Manufacturing is the changing of raw or processed

• Manufacturing is the changing of raw or processed materials into usable products. • Manufacturing occurs in manufacturing plants, or factories.

Understanding technology in manufacturing is critical for several reasons: 1. Virtually everything that is done in a business depends on some type of technology. 2. Technology is evolving at an extremely rapid pace.

Understanding technology in manufacturing is critical for several reasons: 3. Technological innovation in manufacturing, is a competitive necessity.

• Hard technology refers to equipment and devices that perform a variety of tasks in the creation and delivery of goods and services. • Soft technology is the application of the Internet, computer software, and information systems to provide data, analysis and to facilitate the creation and delivering goods and services.

• Consumer Product – “used up” TV, books, food, etc. • Industrial Product – “Used to make other products” Steel, Lumber, tools, etc.

What is a system? • An organized way of achieving a goal • There are seven parts to a manufacturing system

Manufacturing System classification: • • • Project Job shop Repetitive Line Continuous

• • • Project: Products are complex Production quantities are often just one unit. Such as: Oil refineries; Large buildings Cruise ships; Large aircraft

• Project: Products are usually similar, though not identical • • Layout is fixed-position • Assembly equipment must be mobile. Few robot applications are used. Product remains in one location and production equipment and parts are moved to it.

Job Shop: • • • Production quantities are small lots • Most often, equipment used are lathes, mills, grinders, etc. Size and weight of parts are small Parts are moved or routed between fixed production work cells for manufacturing processing.

Job Shop: • Less than 20% repeat production on the same part • • • Products are not complex Product moves between machines a lot. Opportunities for Robotic applications are present but limited by the high variation in parts and products.

Repetitive: • • Orders for repeat business is 100% • High volume while production quantities vary over large range • Little variation in the routings of parts between production machines Customer contracts for multiple years

• • Repetitive: Plant layout remains the same Product example: 10, 000 water pumps per week with a 3 year Contract. • Special-purpose production machines, automated systems with robots are integrated into the process

• • • Line: Delivery time to customer is often shorter than the total time to build all individual parts of the product. Product has many different models Robots are frequently used. Inventory of subassemblies is usually present Example: Automobile assembly

Continuous: • Time required for manufacture is longer than customer waiting time • • Demand is predictable Product inventory is always present High production volumes Products have few options

• • Continuous: Plant layout is limited to one or just a few different products Plant layout is Product-flow type Example: Input chemicals – output Nylon thread (continuous flow) or electrical components for automotive industry • Robots can handle high-speed highvolume operation of this type

Manufacturing System Characteristics: Project Job shop Repetitive Line Continuous Process speed Varies Slow Moderate Fast Very fast Labor content High Medium Low Very low Skill level High Moderate Low Varies Order quantity Very small Low Varies High Very high Unit quantity cost Very large Large Moderate Low Very low Routing variations Very high High None Low Very low Product options Low None Very high Very low Design component Very large Large Very small Moderate small

1. 2. 3. Manufacturing 4. Steps 5. 6. 7. Designing the product Purchasing materials Processing materials Production Packaging Distribution Sales

Design • To sell products, manufacturers must first design products that people will want and buy • Engineers have to design a product to meet a specific need or want

Process The process goes much more smoothly, and cost effectively if it: • • • Uses readily available materials. Uses materials that can be recycled. Uses existing production processes.

• Raw materials occur in nature. They are usually processed into industrial materials. Trees into lumber is a good example. • Industrial materials are used to make products. Lumber into furniture for example.

Primary processes change raw materials into industrial materials. • Mechanical processes use actions such as cutting or crushing. • • Thermal uses heating or melting. Chemical mixing materials and alters their characteristics.

Secondary processes turn industrial materials into finished products. • Forming (rolling, casting, forging, stamping, extrusion) • • Separating (cutting) • Conditioning (thermal, chemical) Combining (mixing, fastening, soldering, brazing, welding, coating)

• Both primary and secondary processes are used in manufacturing. • Many different processing techniques may be needed to produce one type of product.

Production There are 4 major types of Production 1. Custom production – Products are made to order, one at a time. 2. Job-lot production – Products are made in a specific quantity, such as a limited run of collector items.

Production There are 4 major types of Production 3. Continuous production – Identical products are mass produced in large numbers. 4. Mass customization – This process combines elements of custom and mass production. Standard products are individualized. Minor alterations such as a store brand label.

Packaging • Packaging is designed to continuously protect a product, from the time it is produced until the customer buys and uses it.

Distribution Products may go to another manufacturer, a wholesaler, a retailer, or directly to the customer. Wholesalers purchases in large quantities and then sells in smaller amounts to retailers. Retailers sell products directly to their consumers.