Faculty of Mechanical Engineering, University Technology MARA

Content

Faculty of Mechanical Engineering, University Technology MARA

Introduction
Manufacturing
Defined as the conversion process of raw materials(input) into
products(output) which conform to design specification, or the
transformation of materials and information into goods for the
satisfaction of human needs.
The science of planning, designing and managing people and machinery to
produce usable products_SME
The making of goods or wares by manual labour or machinery, especially on a
large scale_Webster Dictionary
The creation and integration of informational and physical processes to create
economic wealth through the production of artifacts_NSF, USA

Faculty of Mechanical Engineering, University Technology MARA

History of Manufacturing
Evidences of manufacturing activities :
Before the middle ages
Bricks to build the Mesopotamian city of Uruk
Clay pots to store grain in ancient Greece
Bronze weapons used during Roman Empire
In the middle ages
Silk factories operated in Syria and textile mills were established
in Europe (Italy, Belgium, France and England)
Factories were built to produce gunpowder, clothing, cast iron and
paper
Using machines powered by water together with simple tools
Faculty of Mechanical Engineering, University Technology MARA

History of Manufacturing
Evolution of manufacturing:
In the Middle Ages
Manufacture was an individual activity practiced by artisans and apprentices
Power was in the form of water and wind power

First Industrial Revolution (1750 A.D.)

Power produced using steam
Introduction of mechanized machinery

Second Industrial Revolution (1900 A.D.)

Mechanized machines powered by electric

Third Industrial Revolution (1970 A.D)

Electronic circuitry was introduced
Invention of transistor which gave rise of computers

Faculty of Mechanical Engineering, University Technology MARA

Future Technologies
Today
Recycling of components, e.g. ;
In automotive industry, excess steel and aluminum can become
scrap stock for new metal
Rubber tires can be chopped and mixed with asphalt for new
roadways
Engine starters can be remanufactured and sold again
Producing of new material, e.g. ;
Composite material combination of material designed with
superior physical and mechanical properties.
Faculty of Mechanical Engineering, University Technology MARA

Contd.
Environmental control, e.g. ;
Smoke scrubbers to remove dangerous gases and particulate from
plant dischargers.
Develop methods of eliminating or reusing dump chemical
products.
Advanced manufacturing technology, e.g. ;
Using sophisticated robotic tools and handling system such as in
automobile and semiconductor industries.
adaptation of computer control system in controlling the
manufacturing operation.
Towards full automation or unmanned factory by combining and
integrating CAD, CAM, CNC, TQM, MIS, MRP etc.
Faculty of Mechanical Engineering, University Technology MARA

Manufacturing Processes
Manufacturing process is the manufacturing activities that are used to
make products. Many manufacturing processes
are used to
manufacture, transform or produce parts and shapes.
Casting
Refers to a metal forming process that delivers a liquid molten
metal into die or mould.

Forming and shaping

Metal forming processes in which the shape of workpieces such as
sheets, rods or tubes is changed to a desired configuration.
Examples are rolling, forging, extrusion etc.

Rapid prototyping
Refers to a solid free-form manufacturing processes
The process of producing a physical prototype directly from CAD
3D surface or solid modeling

Faculty of Mechanical Engineering, University Technology MARA

Contd.
Joining processes
A process of joining or assembling two or more materials or
parts together.
Examples are welding, brazing, soldering, diffusion bonding,
adhesive bonding and mechanical joining.

Machining
Refers to a broad term used to describe removal of material
from a workpiece, in which the size or surface properties of a
part or workpiece are changed.
Examples are cutting, turning, boring, drilling, milling etc.

Finishing operations
An operation used for final finishing of part, to remove any
remaining stock and creates the desired surface finish.
Examples are honing, lapping, polishing, burnishing, deburring
etc.

Faculty of Mechanical Engineering, University Technology MARA

Classification of Manufacturing
Casting processes

Shaping processes

Forming processes
Particulate processes
Material removal processes

Adhesive joining processes

Assembly processes

Welding processes
Brazing & soldering
Mechanical fastening

Manufacturing
Processes

Cleaning & surface treatment

Finishing processes

Coating & deposition

processes
Misc processes

Misc. processes

Property enhancing (heat

treatment processes,
surfaces, treatment), QC etc.

Faculty of Mechanical Engineering, University Technology MARA

Traditional Metalworking Processes

Metal Working
Processes

Hot Working
Processes

Cold Working
Processes

Extrusion

Sheetmetal working

Forging

Drawing etc.

Rolling etc.

Faculty of Mechanical Engineering, University Technology MARA

Material and Processes

Melt
Billet
Bar

Starting
Materials

Section
Plate
Sheet
Strip
Particulate
Materials

Solidification

Bulk
Deformation

Sheet
Forming

Particulate
Processing

Faculty of Mechanical Engineering, University Technology MARA

Groups of Manufacturing Techniques

Manufacturing
Techniques

Original forming

Forming

Machining

Joining

Casting

Forging

Turning

Fastening

Drilling

Welding

Milling

Soldering, brazing

Grinding

Gluing etc.

Powder technology
Plastic Technology etc.

Extrusion
Rolling
Sheetmetal working etc.

EDM/USM etc.

