Introduction to Industrial

Materials and Processes

…requires a sound and broad understanding of materials, processes, and
equipment on the part of the decision makers,
…accompanied by an understanding of the manufacturing systems
University of Santo Tomas
Industrial Engineering Department
Faculty of Engineering
Learning Objectives
 Describe the course of Industrial Materials and
Processes as a scientific discipline
 Understand and appreciate the challenges and
complexities involved in the design and
construction of a product (all major classes of
materials)
 Introduce the broad spectrum of manufacturing
processes to individual who will be involved in
the design and manufacture of finished products
Learning Objectives

 Provide a good theoretical background and a

sound practical knowledge to the engineering
students
 Be aware of the following terms for better
understanding of the scope of the study
Introduction
 All of us live in a world of dynamic change,
and materials are no exception.
 The advancement of civilization has
historically depended on the improvement of
materials to work with.
 Over time, they moved from the materials Stone
Age into the newer Copper (Bronze) and Iron Ages.
 Today’s competitive manufacturing era of high
industrial development and research, is being
Introduction
called the age of mechanization, automation and
computer integrated manufacturing.
 Manufacturing is the backbone of any
industrialized nation.
Since products require materials, engineers should
be knowledgeable about the internal structure and
properties of materials so that they can choose the
most suitable ones for each application and develop
the best processing methods.
History of Materials

 The development of materials and man’s

ability to process them is linked to the history
of man
 Stone Age
 Copper and Bronze Age
 Iron Age
 Steel Age
 The current age is that of plastics, composite
materials, and exotic alloys
Introduction
 Manufacturing and technical staff in industry
must know the various manufacturing
processes, materials being processed, tools
and equipment for manufacturing different
components or products with optimal process
plan using proper precautions and specified
safety rules to avoid accidents.
Introduction
 Future engineers must know the basic
requirements of manufacturing activities in
terms of man, machine, material, methods,
money and other infrastructure facilities
needed to be positioned properly for optimal
shop layouts or plant layout and other
support services effectively adjusted or
located in the industry or plant within a well
planned manufacturing organization.
Introduction
 In many cases what was impossible
yesterday is a reality today!
 Thirty years ago, many people would not have
believed that some day computers would become
a common household item similar to a telephone
or a refrigerator.
 And today, we still find it hard to believe that some
day space travel will be commercialized and we
may even colonize Mars.
Introduction

 Nevertheless, science and engineering push

and transform our most unachievable dreams
to reality.
New Researchers in the
Manufacturing Field
 The advancement has come to this extent
that every different aspect of this technology
has become a full-fledged fundamental and
advanced study in itself.
 This has led to introduction of optimized design
and manufacturing of new products.
 New developments in manufacturing areas are
deciding to transfer more skill to the machines for
considerably reduction of manual labor.
New Researchers in the
Manufacturing Field
 It specifies the need of greater care for man,
machine, material and other equipment involving
higher initial investment by using proper safety
rule and precautions.
Materials, Manufacturing, and the
Standard of Living
 Standard of living of a society is determined
by the goods and services that are available
to its people
 Manufactured goods
 Producer goods:
 Intermediate goods used to manufacture either producer
or consumer goods
 Consumer goods:
 Purchased directly by the consumer
Product Development
 Sustaining technology:
 Innovations bring more
value to the consumer
 Improvements in
materials, processes,
and design
 Product growth
normally follows the “S”
curve
Figure 1-1a) A product development curve
Simplified Steps of the Product Life
Cycle
 Start up—new product or new company, low
volume, small company
 Rapid Growth—products become
standardized and volume increases rapidly.
Company’s ability to meet demand stresses
its capacity
 Maturation—standard designs emerge.
Process development is very important.
Simplified Steps of the Product Life
Cycle
 Commodity or Declined
 Commodity—long-life, standard-of-the-industry
type of product or
 Decline—product is slowly replaced by improved
products
 Figure 1-15 Product life-
cycle costs change with the
classic manufacturing
system designs.

