Manufacturing Process
minimize cost while meeting product performance
Transformed various raw materials into parts
and assembled to make product
Sequence of operation & processes designed to
converting raw materials into parts or products.
Steps for Manufacturing Process:
The design of the product,
Selection of raw materials, and
Sequence of processes.
The Design of the Product
As a designer, understand the limitations available:
Tolerances
Production rates
Economic issues
Design Issue
Designer must consider:
What processes are available/relevant for the
product?
What tolerances can be achieved, and are these
sufficient?
Are there any design features that need to be
incorporated (e.g. webbing, round edges, etc.)?
Can the expected production rate be met?
How will the product be assembled?
Design Steps
(a) Chart showing various steps involved in designing
and manufacturing a product. Depending on the
complexity of the product and the type of materials
used, the time span between the original concept and
the marketing of a product may range from a few
months to many years.
(b) Chart showing general product flow, from market
analysis to selling the product, & depicting concurrent
engineering.
Manufacturing Materials
All manufactured products are made from some
sort of material.
The properties of the material of the final
manufactured product are of utmost
importance.
Microscopic structure of material is often
changed through different manufacturing
processes.
Factors in Selection of Material:
Material selection is a step in the process of designing
any manufactured good. In the context of product
design, the main goal of material selection is to
goals.
Functional properties
Manufacturing properties
Economics
Determine the Properties & Behaviour of a Material
Structure
Composition
Performance or properties to cost ratio
Synthesis and processing
Composition of Material
The material composition of product is defined as the
quantity of a material used in the production.
Properties of Materials
Mechanical properties:
- Strength, toughness, ductility, hardness, elasticity,
fatigue, and creep
Physical properties:
- Density, thermal expansion, conductivity, specific heat,
melting point, and electrical and magnetic properties
Chemical properties:
- Oxidation/corrosion, toxicity, & flammability
Manufacturing properties:
- castability, formability, machinability, weldability, and
hardenability by heat treatment.
Mechanical Properties
Strength - opposes the deformation or
breakdown of material in presence of external
forces or load.
Toughness - It is the ability of material to absorb
the energy and gets plastically deformed
without fracturing.
Hardness - It is the ability of material to resist to
permanent shape change due to external stress.
(i.e. scratch, dent, bounce when dropped a
certain height)
Ductility - material which indicates that how
easily a materials gets deformed under tensile
stress.
Fatigue - is the weakening of material caused by
the repeated loading of material. When a
material is subjected to cyclic loading greater
than certain threshold value but much below
the strength of material (ultimate tensile
 strength limit or yield stress limit, microscopic
cracks begin to form.
Creep - is the property of material which
indicates the tendency of material to move
slowly and deform permanently under the
influence of external mechanical stress.
Elasticity - maximum load that can be absorbed
without permanent deformation.
Physical Properties of Materials:
Physical Properties that define the behaviour of
materials in response to physical forces other
than mechanical.
Strength may also be important, and the two
properties are often related in a strength-to-
weight ratio, which is tensile strength divided by
density
Thermal expansion is the name for this effect of
temperature on density.
Thermal conduction involves the transfer of
thermal energy within a material from molecule
to molecule by purely thermal motions
Chemical Properties of Materials
Chemical properties of materials are the way
that material react and change with other
substances or material.
Oxidation/Corrosion - takes place by gaining
oxygen, losing hydrogen, or losing electrons,
that resulted to rust.
Toxicity basically damage organism
Flammability refer to easily something will
burn or ignite.
Manufacturing Systems
Manufacturing plant consists of process and
system to covert material to final product.
To operate effectively, a manufacturing firm
must have systems that allow it to efficiently
accomplish its type of production.
Manufacturing Systems
A method of organizing production or
procedure.
A collection of integrated equipment and
human resources, whose function is to perform
one or more processing and/or assembly
operation on starting raw materials, part, or set
of parts.
Components:
Equipment:
Production machines & tools.
Material handling & work positioning devices.
Computer system
Human resources - are required either full-time or
periodically to keep the system running. (workers &
management systems)
Manufacturing System Designs:
Production systems can be divided into two categories:
(1) Production facilities
(2) Manufacturing support systems,
Production facilities refer to the physical
equipment and the arrangement of equipment
in the factory.
Facilities also include the way the equipment is
arranged in the factory called, - the plant layout.
Manufacturing support system - are the
procedures used by the company to manage
production and solve the technical and logistics
problems encountered in ordering materials,
moving work through the factory, and ensuring
that products meet quality standard.
Manufacturing System Designs
Types of Production Facility/System: (Low quantity
Production)
Job shop Product cannot be easily moved
during production. Production processes are
brought to the product, & make low quantities
of specialized customized products. (1-100
unit/year). This layout is referred to as a fixed-
position layout or project shop.
Process layout is noted for its flexibility; it can
accommodate a great variety of operation
sequence for different part configuration. The
parts requiring a different operation sequence,
routed through the department in the particular
order for their processing, usually in batch
production. Equipment is arranged in a process
layout.
Cellular layout the processing or assembly of
different parts or products is accomplished in
cells consisting of several workstation or
machines.
Product layout the workstations are arranged
into one long line, or into a series of connected
line segments. The work is moved between
stations by mechanized conveyor, i.e. cars &
household appliances.
Continuous Process facility; Large plants.
Manufacture of oils, gases, petrochemical, etc.
Function of Manufacturing Support System:
To design the processes and equipment, plan
and control the production orders, and satisfy
product quality requirements.
 These support systems do not directly contact Factors that define & distinguish Manufacturing System:
the product, but they plan & control its progress
through the factory. Types of operations performed
Manufacturing engineering for planning the Number of workstation
manufacturing processes, designing & ordering System layout
the machine tools & other equipment. Automation & manning level
Production planning & control ordering Part or product variety
material , logistics, scheduling production.
Quality control producing high quality Casting
products.
Sand casting
Production Machines Die casting (Hot/Cold chamber Die)
Centrifugal casting
All modern manufacturing systems the actual Others; investment/permanent casting
processing or assembly work is accomplished by
machines or with the aid of tools. Forming

