ManufacturingModern manufacturing

technologies and processes can produce quality products that

enhance the quality of life while having a minimal negative impact

on the environment

Manufacturing

Manufacturing processes have been changed by improved tools and techniques based on more thorough scientific understanding, increases in the forces that can be applied and the temperatures that can be reached, and the availability of electronic controls that make operations occur more rapidly and consistently

Manufacturing History

Prior to the 19th Century manufacturing referred to hand-made products◦Artisans were considered the premier

manufacturers

Manufacturing History

The Industrial Revolution◦Lasted from roughly 1760 – 1840, and it is

technically still going…◦Machines began to take over hand-made

production Chemical manufacturing Iron and steel production processes Water and steam power Machine tools Bio-fuels

Manufacturing History

Impacts of the Industrial Revolution◦Average income and population have sustained

growth◦Standard of living increases◦Economic growth◦Social classes begin to come closer together

Manufacturing History

It is the process that changed!!◦The key to the Industrial Revolution and

continued change is efficiency with regard to waste, cost, and the environment

Focus of Manufacturing

Six areas that drive manufacturing◦Cost◦Quality◦Efficiency

Production, waste, environment, resources◦Delivery

Intermodalism – the use of multiple and appropriate forms or transportation in combinations or individually

◦Safety◦Morale

Of employees and industry Customer satisfaction and demand

Manufacturing Fun Fact that Changed Everything

In the mid 1900s the Jervis B. Webb Co. patented and created the first electronically coordinated conveyor system

It is the algorithm under which a system works that defines and shapes it

An algorithm is a logical arithmetical or computational procedure, that if correctly applied, ensures the solution of a problem. In manufacturing this means the recurring production of a product(s).

A Flow Chart is how we represent this in manufacturing

Start/end

ProcessInput/output

Decision

Arrows

Display

Parts of a Flow Chart

Start/End

Shape is a rounded rectangleStart is required of all flow chartsSome flow charts may not have an END

Process

Shape is rectangularProcess involves the action or the “verb”

part of the flowchartExamples include

◦Add 1◦Turn the motor on◦Turn the light off◦Rotate the part

Input/Output

Shape is a parallelogramIndicates that manual operation is neededExamples include

◦Type in the weight◦Check the balance◦Time the operation

Decision

Shape is a rhombusOutcome is either yes or noExamples include

◦Is this number larger than 10?◦Does the weight meet

specifications?◦Has the count been reached?

Arrows

Arrows indicate the flow of the chart.Arrows are drawn from the output of one

block to the input of another.Only one arrow can represent outputs.Multiple arrows may represent inputs.

Example

Count from 1 to 9 by odd numbers.Before attempting to draw the flowchart,

determine what you want the output to be.

What is the first block (always)?

Step 1

The output will be 1, 3, 5, 7, 9.The Start block is always first.

START

Step 2

The program begins with the number 1.

START

INPUT 1

Step 4

Now that there is a number, the program will state the number.

START

INPUT 1

SAY NUMBER

Step 3

The number 2 will be added to 1 so that the program will continue to count by odd numbers.

START

INPUT 1

ADD 2

SAY NUMBER

Why is Manufacturing Important

Manufacturing accounts for 20% of the US Gross Domestic Product

Manufacturing employs 17% of the US work Force◦When adding in all of the jobs that

manufacturing creates, or requires for operation, it accounts for 25% of the total US workforce

What Does Manufacturing Look Like Today

(ASRS) Automatic Storage and Retrieval System◦Moves material vertically or horizontally

between storage compartment and transfer station or within a process

(AGV) Automated Guided Vehicles◦Computer-controlled system using pallets to

transport work pieces to machine tools and other equipment in a flexible manufacturing system

What Does Manufacturing Look Like Today

(AI) Artificial Intelligence◦Machines learn from experience and begin to

problem solve on their own when things go wrong

(CIM) Computer Integrated Manufacturing◦A management philosophy for planning,

integration, and implementation of automation

What Does Manufacturing Look Like today

(FMS) Flexible Manufacturing Systems◦Systems that can adapt and change quickly

and efficiently as design specifications are altered These systems have increased productivity by an

average of 50% overall This type of system was adopted/adapted from

Japanese systems built off of Kaizen◦Kaizen – Japanese word for improvment

What Does Manufacturing Look Like Today

(JIT) Just-in-Time Manufacturing ◦A manufacturing system directed towards

eliminating waste. A management system where all aspects of the system depend heavily on one another for efficient operation This system is capable of producing mixed

products as changes can occur rapidly Utilizes and trains workers for multiple functions

What Does Manufacturing Look Like Today

(TPS) Toyota Production System◦Specifically applied to automotive

manufacturing. Is a very specific manufacturing system centered around CIM, JIT, and Lean Manufacturing Processes

◦Is one of the most efficient mass production systems

What Does Manufacturing Look Like Today

Lean Manufacturing◦Systematic elimination of waste◦Entire system must participate and work

together to produce effectivelyRapid Prototyping

◦Prototyping made directly from a computer model Technologies involved

◦Stereolithography, 3D Printing, Selective Laser Sintering, Fused Deposition Modeling

Manufacturing Processes

Primary Manufacturing Processes◦Turning raw materials into useable goods

These materials can be renewable or exhaustible

Secondary Manufacturing Processes◦Create Products through the use of primary

manufacturing end materials

The Processes

Inputs Processes

OutputsFeedback

Processes

Separating◦Involves the removal of material to expose

another◦Also referred to as the subtractive process

Processes

Forming◦Uses varying forces to cause a material to

permanently take a shape◦Changes material properties

Processes

Finishing◦May be completed before or after final

assembly◦Used primarily to protect a product from

various conditions◦Also used to enhance a product’s apperance

Processes

Finishing / Cleaning◦Techniques

Alkaline Cleaning Electrolitic Cleaning Solvent Cleaning Vapor Degreasing Acid Cleaning Abrasive Blasting Abrasive Wheels

Processes

Finishing◦Other possible Finishing Techniques

Coating Deburring Conditioning

Production Companies

Manufacturing Enterprises◦A complex system centered around a shared mission to

satisfy customer need in a manner in relation to a given product or service, or set of products or services. Professional employment ranges through all aspects of

educational background◦Management◦Design◦Finance◦Production◦Marketing◦Distribution◦Etc. etc. etc…