PPT MFG Chapter40 Final

Manufacturing Engineering Technology in SI Units, 6th Edition
Chapter 40: Product Design and Process Selection in a Competitive Environment

Copyright 2010 Pearson Education South Asia Pte Ltd
Chapter Outline
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Introduction Product Design Product Quality and Life Expectancy Life-cycle Assessment and Sustainable Manufacturing Material Selection for Products Material Substitution Manufacturing Process Capabilities Process Selection Manufacturing Costs and Cost Reduction
Introduction
Selection of materials for products requires much experience, but several databases and expert systems are now available There are numerous opportunities for the substitution of materials for improved performance and cost savings Capabilities of manufacturing processes are an essential guide to the selection processes Life-cycle assessment and life-cycle engineering of products need to be done
Product Design
Guidelines for the selection of materials and manufacturing processes is shown
Product Design
Product Design Considerations Designers must check and verify the following considerations: 1. Alternative designs 2. Design be simplified 3. Smaller and lighter 4. Features eliminated or combined 5. Specified dimensional tolerances and surface finish 6. Time consumed to assemble 7. Use of fasteners minimized 8. Environmental considerations 9. Design activities to be outsourced
Product Design: Product Design and Quantity of Materials
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Cost of materials is a portion of the total cost Reductions can be made in the quantity of the materials used Reductions can be achieved by reducing: Components volume Using materials with higher strength-to-weight or stiffness-to-weight ratios
Product Design: Product Design and Quantity of Materials

EXAMPLE 40.1
An Application of Design for Manufacturing and Assembly
There is a need to redesign instrument panel for a military helicopter Reduce the number of parts in the panel and the time required for its fabrication and assembly Using DFMA software, the number of parts, the panel weight, fabrication time, assembly time and total production time are the main considerations
Product Quality and Life Expectancy
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Product quality and the techniques involved in quality assurance and control High-quality product is considered when it: Satisfies the needs and expectations Has a pleasing appearance and handles well Has a high reliability and functions safely Is compatible and responsive Performs improvements easily
Product Quality and Life Expectancy: Return on Quality
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The understanding of return on quality involves: Quality must be viewed as an investment Improvement in quality cost need to investigate Certain limit on how much should be spent All changes to be made must be evaluated ROQ is minimized and aiming to zero defects
Life-cycle Assessment and Sustainable Manufacturing
Life-cycle assessment (LCA) is defined as a systematic set of procedures for compiling and examining the inputs and outputs
Life-cycle Engineering (LCE) Aim of LCE is to reuse and recycle the components of a product Also called green design or green engineering Can be challenging, time consuming and costly

CASE STUDY 40.1
Automobile Tires: From Cradle-to-grave to Cradle-to-cradle
Traditional model of manufacturing a tire and taking into account its use and disposal It is a classic example of cradle-to-grave production The product life cycle for tires is being transformed by PermaLife products into a cradleto-cradle model

Sustainable Manufacturing Concept of sustainable manufacturing emphasizes the need for conserving resources, through proper maintenance and reuse It is meant to meet: 1. Increasing the life cycle of products 2. Eliminating harm to the environment and ecosystem 3. Ensuring our collective well-being

EXAMPLE 40.2
Sustainable Manufacturing in the Production of Nike Athletic Shoes
Athletic shoes are assembled with the use of adhesives It was found that mixed rubber had better abrasion resistance and durability Its overall performance was higher than the best premium rubber
Material Selection for Products

General Properties of Materials Mechanical properties: strength, toughness, ductility, stiffness, hardness, and resistance to fatigue, creep and impact Physical properties: density, melting point, specific heat, thermal and electrical conductivity, thermal expansion and magnetic properties Chemical properties: susceptibility to oxidation, corrosion and surface-treatment processes

Shapes of Commercially Available Materials We would need to determine the shapes and the sizes and materials availability

Manufacturing Characteristics of Materials Manufacturing characteristics of materials: castability, workability, formability, machinability, weldability and hardenability by heat treatment Quality of the raw material can greatly influence its manufacturing properties

Reliability of Material Supplies Factors that influence the reliability of material supplies: shortages, strikes, geopolitical factors, and the reluctance of suppliers to produce materials in a particular shape or quality

Recycling Considerations Guidelines to facilitate the process during the life cycle of a product are: 1. Reduce the number of parts and types of materials in products 2. Reduce the variety of product models 3. Use a modular design to facilitate disassembly 4. Use single types of polymers 5. Mark plastic parts for ease of identification 6. Avoid using coatings, paints, and plating 7. Avoid using adhesives, rivets, and other permanent joining methods

