SHAD 3083 (01)Manufacturing Process

( Frying Pan)

Lecturer : Dr. Norhayati Zakuan

Group MembersName IC no. Matric no.

Chong Jun Shin 930802-04-5472 A13HA0018Candytha Severinus 940610-12-6744 A13HA0012Nadiah bt Md Razak 941025-06-5244 A13HA0077

Hii Puong Koh 940227-13-5859 A13HA0041

Table of Contents

ACKNOWLEDGEMENT..............................................................................................................2

1.0 INTRODUCTION...............................................................................................................3

1.1 Historical Development of Product...................................................................................3

1.2 Competitors...........................................................................................................................4

1.3 Method of Production............................................................................................................5

1.4 Function of Components........................................................................................................6

1.5 Assumption on Type of Manufacturing System......................................................................6

1.6 Assumption on Quantity of Production..................................................................................7

1.7 Production Cost.....................................................................................................................8

2.0 DETAILED SPECIFICATION OF FINAL PRODUCT.......................................................8

2.1 Material Selection..................................................................................................................8

2.2 Component Analysis............................................................................................................10

2.3 Dimensional, Surface and Specifications..............................................................................11

2.4 Technical Drawing..............................................................................................................12

3.0 STAGES OF THE PROCESSES.......................................................................................15

3.1. Alternative Process........................................................................................................15

3.2. Production Process.........................................................................................................15

3.3. Process Flow Chart........................................................................................................18

4.0 TYPES OF MACHINE/EQUIPMENT FOR EACH PROCESS.........................................19

5.0 CONCLUSION..................................................................................................................22

6.0 REFERENCES..................................................................................................................23

7.0 APPENDIX.......................................................................................................................24

ACKNOWLEDGEMENT

All praise and thanks to God on his grace, finally we had completed our group project on

time. We would like to express our gratitude and appreciation to those who gave us the

possibility to complete this project.

A special thanks to our lecturer, Dr. Norhayati Zakuan, who had been giving us guidance,

instructions and useful comments that enable us to complete this projects. Her advice had made

us able to complete our task successfully. All our gratitude, appreciation and deepest love for our

family for giving us the strength and their prayers even they are not here with us.

In addition, we would also like to thank all the students of 3SHAD that had given us

support in term of knowledge and ideas. Thank to group members for making the production of

this report a pleasurable experience. Finally, we would like to express our gratitude and

appreciation to everyone that involved, directly or indirectly in our project.

1.0 INTRODUCTION1.1 Historical Development of Product

Copper frying pans were first used in ancient Mesopotamia. Frying pans were also known in

ancient Greece where they were called tagēnon and in Rome, where they were called patella or

sartago. Pan are the word that come from Old English panna. In mid-19 th century, cast iron

cooking pan are commonly used and known as spider. It had three legs to help it stand in the

coals and a handle. Not long after cooking stoves become famous, flat bottom and legless

cooking pans were designed

Frying pans were traditionally made of cast iron. Although it is still well known today,

especially for outdoor cooking, most frying pans are now made from metals such as anodized

aluminum, copper and stainless steel. The materials and method of manufacturing modern frying

pans are vary greatly. Nowadays there is non-stick cookware. In 1938, an American chemist was

experimenting with refrigeration gases. A waxy substances formed years later and when it is

bonded to cookware it gained a non-stick reputation. Non-stick make it easier for anyone to cook

since food can hardly stuck on the surface of the pans.

Nowadays cookware is much more complex than it appears at first glance. The quality and

service life of pans are influenced by many factors. What makes the difference are not only the

materials that are used, but also the methods in manufacturing it at the first place. All this,

combined with the high quality standards, defines each one of the products. That is why,

FORTES SDN BHD as a corporate company that producing high quality non-stick coated

aluminum pan, not only acquired know-how, but also the expertise and technology in developing

our product.

1.2 Competitors

Since this is consumers’ product in Malaysia, the market potential for our products is big

in Johor and other part in Malaysia. Right now, we already had a few established company as our

competitor in manufacturing high quality frying pans.

Our first competitor is Ni Hsin Group, which is a leading manufacturer of Premium

Stainless Steel Multi-ply Cookware in Asia. Ni Hsin Group manufactures a complete range of

Premium Stainless Steel Multi-ply Cookware ranging from pressure cookers, woks, pots and

sauce pans for household and commercial use. Currently they located in Seri Kembangan,

Peninsular Malaysia, with an area of almost 20,000 sq.m., Ni Hsin Group employs some 250

employees and produces over 6,000 units of stainless steel premium cookware in a single shift.

