core engineering 2 set Manufacturing Technology

capital

A company involved in a manufacturing process requires money, called capital, to produce a product. Utilities must be paid for, machines and materials must be purchased, and workers must be paid. In addition, investors and owners expect a return on the money they've invested in the company.

Layout

A person using a computer program arranges the various parts of the ad. These parts include headlines and captions, pictures and art, trademarks, brand names, and the copy. The layout is key to the effectiveness of the ad. After the ad is laid out, it is sent to marketing managers for approval.

Functional design

A product must function according to its design. It has to work well under all its intended conditions. Tires that only work well in dry weather aren't functional for the average car.

designed to sell

A successful product sells well. Customers are attracted to a pleasing design. Here are several guidelines for effective design work: Avoid unnecessary design elements. Keep the design simple. Communicate function. Don't make a coffeepot look like a toaster. Design value into the product. You want the customer to think that the product is worth the sales price.

production

After approval, artists and designers finalize the ad. They prepare it in the format that the printer requires and then submit it for publication. The information may appear as a page in a magazine, a newspaper ad, on a billboard, or as a flyer.

what it looks like

All control charts have a center horizontal line that represents the mean, or average, level of acceptable production quality. The vertical axis of the control chart represents the measurement being tracked. The upper horizontal line refers to the upper limit of acceptable quality, while the lower horizontal line represents the lower limit.

Important considerations

Another very important packaging consideration is the effect the package will have on the environment when it's thrown away. Here are some important considerations: Can the packaging materials be recycled? Can the package possibly be reused? (for example, glass milk bottles) Is the packaging material environmentally friendly?

During the Bronze Age (circa 5000-1200 B.C.), people learned to work elements they found in the environment into metals such as copper and bronze. People began to cast weapons and tools from these metals. During this period, they also developed methods of producing high-quality pottery.

Bronze is an alloy consisting primarily of copper, usually with tin as the main additive. It is hard and tough, and it was so significant in antiquity that the Bronze Age was named after the metal.

audi

Companies like Audi, who manufacture very expensive cars, despite all the automation and technology of their paint facility, still employ the use of careful human eyes to inspect each gleaming body that rolls off the end of the assembly line.

JIT system approach

Companies that use the JIT approach integrate the company's suppliers, employees, and customers into the production system. There must be a company-wide commitment to make materials, people, and equipment available on demand. Companies give employees and lower-level managers the power to find and solve problems quickly. This increases employee job satisfaction and commitment. It also prevents problems from developing further down the production line.

Logical or emotional?

Copywriters may use a logical approach in ads when they want to appeal to customers' common sense. These ads stress the low price, dependability, and long life of the product. Expensive consumer goods often use an emotional approach. An ad with an emotional appeal tells people they will feel a certain way if they use the product.

Deformative manufacturing

Deformative manufacturing takes material and reshapes it into products. A steel car fender is made from a single sheet of steel that is pressed between two molds to attain a 3-dimensional shape. Aluminum cans are also made through deformative manufacturing.

small scale manufacturing

Desktop equipment is not designed for mass production; they're small and somewhat limited in the materials they can use. However, much of the manufacturing process can be done at this scale. A good example is in a small batch of plastic parts. Prior to 3-D printing an expensive steel mold would have to made so the parts could be injection molded. Mold costs are very high, in the area of $10,000 to $15,000 for a mold that might produce 2 pair of sunglasses frames at a time. Today with free downloadable 3-D CAD software and a $500 3-D printer, you can produce sunglasses frames of your own design. You could take them to some retailers and see if they would be interested in selling them for you. If they made some suggestions to modify your design you could easily make changes in the 3-D CAD program and then 3-D print the frames again. If you had to do this with an expensive mold for an injection molding machine you would have to throw the mold away and start over.

different thermal properties

Different materials have different thermal properties. Ceramic materials generally have a high resistance to heat, but they often crack when submerged in cold water. Metal has a high degree of conductivity. Therefore, metal pans require plastic or wooden handles, which have a lower level of conductivity, to keep the user from getting burned.

