the concept that, for ease of access, components that are most
likely to be in need of servicing be placed, as much as possible, at the outer layers of the
product.
Discarding
Implies that the products have reached the end of their useful life; does not necessarily mean
that they are wasted and dumped into landfills
Carbon Footprint
Quantifies the amount of greenhouse gases produced in our daily activities
Design For the Environment (DFE)
-Also called environmentally conscious design and manufacturing
-This approach considers all possible adverse environmental impacts of materials, processes,
operations, and products, so they can be all taken into account at the earliest stages of design
and production
Design For Recycling (DFR)
Recycling may involve one of two basic activities:
-Biological cycle
-Industrial cycle
Cradle-to-cradle Production (C2C)
Considers the impact of each stage of a product's life cycle, from the time natural resources are
mined and processed into raw materials, through each stage of manufacturing products, their
use and, finally, recycling
General Types of Materials Used
-Ferrous metals
-Nonferrous metals
-Plastics (polymers)
-Ceramics, glasses, glass ceramics, graphite, diamond, and diamondlike materials
-Composite materials
-Nanomaterials
-Shape-memory alloys, amorphous alloys, semiconductors, and super conductors
Mechanical Properties of Interest in Manufacturing
-Strength, ductility, hardness, roughness, elasticity, fatigue, and creep resistance
Physical Properties of Interest in Manufacturing
Manufacturing Engineering and Technology

-Density, specific heat, thermal expansion and conductivity, melting point, and electrical and
magnetic properties
Chemical Properties of Interest in Manufacturing
-Oxidation, corrosion, degradation, toxicity, and flammability
-Play a significant role under both hostile (such as corrosive) and normal environments
Manufacturing Properties
Indicate whether a particular material can be cast, formed, machined, joined, and heat treated
with relative ease
Appearance
Includes such characteristics as color, surface texture, and feel, all of which can play a
significant role in a product's acceptance by the public.
Availability
The economic aspect of material selection is as important as technological considerations. Thus,
the availability of materials is major concern in manufacturing. Furthermore, if materials are
not available in the desired quantities, shapes, dimensions, and surface texture, substitute
materials or additional processing of a particular material may well be required, all of which can
contribute significantly to product cost
Reliability of Supply
Important in order to meet production schedules and considering the fact that most countries
import numerous raw materials
Geopolitics
The study of the influence of a nation's physical geography on its foreign policy
What factors lead to a shortened service life of a product?
-Improper selection of materials
-Improper selection of production methods
-Insufficient control of processing variables
-Defective parts or manufacturing-induced defects
-Poor maintenance
-Improper use of the product
A product is considered to have failed when it..
-Stops functioning
-Does not function properly or perform to specs
-Becomes unreliable or unsafe for further use
Failure of a product may be a result of..
-Design deficiencies
-Improper material selection
-Incompatibility of materials in contact (friction,corrosion)
-Defects in raw materials
-Defects induced during manufacturing
-Improper component assembly
-Improper product use
Manufacturing Processes
-Casting
-Forming and shaping
Manufacturing Engineering and Technology

-Machining
-Joining
-Finishing
-Microfabrication and nanofabrication
What is the difference between Net-shape and Near-net-shape manufacturing? What is the
benefits?
It is a matter of degree of how close the product is to its final dimensional characteristics. The
benefits from not having to have additional operations performed to arrive at at finished
product.
General types of production, in increasing order of annual quantities produced:
-Job shops (<100)
-Small-batch production (10-100)
-Batch production (100-5000)
-Mass production (generally over 100,000)
Computer-integrated Manufacturing (CIM)
Integrates the software and hardware needed for computer graphics, computer-aided
modeling, and computer aided design and manufacturing activities, from initial product
concept through its production and distribution in the marketplace.
What tasks does CIM make possible?
-Responsiveness to rapid changes in product design modifications and to varying market
demands
-Better use of materials, machinery, and personnel
-Reduction in inventory
-Better control of production and management of the total manufacturing operation
Various elements in CIM
-Computer Numeric Control (CNC)
-Adaptive Control (AC)
-Industrial Robots
-Automated materials handling
-Automated assembly systems
-Computer-Aided Process Planning (CAPP)
-Group Technology (GT)
-Just-In-Time production (JIT)
-Cellular Manufacturing (CM)
-Flexible Manufacturing Systems (FMS)
-Expert Systems (ES)
-Artificial intelligence (AI)
-Artificial Neural Networks (ANN)
Why is product quality one of the most critical aspects of manufacturing?
Because it directly influences customer satisfaction, thus playing a crucial role in determining a
product's success in a global marketplace. Quality must be build into the product from its initial
design through all subsequent stages of manufacture and assembly.
Why is continuous control of processes (online monitoring) a critical factor in maintaining
product quality?
Manufacturing Engineering and Technology