Next, Central Aluminium Manufactory Sdn Bhd (CAMSB) have been established in

1975. It has rapidly grown through those challenging years. Currently, CAMSB has a team of

experienced in-house mold design and development engineers, who are responsible for

continuous development of competitive and quality products. The company involved in the

manufacturing, sale and distribution of aluminum and stainless steel kitchen ware, sinks and

melamine table ware. Currently, CAMSB have two production plants which are located in Hutan

Melintang, Perak, Malaysia. The production plants cover a total area of 22 hectares.

Mengkuang Istimewa Sdn Bhd is a household products & kitchenware dealer company

located in Butterworth, Pulau Pinang. They supply high quality household products and

kitchenware that are widely used for home, office, restaurant or cafe. They are located at 7129-

7131, Jalan Bagan Jermal, Taman Bintang, 12300 Butterworth, Penang, Malaysia.

1.3 Method of Production

We used batch production that manufacturing frying pans ranging from 100-10,000 unit

per year. This is because our products is expensive. Batch production is the method where we

produce our product in groups or batches where it go through the whole production process

together. It is most suited so that we can control our quality and quantity of productions.

Since most of products that we manufactured have small differences, our facility use

cellular layout or functional layout. Therefore, extensive changeover between one product style

and the next may not be necessary. It also eliminate time lost due to setup. In cell manufacturing

layout, each cell is designed to produce a limited variety of part configurations. Only semi-

skilled workers are needed where each workers are required to complete one task before passing

work down the production line to the next worker. But the workers must be able to switch from

one part of the production line to another.

Advantages of this method is it can cut cost. This is because machine are being used

effectively by producing a number of each item in one go. This way is cheaper since materials

can be bought in bulk and workers can be specialize in their task. Workers will become more

productive since they had become more expert at their tasks (output per worker). As only few

workers are needed to produce a set of amount, it will help in cutting costs. High quality

products can be produced since workers have become more familiar with their task and they can

also find ways to improvise it.

Disadvantages of this method is it requires very careful planning to decide when new

batch should be produced and how much. Batch methods can also result in the build up of

significant “work in progress” or stocks (i.e. completed batches waiting for their turn to be

worked on in the next operation). This will in turn increasing cost of warehouse since it takes up

space.

1.4 Function of Components

Basically, frying pan is made up of two parts, which are flat-bottomed pan and handle.

Flat-bottom pan is used for several types of cooking methods, such as frying, searing and

browning foods. It is made out of metals, so that the heat from stove will be transmitted to the

food rapidly and effectively. While the handle enable user to handle the frying pan while the

pans are in heated condition. It serves the purpose of protecting user’s hands from getting burn

while cooking. The handle is normally made out of non-metal, which has poor thermal

conductivity. It means that the heat from stove will not be transmitted to the handle rapidly while

cooking.

1.5 Assumption on Type of Manufacturing System

Manufacturing system is a system that has have three essential elements which is input

material, transformation process and output material. The input material differs from the output

material in a certain area that is meaningful. Manufacturing system also defined as a collection of

integrated equipment and human resources to perform one or more processing and assembly

operations on a starting raw material, part, or set of parts. The equipment consists of production

machines and tools, material handling and work positioning devices, and computer systems.

While human resources are required either full-time or part-time to make sure the system is

running. Manufacturing system is essentially important to make sure the flow of manufacturing

processes are meeting the expectations.

There are several manufacturing systems that has been applied at manufacturing firms in

different field. Examples of manufacturing systems included single-station cells, machine

clusters, manual assembly lines, automated transfer lines, automated assembly systems, machine

cells (cellular manufacturing), and flexible manufacturing systems. Each of the manufacturing

system can be distinguish by the factors such as types of operations performed, number of

workstations, system layout, automation and manning level, and part or product variety.

Figure 1 Manufacturing Systems for Low Product Complexity.

Figure 1 shows the manufacturing systems for low product complexity. As the frying pan

does not has high complexity in terms of product design and also the manufacturing processes,

so the manufacturing system adapt by frying pan can be refer to the figure above by examining

the product variety and annual production quantity. Frying pan does have a soft product variety,

where most of the frying pans which have various design and size shared handle as the common

part. As mentioned in previous section, price of frying pan is quite expensive especially those

that have been produce with high quality materials, thus the annual production quantity is range

around 5,000 to 10,000 units per year. Thus the manufacturing system adapted for frying pan is

single-station cell, manned, batch model production.