Faculty of Mechanical Engineering, University Technology MARA

Classification of Manufacturing(SIC)

1. Food & Beverages

2. Textile
3. Wood production
4. Petroleum and coal production
5. Plastic and rubber product
6. Computer and electronic product etc.

Faculty of Mechanical Engineering, University Technology MARA

Summary
Almost all products used by people are dependent on manufacturing.
The constant improvements to/and efficient use of the manufacturing
tools affect the standard of living of any nation and the quality of life of
the people. Only with manufacturing tools we be able to enjoy such
pleasures as the automobiles, aeroplanes, televisions, home appliances
and many more items on which we rely upon in our daily life.

Faculty of Mechanical Engineering, University Technology MARA

16

Faculty of Mechanical Engineering,

University Technology MARA
December 24, 2013

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Role of Manufacturing
in Nation's Economy
Refer to Video TOYOTA

Faculty of Mechanical Engineering, University Technology MARA

Faculty of Mechanical Engineering, University Technology MARA

In competitiveness market :
Manufacturing company survives if they produce high quality
product at low cost, at the right time, place and quantity to
the market.
Thus, the harmonization, interaction and integration of many
elements, i.e. design, material selection, manufacturing
processes etc. must be emphasized from the very beginning.

Faculty of Mechanical Engineering, University Technology MARA

Goal of Manufacturing
Manufacturing Goal

Product
High Quality

Lower Cost

At the right time, place and

quantity

To achieve
Product design

Material selection

Manufacturing process
selection

Main challenges
Selecting the best
material

Selecting the best

processes

To minimize the cost

Improve the quality

& productivity

Faculty of Mechanical Engineering, University Technology MARA

Manufacturing Costs
Total cost of a product consists of :
Material cost cost of raw materials
Tooling cost cost of making the tools, i.e. die, mold, pattern, jigs
and fixtures ex: cost for die casting is higher than sand casting
Fixed cost e.g. electric power fuel, rent, insurance etc.
Direct labour cost labour cost from initial stage(raw material) to
end product
Indirect labour cost involves activities such as repair,
maintenance, quality, control, research etc.
Capital cost investment in building, land, machinery, tooling and
equipments

Faculty of Mechanical Engineering, University Technology MARA

Breakdown of cost

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Costs Reduction
Material cost
Substitution of materials
Identify and use least expensive material

Production quantity
Large production quantity requires high production rate
Reduces the cost per piece

Product design
Simplifying part design and the number of subassemblies
Applying design for Y (manufacture, assembly, disassembly, service)
Reducing the amount of material (high strength to weight ratio)

Faculty of Mechanical Engineering, University Technology MARA

Contd
Dimensional tolerance and surface finish
Closer dimensional tolerance and better surface finish
Use high quality machinery and costly finishing operations

Machines and equipment

Reduce the labour cost by using automated and computer
controlled machinery
Improve product quality

Methods of manufacturing
Use alternative methods such as software
Optimizing manufacturing process

Faculty of Mechanical Engineering, University Technology MARA

Major factors in process selection

Properties of the workpiece material
Working temperature (room or elevated temperature, etc.)
Material properties (ductility, hardness, etc.)
Manufacturing characteristics (machinability, castability, etc.)
Geometric features
Part, shape, size, thickness, dimensional tolerances, surface
finish requirements etc.
Part produced at or near final shape
Eliminate secondary process and hence reduce manufacturing
cost
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Contd
Option of other possible methods
Cost of raw material
e.g. per unit weight of square bar is more expensive
than round bar
Quantity and rate of production
e.g. machining is for few parts and extrusion for large
quantity

Faculty of Mechanical Engineering, University Technology MARA

Awareness of Value Analysis

Value analysis
System that evaluates each step in design,
material, processes and operations applied to the
product according to its intended functions or
performance at the lowest cost.
Benefits
Cost reduction
Reduced lead times
Better product quality and performance
Faculty of Mechanical Engineering, University Technology MARA

Value Analysis Phases

Information phase
To gather data and determine costs

Analysis phase
To define function and identify problem areas as well as opportunities

Creative phase
To seek ideas to respond to problem areas as well as opportunities

Evaluation phase
To select ideas to be developed and to identify cost involved
Faculty of Mechanical Engineering, University Technology MARA

Value Analysis Phases

Implementation phase
To present facts, cost and values to the company
To develop a plan
To motivate positive action
Review phase
The overall value analysis process is reviewed and
necessary adjustments are made.

Faculty of Mechanical Engineering, University Technology MARA

Trends of Manufacturing
Relocate the company

To take advantage of low labour cost

Become lean production and make better product

Redesign
manufacturing systems Cheaper, faster, flexible

Increase product
variation
Towards better quality
and reliability

Provide optional for customers

Towards zero defects and continuous

improvement

Faculty of Mechanical Engineering, University Technology MARA

Contd
Reduce time to
market
Value added activity

Apply concurrent engineering efforts

Bring product design and manufacturing closer to
customer
Conversion of materials into products
Using the least amount of time, material, money, space
and labour.

Faculty of Mechanical Engineering, University Technology MARA

32

Faculty of Mechanical Engineering,

University Technology MARA
December 24, 2013

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