Types of manufacturing

processes
M a n u fac tu ring
P ro ce sses

D e fo rm a tio n

E x tru s io n
F o rg ing
R o llin g
B a r d ra w in g
W ire d raw in g

C a sting

C e n trif u g a l
D ie ca s ting
In v e stm e nt
P e r m a n e n t m o ld
S a n d c a stin g

Sheet
M e tal

B e n d in g
B la n k in g
D raw in g
P u n c h in g
S h e a rin g
S p in n in g

P o ly m er
P ro cesses

B lo w m o ld in g
C a s tin g
C o m p r e s s io n m o l d i n g
E x tru s io n
I n j e c ti o n M o l d i n g
T h e rm o fo rm ing
T ra n sfe r m o ld in g

M a c h in in g

B o rin g
D r i l li n g
F a c in g
G rin d ing
M i ll i n g
P la n in g
T u rn in g
S a w ing
ECM ,EDM

F in ish in g

A n o d iz ing
H o n in g
P a in tin g
P la tin g
P o lish in g

A s s e m b ly

A u tom a ted
B o n d in g
B ra z in g
M an u al
R iv e tin g
S o ld e rin g
W e ld ing

Selecting manufacturing
processes
Manufacturing process decisions
Deformation processes
Casting processes
Sheet metalworking
Polymer processing
Machining
Finishing
Assembly
Material compatibilities / Process capabilities
Material costs, Tooling costs, Processing costs

Parts undergo sequence of

processes
Primary - alter the (raw) materials basic shape or form.
Sand casting
Rolling
Forging
Sheet metalworking
Secondary - add or remove geometric features from the basic
forms
Machining of a brake drum casting (flat surfaces)
Drilling/punching of refrigerator housings (sheet metal)
Trimming of injection molded part flash
Tertiary - surface treatments
Polishing
Painting
Heat-treating
Joining

Material cost
Materials constitute high proportion of
the total cost.
Material cost includes both direct and
indirect material costs
To determine material cost, return
available from scrap is also
considered.

 Procedure to estimate material cost

Breakup the product in to simple parts so that their
volumes can be easily calculated.
Neglect rounded corners and small fillets and take
suitable approximation wherever necessary.
Calculate volume of each part
Add volumes of parts to give volume of complete
product.
Calculate weight of material by multiplying the
volume by its density.

Manufacturing process
decisions
How do we choose
the specific manufacturing
processes?
How do the selected materials influence the
choice of manufacturing processes?
Would product function or performance issues
influence our choice of processes?
What criteria should we use to select processes?
Which criteria are more important?
Who will make the final decisions?

Manufacturing functions
More conventional manufacturing is
divided in to the following functions:
Process engineering.
Tool engineering.
Work standards.
Plant engineering.
Administration and control.

Process engineering is the development of step by

step

sequence

of operation for production. Vital

parameters in process engineering are the rate of

production and the related tooling.
Tool engineering is

concerned with the design of

tools, jigs, fixtures and gauges to produce the part.

Tools do the machining and forming, gauges determine
weather the dimensions are within specification.

Work standards are

with time values

associated with each manufacturing operation

that are used to determine standard costs to
make the part.
Plant

engineering

plant

engineering

is

concerned with providing the manufacturing

facilities(space, utilities, transportation, storage,
etc) needed to carryout manufacturing process.

 Administration

and

control

deals

with production, planning, scheduling

and supervising to assure that materials
,

machines,

tools

and

people

are

available at the right time and in the

quantities needed to produce the part.

Types of manufacturing
systems

There are four types of manufacturing systems

Job shop.
Batch flow.
Assembly.
Continuous flow.
The job shop is characterized by small batches
of a large number of different parts. There is
no regular work flow, so work in process must
often wait in a queue for its turn on machine.

Batch flow is used when the product design is

relatively stable and produced in periodic
batches.
Ex. Production of heavy equipment or ready-towear clothing.
With the assembly line production, the
equipment is laid out in the sequence of
usage .
The large number of assembly tasks is divided
into small subsets
to be performed at
successive work stations.
Ex. Production of automobiles or power hand
tools.

 A continues-flow processes the most

specialized

type.

The

equipment

is

highly specialized, laid out in a circuit

and usually automated. The material
flows continuously from input to output.
Ex. Gasoline refinery or a paper mill.