1.6 Assumption on Quantity of Production

As mentioned in previous section, production of frying pans used batch production

model. Thus the quantity of frying pans production is range around 5,000 to 10,000 units per

year. However, the quantity of production still depends on the demand of customer in market. It

also depend on the research and development of firms whether improvements exist or not.

1.7 Production Cost

Fixed Assets Cost (RM) Variable Cost Cost (RM)Wages Of Labor 11800 Raw Materials 39800Machinery and Equipment

550000 Variable Manufacturing Overhead Costs 23000Utilities Expense 15560

TOTAL 561800 TOTAL 78360*assume 5500 units produced per year.

Production cost per item = Fixed Cost (FC) + Variable cost (VC) / No. of units produced

= (RM 561800 + RM 78360)/ 5500 units

= RM116.40

2.0 DETAILED SPECIFICATION OF FINAL PRODUCT2.1 Material Selection

Aluminum

Our company use aluminum as our main material for manufacturing frying pans. One of the

reasons is because it is an excellent conductor of heat. Aluminum enable heat spreads quickly

and evenly across the bottom, up the sides and across the cover to completely surround the food

being cooked. Furthermore, it is a lightweight metal, about one-third the weight of steel, so it is

easy to handle. Finally, aluminum does not rust.

Thermoplastic polymer

Handle of the frying pans that use thermoplastic polymer make it easier for customer to handle

the pan while the pan are hot on the stove. The material of thermoplastic is that it is lightweight,

corrosion resistance, durable and have high impact resistant. The thermoplastic category includes

a number of special compositions for ovenware. It can be subjected to multiple heating and

cooling cycles without altering their molecular structure. However, thermoplastic are not as

strong or resistant to heat as that of metals.

Rivets

Unthreaded, headed pin used to join two or more parts by passing pin through holes in parts and

forming a second head in the pin on the opposite side. This is a widely used fasteners for

achieving a permanent mechanically fastened joints.

Diamond coating

For the interior part of the frying pans, we use nonstick coating made with diamonds. The

interior coating of each pan contains up to 200,000 real diamond crystals for a long-lasting

nonstick surface. We use diamonds because it help to distribute heat evenly across the surface of

the pan. It also allow the pan to brown food and easily washed it away with warm soapy water

after done cooking. Next, it have intrinsic nonstick properties, unlike titanium reinforcement.

This gives the coating outstanding nonstick release properties

Ceramic coating

While on the exterior surface of the frying pans, we use ceramic coating. It is much safer than

earlier nonstick pans because they're made without potentially toxic chemical such as

Perfluorooctanoic acid, known as PFOA. The nonstick surface of pans that use ceramic-based

nanotechnology is said to be stable on exposure to high heat and resistant to flaking.

2.2 Component Analysis

Figure 2 Flat-bottomed pan

Basically, frying pan is made up of two parts, which are flat-bottomed pan and handle. Flat-

bottom pan is used for several types of cooking methods, such as frying, searing and browning

foods. It is made out of metals, so that the heat from stove will be transmitted to the food rapidly

and effectively.

Figure 3 Handle Figure 4 Rivet

While the handle enable user to handle the frying pan while the pans are in heated condition. It

serves the purpose of protecting user’s hands from getting burn while cooking. The handle is

normally made out of non-metal, which has poor thermal conductivity. It means that the heat

from stove will not be transmitted to the handle rapidly while cooking.

2.3 Dimensional, Surface and Specifications

Our frying pan is a flat-bottomed pan that can be used for frying, searing, and browning

foods. It is typically 240mm in diameter with relatively high side (52mm), flared and rounded,

without any sharp angles, which means it lets the food slide easily from the pan to the dish or

plate. Next, it also have a long practical off set handles (170mm) firmly fastened with rivets.

Larger pans may have a small grab handle opposite the main handle. Our product are resistant to

scratches and corrosion, have high-quality aluminum body, have excellent and consistent heat

distribution, smooth and non-stick surface for ease of cooking.

Figure 5 Frying pan

170 mm

52 mm

240 mm

2.4 Technical Drawing

Below are the detail specification and measurement of the frying pan in millimeter.

