Module No.

1: INTRODUCTION
Lecture No-2 Facts Trends and Challenges in Manufacturing Some Facts about Manufacturing The proof of the following dates and products is available in literature related to manufacturing 5000-4000 BC Manufacturing started during 5000 4000 BC (Wood work, ceramics, stones, metal works, earth wares) 2500 BC Sculptures produced by lost wax casting, jewelry Production, earth wares, glass beads 600-800 AD 800-1200 AD 1750 AD Steel production Sand casting of cast iron Machine tools run by the power of steam engine, resulting in growth of production and abundant availability of goods 1920-1940 Automation, mass production, interchangeable parts, diecasting and lost wax methods for engineering parts 1940-1960 Computers development, Ceramic mold, nodular iron, semiconductors, continuous castings 1960-1990 NC, CNC machines, group technology, robotics and control, CAD / CAM, adaptive controls etc, squeeze casting, single crystal turbine blades, vacuum casting, organically bonded sand, compacted graphite, automation of molding and pouring, large aluminum castings for aircraft structures for rapid solidification technology, advanced manufacturing processes (advanced, casting, joining, machining, finishing processes) 1990-date Hybrid processes, micro-machining processes, nano materials, hard machining, lean manufacturing, agile manufacturing, etc

Manufacturing Trends

In 1960s, the success of a manufacturing company depended on cost In 1980s, the success of a manufacturing company depended on quality Present day, the success of manufacturing company depends on cost, quality and lead time (lead time is time between placing the order and receiving it, alternatively, it is also known as time to market)

Manufacturing Challenges The emerging economies, the social and political transitions taking place and the new ways of doing business are changing the world dramatically. It is visualized through these trends that manufacturing environment of the future would be extremely competitive and significantly different from what it is today. In-order to remain successful in such an environment, the manufacturers needs to be updated with the latest trends and should possess dynamic capabilities, which need to be distinctly different. The main challenge for the future entrepreneurs is the attainment of such capabilities, some of which are as discussed below: The ability to innovate ideas and to develop a creative environment for such innovations in manufacturing Development of effective and efficient training and education programs for the manufacturing workforce, as more skilled workforce is required The use and implementation of information technology in various areas of the manufacturing industries and their sub-functions Sustainability of small and medium scale enterprises to provide support to the large scale manufacturing organizations Focusing on clean and green manufacturing technologies, the environment and the society issues. The responsibility for the production process thus goes hand-in-hand

with responsibility for the final disposal of products i.e. recycling in line with environmental policies.

Need of Advance Manufacturing Technology

Manufacturing is the basis for all economic activities and future growth of a country At the beginning of 20th century, mass production using efficient machine tools emerged in USA (Ford motors) After the second world war, new / advanced manufacturing processes came into existence Since 1950s, new technologies have been emerged computerized numerical control, flexible manufacturing systems, lean manufacturing, green manufacturing, computer integrated manufacturing are some of those.

Newer materials have been developed and their processing requires special machine tools or special manufacturing process Therefore, there is a vital need to have more efforts to continuously advance manufacturing technology for a better-off and more stable future