Module 1

• Manufacturing


  aka Production; it is the process of converting raw materials into products
• The word "manufacture" was first used


  1567
• The word "manufacturing" first appeared


  1683
• Manufacturing activities


  • Design of the product
  • Selection of raw materials
  • Processes through which the product will be transformed
• Types of Products


  • Discrete products (individual parts/products)
  • Continuous products (can be cut into individual pieces)
• Factors to consider for Responsive Manufacturing

  • Product must fully meet design requirements and product specifications
  • Product manufactured by the most environmentally friendly and economical methods
  • Quality should be built-in the product
  • Flexible production methods to meet change in demand, product type, production rate
  • Appropriate, economical, and timely implementation of new technological developments
  • Should address change in demand, product design, materials, and supplier by viewing it as a large system
  • Must constantly strive for higher levels of quality and productivity
• Manufacturing began with the production of articles made of wood, ceramic, stone, metal
• Hammering and casting are the processes first used to shape products
• Sequential Engineering


  Traditional; Step-by-step / One at a time
• Concurrent Engineering


  AKA Simultaneous Engineering; All aspects of the Life Cycle of the product are considered simultaneously
• Goal of Concurrent Engineering

  Reduce time/ cost/ changes in design from start to finish; Communication between and within disciplines
• Life Cycle of a New Product

  • Product Start-up
  • Rapid Growth in Market
  • Product Maturity
  • Decline
• Design Process


  • Computer-aided design (CAD)
  • Computer-aided engineering (CAE)
  • Computer-aided manufacturing (CAM)
• Designs

  • Design for Manufacture
  • Design for Assembly
  • Design for Disassembly
  • Design for Servicing
• Design for Manufacture and Assembly

  Recognizes the interrelationship between manufacturing components and their assembly into a final product
• Environmentally conscious design and manufacturing

  • Reduce waste of material at source
  • Conduct research and development into environmentally-safe products
  • Reduce use of hazardous materials in products and processes
  • Ensure proper handling and disposal of waste
  • Recycling, Waste Treatment, Reuse
• Previous baseball bat was made of wood from the northern white ash tree
• Overdesign


  Made of materials too high in quality or made with precision and quality unwarranted for the intended use; Result of uncertainties in design calculation; Too much concern for product safety; Performs well over an extended period
• Product Liability


  Consequence of a product malfunctioning and possibly causing bodily injury and financial loss to a person or organization
• Industrial Revolution happened; Modern mechanization

  1750's
• The steam engine was invented by Thomas Newcomen


  1712
• The spinning jenny was invented by James Hargreaves


  1764
• The power loom was invented by Edmund Cartwright


  1780
• Computer-aided design allows the designer to conceptualize objects more easily without making costly illustrations, models or prototypes
• Computer-aided engineering simulates and analyzes performance of structures subjected to static or fluctuating loads and varying temperatures
• Computer-aided manufacturing involves all phases of manufacturing by utilizing and processing information in the organization’s database
• Steam engine was not very useful at that time but the idea of using steam to make machines work was significant for the Industrial Revolution.
• Spinning jenny is a machine that enables an individual to produce multiple spools of threads simultaneously.
• Power loom mechanized the process of weaving cloth
• Design for Manufacture is a comprehensive approach to integrating the design process with production methods, materials, process planning, assembly, testing, and quality assurance
• Design for Assembly – considers the ease of putting parts/components together
• Design for Disassembly considers the ease of disassembly of parts for the purpose of recycling
• Design for Servicing is for maintenance and servicing
• Manufacturing came from the Latin words MANU + FACTUS = made by hand