Figure 6 Top view of Flat-bottomed pan

Figure 7 Bottom view of Flat-bottomed pan

Figure 8 Front view of Flat-bottomed pan

Figure 9 Close view of Flat-bottomed pan

Figure 10 Top view of Handle

Figure 11 Front view of Handle

Figure 12 Back view of Handle

Figure 13 Rivet

Figure 14 Exploded View of final products

3.0 STAGES OF THE PROCESSES 3.1. Alternative Process

There are two alternative processes to produce frying pans. One of the alternatives is

gravity die casting. Gravity die casting is use on aluminum, Zinc and Copper Base alloys. This

casting is suitable to produce medium to high volume products. The advantage of gravity die

casting is that it has good dimensional accuracy, has smooth cast surface. The production speed

is faster than other processes. It use a metal mold constructed of two sections, design for easy,

precise opening and closing. Molds used for casting lower melting point alloy are commonly

made of steel or cast iron. In die casting, mold is preheated and coated, then close the mold. We

will pour the molten metal into the mold. When the molten metal is solidified, we will open the

moveable molds section using hydraulic cylinder to take out the final part. This is how frying

pan can be produced.

In pressure die casting, the production quantity should be more than 10000 units because

it is economical. It is use for production of casting from nonferrous metal alloys and steel. There

are two types of high pressure die casting, which is hot chamber and cold chamber. We choose

cold chamber because it can produce high quality product and the casting metals include

aluminum and alloy. With the die closed and ram withdrawn, molten metal is pour into the

chamber. Then the ram forces metal to flow into the die maintaining pressure during cooling and

solidification.

3.2. Production Process

We select metal forming as our main process to manufacture Frying pans. Besides that, we will

also choose the continuous hot rolling as 1 of the metal forming types.

a. Metal forming

HOT ROLLING PROCESS

Firstly, premium quality aluminum are melt into liquid state at around 660 degree Celsius and

then filtered to remove contaminants. The liquid aluminum flows into vertical rectangular molds.

A jacket of water around the molds cools the aluminum to transform it from liquid state to a solid

slabs. A crane extracts the cast slabs and heading to a heating chamber to soften the slabs. This

will allow the metals to be shaped in forms. A saw slices the slabs in two and trims the end.

More blades scraped the top and bottom to remove impurities. A conveyor repeatedly feed the

shorter slabs to the heated rollers. Guides at the side maintain the width while the rollers

compress the aluminum taking the thickness down to about half a centimeter. The rolling also

elongates the slab substantially. It starts out 2 meters long and after a few minutes rolling, it has

been stretched to over 100 meters. Pizza cutter styles blade trim the edges of the aluminum sheet.

Another roller wind the aluminum into a big coil. Then it will be unwind and squeeze to flatten

it. Machinery now pulls the cold aluminum sheet forward to the next station.

STAMPING METAL PROCESS

In this process, the aluminum sheet are press using 120 tons powerful press machine. It cut out a

round blank out of the aluminum sheet as a starting shape. The workers then clean off any debris

from the metal cutting because even the minute chard getting under the press would damage the

metal. After that, the blank are put into a 200 tons press containing a forming tool. The powerful

press forces the metal and then punches out the shape of the finish frying pans. The freshly

formed aluminum frying pans fall onto the conveyer below. The leftover aluminum will be

recycled to make new frying pans.

b. Machining

PICKLING PROCESS

This is the process where the aluminum pans are clean and then treated with sodium hydroxide.

This opens the pore of the metals to allow an enamel coating to tick to the outside and the non-

stick finish to adhere to the inside. After that, worker will inspect the pans and places them

upside down on spray fixtures.

c. Coating

THERMAL SPRAYING

Before pans are coating, it will be put in the sand blasting chamber to ensure improved adhesion.

The space is tight fit to shield the inside from the enormous spray that comes next. We prepare

up to 5 proprietary coating formulations for each frying pan model. Each one contain dozens of

chemicals and thousands of tiny diamond particle. The diamonds increase durability in heat

conductivity and they also make food less likely to stick to the surface of the pan.

Firstly, the pans receive their ceramic coating where each pans spins on the fixtures as a plasma

flame melts ceramic coating onto it exterior surface. The spinning ensure even coverage as the

coatings adhere to the hot pan. After that, the frying pans go through a furnace to adhere the

coatings of the pans in 560 degree Celsius. Then, a special primer is applied to the interior

surface that will make the non-stick coating adhere to the pans. It then applies the non-stick

coating and send again to a furnace to cure the non-stick finish at around 425 degree Celcius.

d. Joining

RIVETING PROCESS

Once the pans are cold, a robot transfers them to a lay where the pans bottom are accurately trim

to a perfectly flat base. This leaves a clean level surface on the bottom of the pan and ensure the

stability of the pans on the cooktop. After that, a suctioning robot moves the frying pans to the

next station, where handle holes are punched in a precise location on the side of the pans using

hydraulic punch press. Next, the workers will slides pins into the holes and slots them through

holes in the handle fitting. Using a ram, the worker will flatten the pin to rivet the polymer

handle to the pans.

e. Processing of polymer

THERMOPLASTIC INJECTION MOLDING

The thermoplastic injection molding process begins by adding pelletized material to a hopper.