The objective is to control processes not the products. A machine for example may perform
different once it has warmed up, affecting the products it produces.
Quality Assurance and Total Quality Management (TQM)
Widely recognized as being the responsibility of everyone involved in the design and
manufacture of products and their components.
Product integrity is a term generally used to define the degree to which a product:
-Functions reliably during its life expectancy
-Is suitable for its intended purposes
-Can be maintained with relative ease
W.E. Deming, J.M. Juran, and G. Taguchi all emphasized the importance of management's
commitment to..
-Product quality
-Pride of workmanship at all levels of production
-the necessity of using Statistical Process Control (SPC) and control charts
-Importance of online monitoring and rapidly identifying the sources of quality problems in
production, before even another defective part is produced
What is the major goal of process control?
To prevent defective parts from ever being made, rather than to inspect, detect, and reject
defective parts after they have been made.
Standard Deviation
The level of defects are identified by this term. Denoted by the symbol sigma
-six sigma is 3.4 defective per million parts made
Experimental Design
A technique in which the factors involved in a manufacturing process and their interactions are
studied simultaneously. For example, variables affecting dimensional accuracy or surface finish
in a machining operation can be identified readily, making it possible for appropriate preventive
on-time actions to be taken.
Ergonomics
The study of how a workplace and the machinery and equipment in it can best be designed for
comfort, safety, efficiency, and productivity.
Product Liability
Someone who is injured from a product's unsafe or defective condition may recover damages.
Manufactures, sellers and suppliers may be held responsible.
Lean Production
A methodology that involves a thorough assessment of each activity of a company, with the
basic purpose of minimizing waste at all levels and calling for elimination of unnecessary
operations that do not provide any added value to the product being made. Also called lean
manufacturing optimizes the processes used in order to maximize added value.
What does Lean Production focus on?
-Efficiency and effectiveness of each and every manufacturing operation
-Efficiency of the machinery and equipment used
-Activities of the personnel involved in each operation
Agile Manufacturing
Manufacturing Engineering and Technology

The principle behind agile manufacturing is ensuring agility--and hence flexibility--in the
manufacturing enterprise, so that it can respond rapidly and effectively to changes in product
demand and the needs of the customer.
Benchmark
Involves assessing the competitive position of other manufacturers with respect to one's own
position and setting realistic goals for the future. Becomes a reference point from which various
measurements can be made and to which they can be prepared.
World-class Manufacturing
The demand for high quality products in an ever increasing global competition
The total cost of manufacturing a product generally consists of these components:
-Materials
-Tooling
-Fixed
-Capital
-Labor
Direct Labor
Also called productive labor, concerns the labor that is directly involved in manufacturing
products.
Indirect Labor
Pertains to servicing of the total manufacturing operation; It is also called nonproductive labor
or overhead.
Outsourcing
The purchase by a company of parts or labor from an outside source, either from another
company or country, in order to reduce design and manufacturing costs
What are some problems with manufacturing abroad?
-Rising cost of shipping
-Social impact in political implications of any ensuing lower employment, especially in the
European Union countries and the United States

5 Written questions

1. -Involves the creative and systematic prescription of the shape and characteristics of an
artifact of achieve specified objectives while simultaneously satisfying several
constraints
-80% of the cost of product development and manufacture is determined by decisions
made in the initial stages of design

Product Design

2. -Stops functioning
-Does not function properly or perform to specs
-Becomes unreliable or unsafe for further use
Manufacturing Engineering and Technology

A product is considered to have failed when it..

