Manufacturing Processes and Product Development: An Overview, High school final essays of Mathematics

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Presented By: Eng. Ajit Yesodhara

INTRODUCTION TO

MANUFACTURING

1

Contents

 (^) Product development phases  Production Process  (^) Classification of manufacturing processes  (^) Product simplification and standardization  (^) Inspection and quality control  (^) Mechanization and automation 2

Redesign of Parts

Classification of Manufacturing Process

There is often more than one method that can be employed to produce a component for a product from a given material. The following broad categories of manufacturing methods are all applicable to metallic as well as nonmetallic materials: 1

• (^) Casting 2
• (^) Forming and Shaping 3
• (^) Machining 4
• (^) Joining 5
• (^) Finishing 6
• (^) Microfabrication and nanofabrication 5

Manufacturing Processes: Forming and Shaping Schematic illustration of various bulk deformation processes Extrusion & Drawing

Manufacturing Processes: Forming and Shaping Schematic illustration of various sheet

Manufacturing Processes: Machining Schematic illustrations of various machining and

Manufacturing Processes: Joining Schematic illustration of various joining processes

Product Simplification

 Simplification is a process of determining limited number of grades, types and sizes of a components or products or parts in order to achieve better quality control, minimize waste, simplify production and, thus, reduce cost of production. Simplification leads to manufacture identical components or products for interchangeability and maintenance purposes of assembly of parts. 13

Standardization  Standardization comprises of determining optimal manufacturing processes, identifying the best possible engineering material, and allied techniques for the manufacture of a product. Standards are set up for a specified product with respect to its quality, required equipment, machinery, labor, material, process of manufacture and the cost of production. Improvements over the existing standards in all respects should always be welcomed.. 14

Job/small batch production

Job production comprises of an operator or group of operators to work upon a single job and complete it before proceeding to the next similar or different job. The production requirement in the job production system is extremely low hence it requires fixed type of layout for developing same products. This type of production is usually undertaken by small businesses and produces less than 100 units. 16

Batch Production

Manufacturing of products (say 100 to 1000) with variety of similar parts with very little variation in size and shape is called Batch Production. Whenever the production of batch is over, the same manufacturing facility is used for production of other batch product or items. The batch may be for once or of periodical type or of repeated kinds after some irregular interval hence it requires process or functional layout. 17

Types of Standards Managerial Accounting procedures, performance evaluation, control of expenditures etc… Design, Manufacture & Tech. Needs Techniques, materials, methods of testing, drafting method, abbreviations etc… 19

Inspection & Quality

Control

For manufacturing the product to the specified size, the dimensions should be measured and checked during and after the manufacturing process. It involves measuring the size, smoothness and other features, in addition to their checking. These activities are called measurement and inspection respectively. 20