The stage of the

product life cycle
affects
--the product
design stability,
--the length of the
product
development
cycle, Note: All of which
--the frequency of have implications
engineering for manufacturing
change orders, process
and technology
--the commonality
of components
 Interactive Factors in Manufacturing
 Factors
 Product design
 Materials
 Labor costs
 Equipment
Figure 1-2
Manufacturing cost is
 Manufacturing costs
the largest part of the
selling price, usually
 Strategies to reduce
around 40%. The
largest part of the cost
manufacturing cost is
materials, usually
 Lean manufacturing
50%.  Systems approach
Materials and Processes

 Manufacturing cost is the largest cost in the

selling price.
 The largest manufacturing cost is material costs,
not direct labor.
 Materials, men, methods, and equipment are
interrelated factors in manufacturing that
must be combined properly to achieve low
cost, superior quality, and on-time delivery.
Materials and Processes
 Materials to be used must be selected and
specified to meet the design engineer’s
requirements.
 Must have a broad knowledge of manufacturing
processes and of material behavior so that
desired operations can be done effectively and
efficiently without overloading or damaging
machines and without adversely affecting the
materials being processed
Materials and Processes
 The elements of design, materials, and
processes are closely related, each having its
effect on the others.
 A design change would have a significant impact
on the entire manufacturing process and on the
cost.
 Key to Success: To build a Manufacturing
system that can deliver on time to the customer,
superior- quality goods at the lowest possible
cost in a flexible way.
Manufacturing and Production Systems

 Goods
 Material things
 Services
 Nonmaterial things
 Service Production Systems (SPSs)
 Nonmaterial systems that do not provide a
product (i.e. banking, health care, education, etc.)
Manufacturing and Production Systems

 Manufacturing is the ability to make goods and services to

satisfy societal needs
 Manufacturing processes are strung together to create a
manufacturing system (MS)
 Production system is the total company and includes
manufacturing systems

Figure 1-3
The manufacturing
system converts
inputs to outputs using
processes to add
value to the goods for
the external customer.
Manufacturing and Production Systems

 Production System--process of converting or

transforming raw materials in manufacturing the
right products for the right customers, at the
right quality , right quantity, right location at the
least possible cost (Satisfy the customer).
 Manufacturing System--process of conversion
or transforming raw materials into usable
products at the least possible cost.
Figure 1-4 The functions and
systems of the production
system, which includes (and
services) the manufacturing
system. The functional
departments are connected by
formal and informal information
systems designed to service
the manufacturing system that
produces the goods.
Production System- The Enterprise
 Production systems include
 People
 Money
 Equipment
 Materials
 Supplies
 Markets
 Management
 Manufacturing System
 All aspects of commerce
Manufacturing Systems
 Manufacturing systems
 Collection of operations and processes to produce
a desired product or component
 Design or arrangement of the manufacturing
processes
 Manufacturing processes
 Converts unfinished materials to finished products
 Often is a set of steps
 Machine tool is an assembly that produces a
desired result
Basic Manufacturing Processes

 Casting, foundry, or molding process

 Forming or metalworking processes
 Machining (material removing/removal)
processes
 Joining and assembly
 Surface treatments (finishing)
 Rapid prototyping
 Heat treating
7 Basic Machining Processes

 Shaping
 Drilling
 Turning
 Milling
 Sawing
 Broaching
 Abrasive Machining
8 Basic Types of Machine Tools

 Shapers (Planers)
 Drill Presses
 Lathes
 Boring Machines
 Milling Machines
 Saws
 Broaches
 Grinders
Common Aspects of Manufacturing
 Job and station
 Job is a group of related operations generally done at one
station
 Station is the location or area where production is done
 Operations
 Distinct action to produce a desired result or effect
 Categories of operations
 Materials handling and transport
 Processing
 Packaging
 Inspecting and testing
 Storing
Common Aspects of Manufacturing
 Treatments operate continuously on a workpiece
 Heat treating, curing, galvanizing, plating, finishing,
chemical cleaning, painting
 Tools, tooling and workholders
 Lowest mechanism in the production is a tool
 Used to hold, shape or form the unfinished product
 Tooling for measurement and inspection
 Rulers, calipers, micrometers, and gages
 Precision devices are laser optics or vision systems that
utilize electronics to interpret results
Products and Fabrications
 Products result from manufacture
 Manufacturing can be from either fabricating or
processing
 Fabricating is the manufacture of a product from pieces
such as parts, components, or assemblies
 Processing is the manufacture of a product by
continuous operations
 Workpiece and its configuration
 Primary objective of manufacturing is to produce a
component having a desired geometry, size, and
finish
Roles of Engineers in Manufacturing

 Design engineer responsibilities

 What the design is to accomplish
 Assumptions that can be made
 Service environments the product must withstand
 Final appearance of the product
 Product designed with the knowledge that certain
manufacturing processes will be used
Roles of Engineers in Manufacturing