Recycling Cost of Materials and Processing Unit cost of a raw material depends only on the material and its shape, size and condition Powder metals are more expensive than bulk metals Cost of materials decreases as the quantity purchased increases Cost of a material is subject to fluctuations caused by supply and demand or complexity

Scrap Value of the scrap is deducted from the materials cost in order to obtain the net material cost Value of the scrap depends on the type of metal and on the demand for it

EXAMPLE 40.3 Effect of Workpiece Hardness on Cost in Drilling Blanks were drilled with a standard helix drill In order to improve machinability and reduce galling, the hardness of the gear blanks was increased to range from 217 to 241 HB by heating them to 840C and then quenching them in oil
Material Substitution
1. 2. 3. 4. 5.
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Majority of the design and manufacturing activities are concerned with improving existing products Reasons for substituting materials are: Reduce the costs of materials and processing Improve manufacturing, assembly, and installation Improve the performance of the product Increase stiffness-to-weight and strength-to-weight ratios Reduce the need for maintenance and repair Reduce vulnerability to the unreliability of the supply of materials Improve compliance with legislation and regulations
Substitution of Materials in the Automobile Industry Automobile industry is a major consumer of both metallic and nonmetallic materials Constant competition among suppliers, particularly in steel, aluminum, and plastics Efforts in investigating the advantages and limitations of principal materials
Substitution of Materials in the Aircraft and Aerospace Industries
Advanced materials are used in the Lockheed C-5A transport aircraft
EXAMPLE 40.4 Material Substitution in Common Products Available products can be made by either set of materials: 1. Metal vs. wooden baseball bat 2. Metal vs. reinforced-plastic or wood handle for a hammer 3. Plastic vs. metal intake manifold 4. Cast-iron vs. aluminium lawn chair 5. Plastic vs. sheet-metal light-switch plate
EXAMPLE 40.5
Material Changes between C-5A and C-5B Military Cargo Aircraft
Table shows the changes made in materials for components of the two aircraft listed and the reasons for the changes
Manufacturing Process Capabilities
Process capability is the ability of a manufacturing process to produce defect-free parts within limits of precision
There are also capabilities for processes to meet stringent dimensional tolerance and surface-finish requirements

Dimensional Tolerances and Surface Finish The dimensional tolerances and surface finish produced are important in assembly operations and proper operation of machines and instruments Closer tolerances and better surface finish can be achieved by additional finishing operations but higher cost

Production Rate Production rate is defined as the number of pieces to be produced per unit of time Production rate can be increased by using multiple equipment and highly automated machines Lead Time Defined as the length of time between the receipt of an order for a product and its delivery time

Lead Time Lead time can be critical in a competitive marketplace and under adverse conditions Machining centers, flexible manufacturing cells, and flexible manufacturing systems are able to response to product changes and production quantities

Robustness of Manufacturing Processes and Machinery
Robustness was described as characterizing a design, a process, or a system within acceptable parameters To obtain or sustain good product quality, it is necessary to understand the effects of each element of noise in the operation
Process Selection
Process selection is intimately related to the characteristics of the materials to be processed
Process Selection
Characteristics and Properties of the Workpiece Materials
Materials manufacturing characteristics include castability, forgeability, workability, machinability, and weldability Materials have different responses to the rate of deformation The speed of machine can affect product quality, development of external and internal defects
Process Selection
Geometric Features of the Part Part shape, size, and thickness, dimensional tolerances, and surface-finish requirements greatly influence the selection of a process or processes Production Rate and Quantity Requirements dictate process selection by way of the productivity of a process, machine, or system
Process Selection
Process Selection Considerations Some factors are: 1. Parts commercially available as standard items? 2. Components of the product have to be manufactured in the plant? 3. Group technology be implemented? 4. Alternative manufacturing processes? 5. Methods selected economical for the type of material?
Process Selection
EXAMPLE 40.6 Process Substitution in Making Common Products Some process selection for the products: Forged vs. cast crankshaft Forged vs. powder-metallurgy connecting rod Sheet metal vs. cast hubcap Machining vs. precision forming of a large gear Forging vs. powder-metallurgy production of a spur gear
Process Selection
EXAMPLE 40.7 Process Selection in Making a Simple Part Various methods of making a simple part: 1. Casting or powder metallurgy 2. Forging or upsetting 3. Extrusion 4. Machining 5. Joining two pieces
Process Selection
EXAMPLE 40.8
Manufacturing a Sheet-metal Part by Different Methods
Two methods of making a dish-shaped sheetmetal part: (a) pressworking (b) explosive forming
Manufacturing Costs and Cost Reduction
The total cost of a product consists of material costs, tooling costs, fixed costs, variable costs, direct-labor costs, and indirect-labor costs Depending on the particular company and the type of products made, different methods of cost accounting may be used Costing systems are also called cost justification Costs are also attributed directly to product liability