Classification of Production Machines: Forging

Extrusion
Manually operated controlled by a operator Rolling
Semi-automated - a portion of the work cycle is Electromagnetic forming
form by program control, & the rest of the cycle Others
by operator.
Fully automated - machine operate with no Joining
human attention
Welding (Electric or Gas)
Material Handling System Brazing
Soldering
Manufacturing system that process or assemble Bolting
discrete parts &product, the material handling functions Riveting
are:
Material Removal or Machining
Loading work units at each station
Positioning work units at each station Drilling
Unloading work units at each station Turning
Transporting work units between stations in Milling
multi station systems Grinding
Temporary storage of work units
Drilling Process
Work Transport Between Stations
Drilling is done by forcing a rotating drill into stationary
Fixed routing work units always flow through job as on a drilling machine or by forcing stationary drill
the same sequence of workstations. in a rotating work piece as on a lathe.
Variable routing work units are moved
Turning Process
through a variety of different station sequences.
In turning, a work piece is rotated about its axis as
Computer Control System
single-point cutting tools are fed into it, shearing away
Computer function in a manufacturing system: unwanted material and creating the desired part.

Communicate instructions to workers (receive Milling Process

processing or assembly instructions for the
Milling is the machining process of using rotary cutters
specific work unit)
to remove material from a work piece by advancing or
Download part program to computer-controlled
feeding in a direction at an angle with the axis of the
machines
tool.
Control material handling system
Schedule production Grinding Process
Failure diagnosis
Safety monitoring Manufacturing process of grinding is used to better the
Quality control quality of the surface of the material. Normally is used
Operation management (manage overall as a finishing process in the end of the manufacture.
operations)
Surface Finishing Process - to achieve perfectly flat
surfaces.
Lapping
Honing
Superfinishing

Lapping Process
Lapping is a machining process in which two
surfaces are rubbed together with an abrasive
between them, by hand movement or using a
machine.
Lapping is a machining process used to achieve
super-flat surfaces and incredibly tight
tolerances on parts that require accuracy at the
microscopic level.
Honing Process

Honing is a finishing process used to improve

the geometry of a part, readjust the alignment
of features such as holes or bores, and produce
a finer surface finish.
Superfinishing Process
Superfinishing is used to refine the surface
finish of a component to produce a very fine
surface with an exceptionally low roughness
average (RA).

Powder Processing
Material in fine powder form (particle size
generally ranging from 50 to 500 m though
sometimes as small as 1 m for some specialist
applications) is pressed into the required shape
and then heated to bond the particles together
by inter-diffusion to form components, which
generally require very little further processing.
Powder processing normally involves cold
compaction followed by a high temperature
sintering stage, in which heat is applied with or
without pressure.