 Manufacturing engineer responsibilities

 Select and coordinate specific processes and
equipment
 Supervise and manage their use
 Industrial (Manufacturing) engineer
 Manufacturing systems layout
 Materials engineers
 Specify ideal materials
 Develop new and better materials
3 Major Changes in the World of
Goods Manufacturing
 Worldwide or global competition
 Advanced technology
 New manufacturing systems structure,
strategies, and management
Changing World Competition

 Globalization has impacted manufacturing

 Worldwide competition for global products and
their manufacture
 High tech manufacturing for advanced technology
 New manufacturing systems, designs, and
management
Manufacturing Systems Designs

 Job shop is characterized by large varieties

of components, general-purpose machines,
and a functional layout.
 Machines are collected by function.
 Material is moved from machine to machine in
carts or containers and is called the lot or batch.
 To be the least cost-efficient of all the systems
because of its design
Manufacturing Systems Designs

 Flow shop are characterized by larger

volumes of the same part or assembly,
special-purpose machines and equipment,
less variety, less flexibility, and more
mechanization.
 Common light bulb
 A transfer line producing an engine block
 If interrupted, the line manufactures large lots but is
periodically “changed over” to run a similar but
different component.
Manufacturing Systems Designs

 Linked-cell shop is composed of

manufacturing and subassembly cells
connected to final assembly (linked) using a
unique form of inventory and information
control called Kanban.
 Used in lean production systems where
manufacturing processes and subassemblies are
restructured into U-shaped cells so they can
operate on a one-piece-flow basis, like final
assembly.
Manufacturing Systems Designs

 Project shop is characterized by the

immobility of the item being manufactured.
 In the construction industry, bridges and roads
 In the manufacture of goods, large airplanes,
ships, large machine tools, and locomotives
 Workers, machines, and materials come to the
site
 Job shop usually supplies parts and
subassemblies to the project shop in small lots.
Manufacturing Systems Designs

 Continuous process are used to manufacture

liquids, oils, gases, and powders.
 Usually large plants producing goods for other
producers or mass-producing canned or bottled
goods for consumers.
Figure 1-7 Schematic layouts of
factory designs:.
Other Manufacturing Operations

 Testing
 Transportation
 Automation
 Removal of material waste
 Packaging
 Storage
Characteristics of Process
Technology
 Mechanics (static or dynamic)
 Economics or costs
 Time Spans
 Constraints
 Uncertainties and process reliability
 Skills
 Flexibility
 Process capability
New Manufacturing Systems

 Toyota Production System

 Lean manufacturing system
 100% good units flow without interruption
 Integrated quality control
 Responsibility for quality is given to manufacturing
 Constant quality improvement
World Class Manufacturing (WCM)

RAPID e.g., TOYOTA Cycle Time

64 days
32 days
16 days
8 days
4 days
30 minutes
World Class Manufacturing (WCM)

 Is it a Philosophy?
 Concept?
 System?
 Method?
 Techniques?
 Tool?
World Class Manufacturing (WCM)

 A concept of continual rapid improvement

 Everything we do, it should be viewed as a
process-there is always a better way.
 Time-Based Manufacturing—the faster
customer lead time the better
 How do we measure leadtime? WCM
measures the reduction in customer,
production, and manufacturing’s lead time.
Manufacturing Systems and Production
Volumes

Figure 1-17 This figure shows in a general way the relationship between manufacturing systems and
production volumes.
5 Major Dimensions

 Quality
 Cost
 Lead Time – Responsiveness
 Flexibility – Flexibility
 Customer Satisfaction
Summary

 Economical and successful manufacturing

requires knowledge of the relationships
between labor, materials, and capital
 Design a manufacturing system that
everyone understands
 Engineers must possess a knowledge of
design, metallurgy, processing, economics,
accounting, and human relations
Summary

 Giving a great deal of attention to design,

selection of materials, selection of processes,
selection of equipment used for
manufacturing (tooling), and utilization of
personnel could such a result be achieved
Back Up

University of Santo Tomas

Industrial Engineering Department
Faculty of Engineering
Joining Processes

 Mechanical fastening
 Soldering and brazing
 Welding
 Press, shrink, or snap fittings
 Adhesive bonding
 Assembly processes
Surface Treatments
 Finishing operations
 Cleaning
 Removing burrs left by machining
 Providing protective/decorative surfaces
 Painting
 Plating
 Buffing
 Galvanizing
 Anodizing