3. The purchase by a company of parts or labor from an outside source, either from
another company or country, in order to reduce design and manufacturing costs

Outsourcing

4. -Design For Assembly

-Design For Manufacture and Assembly
-Design for Disassembly

DFA, DFMA, and DFD

5. The demand for high quality products in an ever increasing global competition

World-class Manufacturing

5 Matching questions

1. What is essential for successful product design?

D. -Innovative approaches
-Clearly specified functions
-Clear statement of performance expected
-Defined market and anticipated use(s)

2. What is the major goal of process control?

E. To prevent defective parts from ever being made, rather than to inspect, detect, and
reject defective parts after they have been made.

3. Cradle-to-cradle Production (C2C)

B. Considers the impact of each stage of a product's life cycle, from the time natural
resources are mined and processed into raw materials, through each stage of
manufacturing products, their use and, finally, recycling

4. What tasks does CIM make possible?

A. -Responsiveness to rapid changes in product design modifications and to varying

market demands
-Better use of materials, machinery, and personnel
Manufacturing Engineering and Technology

-Reduction in inventory
-Better control of production and management of the total manufacturing operation

5. Sequential Design (Traditional)

C. -Wasteful of resources and time

-Changes at material specification stage will necessitate a repeat of the Design Analysis
Stage and subsequent stages

A. -Responsiveness to rapid changes in product design modifications and to varying market

demands
-Better use of materials, machinery, and personnel
-Reduction in inventory
-Better control of production and management of the total manufacturing operation
B. Considers the impact of each stage of a product's life cycle, from the time natural
resources are mined and processed into raw materials, through each stage of
manufacturing products, their use and, finally, recycling
C. -Wasteful of resources and time
-Changes at material specification stage will necessitate a repeat of the Design Analysis
Stage and subsequent stages
D. -Innovative approaches
-Clearly specified functions
-Clear statement of performance expected
-Defined market and anticipated use(s)
E. To prevent defective parts from ever being made, rather than to inspect, detect, and
reject defective parts after they have been made.

5 Multiple choice questions

1. -Idea
-Prototype
-Testing
-Manufacturing

Steps for Finished Product

2. -Fundamental understanding of the characteristics, capabilities, and limitations of

materials, manufacturing processes, machinery, equipment, and tooling
-Variability in machine performance, dimensional accuracy and surface finish of the
workpiece, processing time, and the effect of processing methods on product quality
Manufacturing Engineering and Technology

DFM requirements

3. Began in the mid-1900s with the development of solid-state electronic devices and
computers

Second Industrial Revolution

4. In concurrent engineering, a view toward optimizing all elements involved in the life
cycle of the product. Consists of four stages:
-Product start-up
-Rapid growth of the product in the marketplace
-Product maturity
-Decline

Life Cycle

5. Important in order to meet production schedules and considering the fact that most
countries import numerous raw materials

Reliability of Supply

5 True/False questions

1. The level of defects are identified by this term. Denoted by the symbol sigma
-six sigma is 3.4 defective per million parts made → Ergonomics

False

It should be → Standard Deviation

2. Indicate whether a particular material can be cast, formed, machined, joined, and heat
treated with relative ease → Manufacturing Properties

True

3. Recycling may involve one of two basic activities:

-Biological cycle
-Industrial cycle → Design For Recycling (DFR)

True

4. -Ferrous metals
-Nonferrous metals
Manufacturing Engineering and Technology

-Plastics (polymers)
-Ceramics, glasses, glass ceramics, graphite, diamond, and diamondlike materials
-Composite materials
-Nanomaterials
-Shape-memory alloys, amorphous alloys, semiconductors, and super
conductors → Life-cycle Engineering

False

It should be → General Types of Materials Used

5. -Began in England in the 1750s till 1851.

-Before it, goods were produced and batches and required much reliance on manual
labor in all phases of production.
-Centered around three new developments
-Coal-powered steam engine
-Textile machines
-Blast furnaces to produce iron → First Industrial Revolution

True