MFG 1

Dr. HABEEB ALANI Office: BN-Block, Level-3, BNLevelRoomRoom-088 Email: hbuni61@yahoo.com Ext. No.
: 7292
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
University TENAGA National
College Of Engineering Mechanical Department Academic Year 2009-2010 2009Lecture Note

Introduction To Manufacturing and Manufacturing Systems

Japanese sword reworked for hard and soft metal parts

Space Shuttle
The Transistor
Everyday products
Manufacturing derived from:
Manufacturing (derived from Latin)
= manus (hand) + factus (made) = made
by hand
University TENAGA Nasional
Lecturer: Dr. HABEEB ALANI
Definition of Manufacturing:
Manufacturing is an industrial activity

that converts raw materials to useful products by the means of machines.
Development of Manufacturing depends on:

1
Materials Machine-Tools Computer-aided Design (CAD)& Computer-aided mfg (CAM). Robotics
Electronics
1-1
Evolution of the Enterprise
Evolution Steps:
1 2 3 4 5
Hand Tool Animals Water Power Steam Engines Electrical Motors

The MFG System:
INPUT
PROCESS
OUTPUT
INPUT
Energy HR Education R&D
Customer Demand Material Money
PROCESS
Design Production
Management
OUTPUT
Consumer Goods Capital Goods Quality Cost Effectiveness
INPUT
Money
- Working Capital
(Money for employee)
-Fixed Capital buildings)
(For machine tools and
INPUT Energy
- Electricity To run the machines
- Compressed air To run the pneumatic systems and clean machines and products - Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.)
To use it in Furness, welding operations and boilers.

- Gas
PROCESS
Design
- Creating plans for new products
-Lowering the product cost at maintained high quality
PROCESS Production
- Designated at the design stage - Machine tools types - Machining processes - People are selected at the design stage
OUTPUT Products
Goods
- Consumers goods: People use them (Food, Cars, .) - Capital goods: Products used to make other consumer goods (Machine tools, Plant, .)
1-2
The Classification of basic Manufacturing
Mass production
a
Moderate
b
Job-lot
c
Mass Production Features:
- Goods are produced at a high volume for considerable period of time ( >100.000 parts per year).
- Machine are not flexible (They are not able to produce other types of products). - Products of this type of mfg are the cheapest.
Moderate production Features:
- Variable products (depends on the sale order and the market demand) (2,500-100,000 parts per year). - Multipurpose machine tools and CNC machine tools are usually used in this type of mfg. - Product Ex.: Tools, Moulds, Radio transmitters.
Job-lot production Features:
- The plant does not any specific type of products but it is able to produce any type of product that the market is in need of. - Products move in lots between mfg processes (10-500 parts per lot). - Machine are more flexible and universal. - Product Ex: Airplanes, Automobile parts, and Plastic products .
Organization for Manufacturing

-A plant needs an affective organizing method for manufacturing in order to manage its resources /
1 4
Employees Materials
2 5
Money
Power
Machines .
*A good mfg strategy is needed. See table 1.1 (Evolution of strategy mfg sys..
Concurrent Engineering CE
-It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes simultaneously. CE is not an engineering discipline. - CE Objective: Optimizing the use of company resources and reducing time to market cycle.
General CE phases for a new project:

Ph.-1
Technology and concept development:
Definition of customer requirement implementation. of primary alternatives
b Assessment
processes.
c
Development of required resources.

Preparation of product plan.
Ph.-2
and Process Development and Prototype validation -CE Function:

This is the phase in which the CE team will
a
Product
Product improvement for assembly and mfg Development the mfg and assembly processes Establish baseline process technology
Establish program goals and risk-reduction plans freezing
c d
Ph.-2
Cont
Note:
Generally other project elements are addressed I this phase Ph.-2 , such as financial business plans, product concept demonstration, freezing of engineering content, and final project approval.
Ph.-3
Process Validation and Product Design Confirmation :

This is the execution phase where
a
The Production process and methods are finalized Simulation and pilot runs are conducted to test critical steps Machine and equipment are validated for production readiness, quality and performance
Ph.-4
Production and continuous improvement :
- This face is the Acceleration of production floor into Full rated capacity. This means: Attaining high product quality at the lowest costs.
1-3
Design, Material and Production
-According to the existing machine tools and the

designed product we choose the raw materials. On the other hands, according to the existing materials and required quality we choose the machine tools.
- Efficiency of production :
- In order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive.
Cont.. Efficiency of production
- The quality and accuracy must be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable).
- Economical production is determined by:

A functional simple design that has appropriate quality (no more or less).
1 2
A material choice that represents the best compromise among physical properties, cost, and machinability.
The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost.
3
Engineering Materials Materials

Metallic Non-Metallic
Ferrous Non-Ferrous
Organic Non- Organic
Materials Application Chain

Processing Structure Properties Performance Selection Field Application
* SELECTION is the Critical Step for Technologists.
Mechanical Properties
Stress & Strain

Dislocations &
Deformation Elasticity & Plasticity

Elastic Constants
Tests

Mechanical Testing Mechanical Properties Strengthening Mechanisms Failure Analysis

