Part I

OVERVIEW OF MANUFACTURING
Chapters:
2. Manufacturing Operations
3. Manufacturing Models and Metrics

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Ch 2 Manufacturing Operations
Sections:
1. Manufacturing Industries and Products
2. Manufacturing Operations
3. Production Facilities
4. Product/Production Relationships
5. Lean Production

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Manufacturing Defined Technological Definition

Application of physical and chemical processes to
alter the geometry, properties, and/or appearance of
a given starting material to make parts or products
Manufacturing also includes the joining of multiple
parts to make assembled products
Accomplished by a combination of machinery, tools,
power, and manual labor.
Almost always carried out as a sequence of
operations

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Manufacturing Defined Technological Definition

Fig. 2.1.a

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Manufacturing Defined Economic Definition

Transformation of materials into items of greater value
by means of one or more processing and/or assembly
operations
Manufacturing adds value to the material
Examples:
Converting iron ore to steel adds value
Transforming sand into glass adds value
Refining petroleum into plastic adds value

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Manufacturing Defined Economic Definition

Fig. 2.1.b

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Classification of Industries
1. Primary industries cultivate and exploit natural
resources
Examples: agriculture, mining
2. Secondary industries convert output of primary
industries into products
Examples: manufacturing, power generation,
construction
3. Tertiary industries service sector
Examples: banking, education, government, legal
services, retail trade, transportation
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Manufacturing Industries

ISIC Code
Food, beverages, tobacco
31
Textiles, apparel, leather and fur products
32
Wood and wood products, cork
33
Paper, printing, publishing, bookbinding
34
Chemicals, coal, petroleum and their products 35
Ceramics, glass, mineral products
36
Basic metals, e.g., steel, aluminum
37
Fabricated products, e.g., cars, machines, etc. 38
Other products, e.g., jewelry, toys
39

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More Industry Classifications

Process industries, e.g., chemicals, petroleum, basic
metals, foods and beverages, power generation
Continuous production
Batch production
Discrete product (and part) industries, e.g., cars, aircraft,
appliances, machinery, and their component parts
Continuous production
Batch production

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Process Industries and

Discrete Manufacturing Industries

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Manufactured Products
Consumer goods: products purchased directly by
consumers
Ex: cars, personal computers, Tvs, toys...
Capital goods: products purchased by other companies to
produce goods and supply services
Ex: commercial aircraft, mainframe computers, machine
tools, construction machinery...

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Manufacturing Operations

There are certain basic activities that must be carried out

in a factory to convert raw materials into finished products
For discrete products:
1. Processing and assembly operations
2. Material handling
3. Inspection and testing
4. Coordination and control
A processing operation transforms a work material from one state of
completion to a more advanced state using energy to alter its shape,
properties or appearance to add value to the material.

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Fig. 2.3

Classification of
manufacturing
processes

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Processing Operations
A processing operation transforms a work material from
one state of completion to a more advanced state
that is closer to the final desired part or product.
Adds value to the material using energy to alter a work
parts shape, physical properties or appearance.

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Processing Operations

Shaping operations apply mechanical force and/or heat or

other forms and combinations of energy to change the
geometry of the work material. Classification is based on
the state of the starting material.

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Processing Operations

Shaping operations
1. Solidification processes
Casting (metal)
Molding (plastic/glass)
2. Particulate processing pressing then sintering powder
material (ceramics)
3. Deformation processes forging/extrusion/rolling
Starting material is ductile metal
4. Material removal processes turning/drilling/milling/grinding

Starting material is solid

Excess material is removed so that resulting product
has the desired geometry

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Processing Operations
Property-enhancing operations are designed to
improve mechanical or physical properties of the
work material
heat treatments (sintering)
Surface processing operations
Cleaning (remove contaminants)
Surface treatments mechanical work
Coating and thin-film deposition coating of
material to exterior surface

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Assembly Operations
Joining processes
Welding
Brazing and soldering
Adhesive bonding
Mechanical assembly
Threaded fasteners (e.g., bolts and nuts, screws)
Rivets
Interference fits (e.g., press fitting, shrink fits)
Other
An assembly operation joins two or more components to create
a new entity which is called an assembly, subassembly, etc.

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Other Factory Operations

Material handling and storage
Inspection and testing
Coordination and control

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Material Handling
A means of moving and storing materials between processing
and/or assembly operations
Material transport
Vehicles, e.g., forklift trucks, AGVs, monorails
Conveyors
Hoists and cranes
Storage systems
Unitizing equipment
Automatic identification and data capture (AIDC)
Bar codes
RFID
Other AIDC equipment
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Time Spent in Material Handling

Fig. 2.4 A typical part in a batch production machine shop

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Inspection and Testing

Inspection examination of the product and its
components to determine whether they conform to
design specifications
Inspection for variables - measuring
Inspection of attributes gaging
Testing observing the product (or part, material,
subassembly) during actual operation or under
conditions that might occur during operation

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Coordination and Control

Regulation of the individual processing and assembly
operations
Process control
Quality control
Management of plant level activities
Production planning and control
Quality control

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Production Facilities
A manufacturing company attempts to organize its
facilities in the most efficient way to serve the particular
mission of the plant
Certain types of plants are recognized as the most
appropriate way to organize for a given type of
manufacturing
The most appropriate type depends on:
Types of products made
Production quantity
Product variety
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Production Quantity

Number of units of a given part or product produced

annually by the plant
Three quantity ranges:
1. Low production 1 to 100 units
2. Medium production 100 to 10,000 units
3. High production 10,000 to millions of units

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Product Variety
Refers to the number of different product or part
designs or types produced in the plant
Inverse relationship between production quantity and
product variety in factory operations
Product variety is more complicated than a number
Hard product variety products differ greatly
Few common components in an assembly
Soft product variety small differences between
products
Many common components in an assembly
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Product Variety vs.