Materials Costs Costs depend on the type of material, processing history, size, shape, and surface characteristics Tooling Costs Costs are involved in making the tools, dies, molds, patterns, and special jigs and fixtures required for manufacturing a product Greatly influenced by the production process selected

Fixed Costs These costs include electric power, fuel, taxes on real estate, rent, insurance, and capital Capital Costs Represent machinery, tooling, equipment, and investment in buildings and land

Direct-labor Costs Costs for labor that is directly involved in manufacturing products Time required for producing a part depends on its size, shape, dimensional accuracy and surface finish Labor costs in manufacturing and assembly vary greatly from country to country Manufacturers consider moving production to countries with a lower labor rate known as outsourcing

Indirect-labor Costs Consist of costs for supervision, maintenance, quality control, repair, engineering, research, and sales and cost of office staff Manufacturing Costs and Production Quantity Large production require the use of mass-production special machinery (dedicated machinery) Small-batch production involves general-purpose machines

Cost Reduction Cost reduction use relative costs as a parameter Some products require complex and expensive production steps to process Design phase has the largest influence on the quality and success of a product in the marketplace Costbenefit analysis requires reliable input data, technical and human factors
Manufacturing Costs and Cost Reduction: Value Analysis
Manufacturing adds value to materials as they become discrete products and are marketed Value analysis is a system that evaluates each step in design, material and process selection, and operations Value of a product is defined as Consists of 6 phases: Information phase, Analysis phase, Creativity phase, Evaluation phase, Implementation phase and Review phase

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Manufacturing Engineering Technology in SI Units, 6th Edition

Chapter 40: Product Design and Process Selection in a Competitive Environment

Guidelines for the selection of materials and manufacturing processes is shown

Copyright 2010 Pearson Education South Asia Pte Ltd

Product Design: Product Design and Quantity of Materials

Copyright 2010 Pearson Education South Asia Pte Ltd

Product Design: Product Design and Quantity of Materials

Product Quality and Life Expectancy

Product Quality and Life Expectancy: Return on Quality

Copyright 2010 Pearson Education South Asia Pte Ltd

Life-cycle Assessment and Sustainable Manufacturing

Life-cycle Assessment and Sustainable Manufacturing

Life-cycle Assessment and Sustainable Manufacturing

Copyright 2010 Pearson Education South Asia Pte Ltd

Life-cycle Assessment and Sustainable Manufacturing

Copyright 2010 Pearson Education South Asia Pte Ltd

Material Selection for Products

Material Selection for Products

Copyright 2010 Pearson Education South Asia Pte Ltd

Material Selection for Products

Copyright 2010 Pearson Education South Asia Pte Ltd

Material Selection for Products

Copyright 2010 Pearson Education South Asia Pte Ltd

Material Selection for Products

Material Selection for Products

Copyright 2010 Pearson Education South Asia Pte Ltd

Material Selection for Products

Copyright 2010 Pearson Education South Asia Pte Ltd

Material Selection for Products

Copyright 2010 Pearson Education South Asia Pte Ltd

Copyright 2010 Pearson Education South Asia Pte Ltd

Advanced materials are used in the Lockheed C-5A transport aircraft

Copyright 2010 Pearson Education South Asia Pte Ltd

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Process Capabilities

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Process Capabilities

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Process Capabilities

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Process Capabilities

Manufacturing Process Capabilities

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Process Capabilities

Copyright 2010 Pearson Education South Asia Pte Ltd

Process selection is intimately related to the characteristics of the materials to be processed

Copyright 2010 Pearson Education South Asia Pte Ltd

Copyright 2010 Pearson Education South Asia Pte Ltd

Copyright 2010 Pearson Education South Asia Pte Ltd

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Costs and Cost Reduction

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Costs and Cost Reduction

Manufacturing Costs and Cost Reduction

Manufacturing Costs and Cost Reduction

Manufacturing Costs and Cost Reduction

Manufacturing Costs and Cost Reduction

Copyright 2010 Pearson Education South Asia Pte Ltd

Manufacturing Costs and Cost Reduction: Value Analysis

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