The material is gravity fed into a heated barrel and screw. Rotation of the screw results in

shearing action on the raw pellets causing them to melt.  The screw rotation also pushes the

molten plastic forward in the barrel toward the mold. The material is then injected into the closed

mold at high pressure through a runner system to fill all the cavities. The mold is clamped shut

under enough force to keep the mold halves together while the molten plastic is flowing. A hot

runner system is used, where the plastic in the runner stays molten so no material is wasted.

When the mold cavities are filled, the part cools until rigid enough to be ejected. Part cooling

within the mold is accomplished through water lines cut into the mold. At the completion of the

cooling cycle, the mold opens and the parts are ejected for part removal.

3.3. Process Flow Chart

Figure 1: A flow chart showing steps involve in manufacturing frying pan

Raw material storage

Transform aluminum slab into aluminum

sheet

Aluminum slab is heated and cut

Finish good storage

Form the desired shape of the finish

product on the blank

Pans goes through furnace to adhere the

coatings

Trim bottoms of the pan

Transform premium quality aluminum

into slab

Riveting handle to the pans

Punch out a round blank out of the aluminum sheet

Coat the exterior and interior surface

Labelling and packaging

4.0 TYPES OF MACHINE/EQUIPMENT FOR EACH PROCESS

Figure 15 Continuous Hot Rolling Machine

In the continuous hot rolling mill, the slabs are rolled in a number of passes until it reach the thickness of a sheet.

Figure 16 120 tons Hydraulic Circle Punch Press

By using this machine, a round blanks are cut out of the aluminum sheet. The blank are used and the leftover aluminum will be recycled to make new frying pans.

Figure 17 200 tons Hydraulic Deep Drawing Press

Next, the round blank will be put on this machine and the machine will punch out the desired shape of the finish frying pans.

Figure 18 Plasma Deposition Machine

Frying pans will receive their ceramic coating by plasma flame, where each pans spins on the fixtures as a plasma flame melts ceramic coating onto it exterior surface.

Figure 19 Furnace

Next, frying pans will go through a furnace to improve adhesion of the coatings to the frying pans.

Figure 20 Trimming Machine

Frying pans bottom are accurately trim to a perfectly flat base to ensure stability of the pans on the stove.

Figure 21 Injection Molding Machine

By using this machine, we can manufacture thermoplastic handle of the frying pans.

Figure 22 Automated Riveting Machine

The handle and flat-bottomed pans are joined together with the rivet.

5.0 CONCLUSIONIn conclusion, we will choose batch production to produce frying pans. The materials that

are needed to produce frying pan is aluminum, thermoplastic polymer and rivet. The aluminum is

used to produce the flat-bottomed pan while the thermoplastic polymer is used to produce the

handle and rivet is used to join the parts of frying pan. In order to produce frying pan, a series of

processes will be conducted, which are hot rolling, stamping metal, pickling, thermal spraying,

riveting, and thermoplastic injection molding. In addition, a lot of machines are required to

conduct the processes. Roughly, production cost for our product is RM116.40 per unit.

6.0 REFERENCES

1. https://www.swissdiamond.com/about-us/our-nonstick-technology

2. https://www.swissdiamond.com/about-us/why-swiss-diamond

3. http://www.lovelowfat.com/ceramic-vs-teflon/

4. https://www.youtube.com/watch?v=QmXrLrQBwUk

5. http://www.falkcoppercookware.com/info/technical

6. http://www.drweil.com/drw/u/QAA400862/Are-Nonstick-Ceramic-Pans-Better.html

7. https://en.wikipedia.org/wiki/List_of_manufacturing_processes

8. https://en.wikipedia.org/wiki/Rolling_(metalworking)#Hot_rolling

9. https://en.wikipedia.org/wiki/Stamping_(metalworking)

10. http://engineershandbook.com/MfgMethods/

11. https://en.wikipedia.org/wiki/Methods_of_production

12. http://engineershandbook.com/MfgMethods/pressbrakeforming.htm

13. http://smallbusiness.chron.com/methods-manufacturing-plastic-72181.html

7.0 APPENDIX

Figure 23 Process in manufacturing frying pan