Materials everywhere

Everything in our world is made up of some type of materials. We use some materials in their natural states, such as gravel, sand, water, and fruits. We change other materials into different things. We do this by changing their size, shape, or by combining them with each other. Many materials are processed to change them into forms we can use. Trees are cut into lumber and then processed into paper. Clay is baked into bricks or bowls.

Lean manufacturing examples

Examples of processing waste in Lean Manufacturing processes could be things such as: Having to manually clean dust or burrs from a piece during the manufacturing process Having to manually trim a piece because of worn out dies Too many Inspections Completing a step manually when it could be automated. Some other non-product types of waste are: Looking for tools or parts Multiple hand-offs Unnecessary approvals Machine breakdowns Sending bad products to customers

copy preparation

First, copywriters prepare an effective message about the product and its features. They may use either a logical or emotional approach. When the approach has been chosen, the copy is written and reviewed by various marketing personnel.

fixed automation

Fixed automation, or "hard automation," is built into machinery in the form of gears, wiring, and other hardware. The functions of the machinery are considered permanent. Fixed automation machinery is expensive and is used exclusively in high-volume manufacturing.

flexible automation

Flexible automation is similar to programmable automation in that it is also used for custom and batch production. Yet, in programmable automation no production occurs while the program is being changed; in flexible automation there is no down time. In flexible automation, a computer outside the production machinery makes changes in programs quickly and automatically. The computer can be programmed to produce a mixture of products, one after another.

The Prototype

From a CAD rendering, a prototype of the product can be built either in whole or various parts can be 3-D printed then assembled. This prototype displays the styling and size of the product, but not its functionality. It gives the designer a three-dimensional view of the product that can be physically manipulated. After the prototype has been evaluated and the project moves forward designers can easily make subtle changes to their design and the part can then be made again using the 3-D printer.

Designing for manufacture

Good design presents the simplest solution to a problem. In other words, the product should always be designed to make production as simple as possible. The fewer resources that are needed, the more profitable the product is. Generally, the greater the number of parts and materials used, the more expensive the product is to produce. However, standardized parts can reduce the number of specific parts a company must produce. If parts are standardized, they're more readily available and usually cost less.

In the early 1900s, an American industrialist named Henry Ford invented the assembly line. Ford discovered that cars could be built faster if the workers stayed in one spot, performing only one operation, while the cars came to them on a moving belt. Today, manufacturing is more efficient and sophisticated because of advances in technology. Most modern manufacturing processes are automated. Computers assist in design and planning. Most manufacturing processes have been taken over by robots.

Henry Ford's early assembly line could produce a car every two hours. Today's modern assembly line can produce up to 200 cars every two hours.

Benefits of ISO standards

ISO International Standards ensure that products and services are safe, reliable and of good quality. For business, they are strategic tools that reduce costs by minimizing waste and errors, and increasing productivity. They help companies to access new markets, level the playing field for developing countries and facilitate free and fair global trade.

desktop fabrication

In 1985, Pagemaker, the first desktop publishing program came to market. Pagemaker brought desktop publishing to anyone who was interested in a new printing process that use to require typesetters and printing presses. Now, desktop 3-D printing is doing the same for physical objects as Pagemaker did for the printed page. Many home workshops use desktop CNC mills, like the one used in this module. This is a subtractive process that cuts away material, unlike a 3D printer's additive process of laying down new material. Scanners and CAD software are also finding their way into the home workshop. Some 3D printers cost less than $500 each, and they are getting as easy to use as an inkjet printer.

JIT philosophy

In JIT production, each stage of manufacturing is completed just in time for the next process. This means that fewer workers, materials, and equipment are used in each process. Since smaller amounts of materials need to be moved, overall efficiency is increased. A successful JIT manufacturing company brings production rates exactly in line with market demand. The result is an increase in productivity, work performance, and product quality.

fixed path system

In a fixed path system, the product moves from machine to machine or worker to worker. Devices such as conveyor belts, chutes, and pipes are used to move the materials. This type of system is expensive to set up, but inexpensive to operate. Ford's assembly line is an example of this type of materials handling.

variable path system

In a variable path system, the movement of materials is not set. Plants in which the same machinery or cells of machines, called work cells, manufacture different products use this system. Typically, robot transporters, forklifts, carts, and hand trucks move the materials.