Electrical Properties
Electrical Properties

Resistivity & Conductivity Electronic-Band Structure Semiconductivity Refraction & Reflection Transmission
The Evolution of Materials
Classes of Materials
Basic Metals Ceramics Polymers Advanced
University TENAGA Composites Nasional
Semiconductors Lecturer: HABEEB ALANI
Biomaterials
Metals
Materials that are normally combinations of "metallic elements". Metals usually are good conductors of heat and electricity. Metals are quite strong but malleable and tend to have a lustrous look when polished
Ceramics

Ceramics are generally compounds between Metallic and NONmetallic elements and include such compounds as: -Oxides -Nitrides -Carbides
Ceramic materials developed for gas turbine rotors are used in aircraft and diesel engine parts.
Typically they are insulating and resistant to high temperatures and harsh environments. University TENAGA
Nasional Lecturer: HABEEB ALANI
Plastics

Plastics (or polymers) are generally compounds based upon carbon and hydrogen (Organic Compounds). They are very large molecular structures. Usually they are low density and are not stable at high temperatures.
Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, highcontrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for the backlight required in display technologies such as liquid crystal displays (LCDs). University TENAGA Nasional Lecturer: Dr. HABEEB ALANI
Semiconductors

SEMIconductors have electrical properties intermediate between Metallic conductors and Ceramic insulators. Also, the electrical properties are strongly dependent upon small amounts of Impurities.
Composites
Composites consist of more than one material type. Fiberglass, a combination of glass and a polymer, is an example. Concrete and plywood are other familiar composites. Many new combinations include ceramic fibers in a metal or polymer matrix.
Composites
Composites
Ghost airplane
Hand bag
Graphite Matrix Composite Shaft

Golf Clubs
Liquid Metal FacePlate
BioMaterials

Materials compatible with an organism (e.g. Humans) that can be used to make implants, prostheses, and surgical instruments.

Designed not to provoke rejection by our bodies (skin, blood, bone, etc.), they can be natural (collagen, cellulose, etc.) or synthetic (metallic, alloy, ceramic, plastic, and others). Dental crowns and contact-lenses use biomaterials.
Data Organization of Materials

Kingdom Family Class Member Attributes
Density
Ceramics Polymers
Steels Cu-alloys Al-alloys Ti-alloys Ni-alloys Zn-alloys
Materials
Metals Natural Foams Composites
1000 2000 3000 4000 5000 6000 7000 8000
Mechanical props. Thermal props. Electrical props. Optical props. Corrosion props. Supporting information -- specific -- general
Unstructured information Structured information
A material record or properties

Metallography: to see microstructures
metal
mount
Steel (Fe-C) Nickel Alloy 242

Materials Information for Design

The goal of design:
To create products that perform their function effectively, safely, at acceptable cost What do we need to know about materials to do this? More than just test data.
Data capture Stat/Math analysis
Mec anical Properties
ulus r ssi tr t uctilit l stic i it ur c i it r ctur T ughness H r ness ss efficient ulus f Rupture Poisson's Ratio hear Modulus Tensile trength Young's Modulus Bulk . 6. . 950 0. 0. 5 45 .5 .
Selection of material and process
Economic analysis and business case
Test
Test data
Design data
C aracterization
# # ' & # #
.6 G 6 . .6 .
/
# ( (% " %# $ " ! # " !
. 6 55 MPa 0. 0.95 GPa 48 MPa .8 GPa
$
Potential applications Successful applications
Selection and implementation
Next Lecture: Nature And Properties of Materials

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Dr. HABEEB ALANI Office: BN-Block, Level-3, BNLevelRoomRoom-088 Email: hbuni61@yahoo.com Ext. No.

University TENAGA National

College Of Engineering Mechanical Department Academic Year 2009-2010 2009Lecture Note

Introduction To Manufacturing and Manufacturing Systems

Japanese sword reworked for hard and soft metal parts

Manufacturing derived from:

Manufacturing (derived from Latin)

= manus (hand) + factus (made) = made

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

Manufacturing is an industrial activity

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

Development of Manufacturing depends on:

Materials Machine-Tools Computer-aided Design (CAD)& Computer-aided mfg (CAM). Robotics

University TENAGA Nasional

Evolution of the Enterprise

Hand Tool Animals Water Power Steam Engines Electrical Motors

The MFG System:

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

Customer Demand Material Money

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

Consumer Goods Capital Goods Quality Cost Effectiveness

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

(Money for employee)

-Fixed Capital buildings)

(For machine tools and

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

To use it in Furness, welding operations and boilers.

- Creating plans for new products

-Lowering the product cost at maintained high quality

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

The Classification of basic Manufacturing

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

Mass Production Features:

Moderate production Features:

Job-lot production Features:

Organization for Manufacturing

General CE phases for a new project:

Technology and concept development:

Definition of customer requirement implementation. of primary alternatives

Development of required resources.

University TENAGA Nasional

and Process Development and Prototype validation -CE Function:

University TENAGA Nasional

Process Validation and Product Design Confirmation :

University TENAGA Nasional

Production and continuous improvement :

University TENAGA Nasional

Lecturer: Dr. HABEEB ALANI

Design, Material and Production

-According to the existing machine tools and the

Lecturer: Dr. HABEEB ALANI

Cont.. Efficiency of production

Stress & Strain

Deformation Elasticity & Plasticity

# ( (% " %# $ " ! # " !