Production Quantity
Manufacturing plants tend to specialize in a combination of
production quantity and product variety that lies
somewhere inside the diagonal band in the figure.

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Low Production Quantity

Job shop makes low quantities of specialized and
customized products
Also includes production of components for these
products
Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
Equipment is general purpose

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Low Production Quantity

Plant layouts:
Fixed position: The product remains in a single location
during its entire fabrication and workers/equipment are
brought to the product rather than moving the product.
Ex: ships, aircraft, heavy machinery
Process layout: The equipment is arranged according
to function or type.
Different parts, each requiring a different operation
sequence, are routed through the departments in the
particular order needed for their processing, usually in
batches.
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Fixed-Position Layout
Fig. 2.6 (a)

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Process Layout
Fig. 2.6 (b)

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Medium Production Quantities

1. Batch production A batch of a given product is
produced, and then the facility is changed over to
produce another product
Changeover takes time setup time
Typical layout process layout
Hard product variety
2. Cellular manufacturing A mixture of products is made
without significant changeover time between products
Typical layout cellular layout
Soft product variety
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Cellular Layout
Fig. 2.6 (c)

Each cell is designed to produce a limited variety of part

configurations; that is, the cell specializes in the production
of a given set of similar parts or products (group technology).
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High Production (mass production)

1. Quantity production Equipment is dedicated to the
manufacture of one product
Standard machines tooled for high production (e.g.,
stamping presses, molding machines)
Typical layout process layout
2. Flow line production Multiple workstations arranged in
sequence and parts or assemblies are physically moved
through the sequence to complete the product
Product requires multiple processing or assembly
steps
Product layout is most common
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Product Layout
Fig. 2.6 (d)

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Relationships between Plant Layout

and Type of Production Facility
Fig. 2.7

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Product/Production Relationships
Parameters that influence to determine how the products
are manufactured:
1.Production quantity
2.Product variety number of products
3.Product complexity (of assembled products) number
of parts
4.Part complexity number of operations

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Product/Production Relationships
P

Total number of product units = Qf =

Q j
j 1

Qj: annual quantity of style j

Qf: total quantity of all parts/products made in the factory
P: total number of different part or product styles

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Product/Production Relationships
Let
P1: number of distinct product lines produced-hard variety
P2: number of models in a product line-soft variety
P1

P P2 j P21 P22 ... P2 P1

j 1

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Product/Production Relationships
Product variety
Hard product variety = differences between
products
Soft product variety = differences between models
of products
Product and part complexity
Product complexity np = number of parts in product
Part complexity no = number of operations per part

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Product and Part Complexity

npj: number of parts in product j
npf: total number of parts manufactured by the plant per
year (pc/yr)
P

n pf Q j n pj
j 1

nof: total number of operation cycles performed (ops/yr)

nojk: number of processing operations for each part k for
all parts of product j
P

n pj

j 1

k 1

nof Q j n pj nojk
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Factory Operations Model

Simplified for purposes of conceptualization:
Total number of product units Qf = PQ
Total number of parts produced npf = PQnp
Total number of operations nof = PQnpno

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Production Plants
no>1

Parts producer: makes individual Vertically integrated plant: makes all

components, each component
its parts and assembles them into its
requires multiple processing
final products.
steps, no assembly.

no=1

Handicraft shop: not really a

Assembly plant: produces no parts,
production plant, makes one part purchases all parts from suppliers, one
per year.
operation is required to assemble each
part to the product.
np=1

np>1

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Limitations and Capabilities of a

Manufacturing Plant

Manufacturing capability - the technical and physical

limitations of a manufacturing firm and each of its plants
Three dimensions of manufacturing capability:
1. Technological processing capability - the available set
of manufacturing processes
2. Physical size and weight of product
3. Production capacity (plant capacity) max production
quantity that can be made in a given time under
assumed operating conditions

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Lean Production
Operating the factory with the minimum possible
resources and yet maximizing the amount of work
accomplished
Resources include workers, equipment, time, space,
materials
Also implies completing products in the minimum possible
time and achieving a very high quality level to completely
satisfy the customer
In short, lean production means doing more with less, and
doing it better
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Lean Production and

Manufacturing Activities
Manufacturing activities can be divided into three categories:
1. Value-adding activities - contribute real value to the work
unit. Ex: processing/assembly operation
2. Auxiliary activities - support the value-adding activities but
do not contribute value to the product. Ex: loading/
unloading machines
3. Wasteful activities - do not add value nor do they support
the value adding activities
If not performed, there would be no adverse effect on
the product ELIMINATE !
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Programs Associated with

Lean Production
Just-in-time delivery of parts: refers to the manner in which
parts are moved through the production system when a
sequence of manufacturing operations is required to make
them.
Worker involvement: Workers with greater responsibility
and training that allow them to be flexible.
Continuous improvement: Search for ways to make
improvements in products and manufacturing operation
(Kaizen)
Reduced setup times: Minimize the time needed to change
over from one setup to the next in batch production
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Programs Associated with

Lean Production
Stop the process when something is wrong
Error prevention: Refers to the use of low-cost devices and
design features at each workstation that prevent errors
occuring.
Total productive maintenance: A program that includes
preventive maintenance and other procedures to avoid
machine breakdowns that disrupt production operations.

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