Think quality

In quality control programs, workers often learn about the importance of quality work. Some of these programs, called quality circles, require workers to meet and discuss how to improve quality. In quality assurance programs, inspectors check the product against the written product specifications. Inspection is a three-step process: The product is inspected. The results are reported. Corrective action is taken. Inspectors read blueprints, data, manuals, or other materials to determine specifications, inspection and testing procedures. They also determine adjustment methods, certification processes, formulas, and measuring instruments required.

The DMLS process

In the DMLS 3-D printer, a very precise and powerful laser is directed to metal powder particles in order to selectively build up thin horizontal metal layers. The metal powder particles pinpointed by the laser quickly and fully melt so that the new material fuses and attaches to the previous layer, without glue or any type of binder liquid. DMLS utilizes a variety of metal and alloy materials to create strong durable parts from 3-D CAD data without the need of tooling. 3-D printed metal parts built with this technology have the design versatility of additive manufacturing while possessing the mechanical properties and appearance of metal materials.

Manufacturing has a history as old as humankind. People have always fashioned tools and useful objects from the materials they found around them. They've always used technologies available at the time to make the tools and objects.

In the Stone Age, people made tools such as axes and knives for personal use, using particular types of stones.

learning manufacturing

Lean manufacturing is a manufacturing strategy that seeks to produce a high level of production with a minimum of inventory. In addition to eliminating waste, lean manufacturing seeks to provide optimum quality by building in a method whereby each part is examined immediately after manufacture, and if there is a defect, the production line stops so that the problem can be detected at the earliest possible time.

quality hammer heads

Let's say that you're creating a control chart for a process that produces heads for hammers. When the quality of your process is acceptable, the mean weight of each hammer head is 300 grams. The weight of each hammer head can be 5 grams over or under the 300 grams and still maintain quality. The numbers 305 and 295 become your upper and lower horizontal lines on the chart.

Marking parts in space

Living aboard the International Space Station is perhaps no different than living at home when it comes to having things break or become lost. However, while in space, you can't just go to the local hardware store to get a replacement part. Because of the weight limitations in a space vehicle, you also can't carry all of the spare parts you may need. This video will give you an idea of what NASA has come up with to solve this problem.

Paper or plastic

Many product packages use plastic. These include form trays, blister packs, shrink wrap, clamshell packaging, and bags. Paper is also used in many forms of packaging, including bags and boxes. Sometimes packaging is produced at another manufacturing plant and shipped to the company where the product is packaged.

Ferrous or nonferrous

Metals are usually categorized as either ferrous or nonferrous. All ferrous metals have iron as an ingredient, although the amount of iron content can vary greatly. Nonferrous metals, including copper, lead, gold, silver, and aluminum, contain little or no iron.

Computer Numerical Control (CNC)

More advanced manufacturing plants use computer numerical control, or CNC, systems. In these systems, minicomputers are used as the control units. Each machine tool is controlled by its own computer, which results in flexibility. Changes in the production process can be programmed into the computer quickly. This allows the machinery to be used for different products.

Wholesale

Most manufacturers sell their products to wholesalers. These wholesalers buy products from many manufacturers, then rely on retailers to sell the products. In this system, manufacturers don't usually know who sells their products. High-volume, low-priced goods are often sold this way.

Flow Process Chart

Most products consist of multiple parts, and each part requires its own set of production processes to manufacture. An engineer uses the flow process chart to study all these different processes. He or she uses the information in the product specifications, including the product design drawings and a list of the materials, to build the chart. Symbols and written descriptions show all the production steps required to create a single part. These production processes are divided into five groups: operations, transportation, inspections, storage, and delays.

Lunar habit

NASA and space agencies in other countries are struggling with the problems of how to provide living quarters for astronauts while on missions to the moon and planets. How about a robotically controlled 3-D printer on the moon, constructing housing for astronauts and scientists? Check out the video.

3-D printing in space

NASA is exploring three very different uses for 3-D printing in space. One possibility is using a 3-D printer on deep space missions in which the D would stand for dining. The printer would use a series of raw nutrient containers, both in liquid and solid form, to deposit the right amounts of nutrients, color, and textures to create food items to suit the tastes of each astronaut. Could this be the first 3-D printed pizza?

Preparing employees

New employees are introduced to company policies and procedures and are trained in their jobs. In manufacturing, employees go through safety training to learn how to perform required tasks in a safe manner--even though it may not be the fastest way. Employees must develop the habit of using safe procedures.

Secondary Processing

Next, during secondary processing, the materials are processed into something useful. The material is shaped through casting, forming, and separating actions. Parts are made and assembled into products. For example, at this stage, lumber is made into furniture and steel becomes cars.

more manufacturing review

Next, the company develops a quality assurance program to guarantee high-quality production. Meanwhile, the marketing department is working to develop an effective advertising campaign. Designing packaging and a distribution system are the final steps before the product gets to the consumer. So, the next time you see a new product on the market, stop to think about all the steps required to get it there.

preliminary design

Next, the rough sketches from the initial phase are produced as a drawing called a rendering. This image allows managers and designers to visualize the appearance of the final product. Today, computer-assisted design, or CAD, software programs are used to produce the renderings. CAD provides another way for designers to take an idea and formalize the object so it can be examined and evaluated. Designers can draw faster and more accurately using CAD software. CAD drawings are also more easily modified. CAD programs that produce 3-D images provide decision-makers and designers a realistic look at the new product. CAD drawings also allow potential users to evaluate and analyze a new product directly on the computer display.

organic and inorganic

Organic and Inorganic Materials are either organic or inorganic. Organic materials, such as wool, coal, and silk, came from living beings. Inorganic materials, such as rock, copper, and gold, came from nonliving sources. All materials, inorganic and organic, are either gases, liquids, or solids. There are three types of solid materials used in manufacturing: metallic polymeric ceramic

Product advertising

Product advertising promotes a particular product. This type of advertising is designed to attract attention, inform customers, and persuade them to buy a certain product. Product advertising compares one product to another. Usually, the advertisement presents the advantages of the product, but doesn't mention competing products. Occasionally, a company will make a direct comparison between their product and a competing product, such as the case of Coke and Pepsi advertisements.

Product specifications

Product designers must clearly communicate the specifications and characteristics of a product to the people who will build it. There is no room for guesswork here. Manufacturing personnel need detailed and accurate descriptions of the product in order to build it as it was designed. Engineering drawings convey this information by: illustrating the size, shape, and location of features supplying specification sheets that describe mechanical, physical, chemical, electrical, and thermal data listing the materials needed to manufacture a single unit of the product

Programmable Automation

Programmable automation is used in custom or small batch production. For each new batch, the production equipment is reprogrammed. This type of automation is used for lower-volume production.

Company or Idea advertising

Rather than promoting a particular product, advertising can promote a company or idea. The Click It or Ticket campaign is an example. Click It or Ticket (CIOT) is the most successful seat belt enforcement campaign ever, helping create the highest national seat belt usage rate of 85 percent. Coast to coast, day or night, the message is simple - Click It or Ticket. This type of advertising is aimed at shaping your attitude towards something. The government wants you to feel a certain way about wearing a seat belt.

Imagine being an inventor or product designer and having the opportunity to see your new product vision come to life in a matter of hours and not weeks and months. This reality is the 3-D printing revolution.

Solid Concepts is a 3-D printing company with offices in many locations in the US. This video courtesy of Solid Concepts explains the process of FDM 3-D printing. FDM or Fused Deposition Modelling is the same type of 3-D printing you will be doing, but on a larger scale. As you watch the video think of some of the objects around you and see if you think that they could be made by the FDM process.

Retail versus direct In a retailer system, the manufacturer sells to retailers, which are stores that sell the product to the customer. Manufactures often limit the number of retailers that carry their product. This is why you can't buy RayBan sunglasses at the local discount store.

Some manufacturers sell directly to customers through a system called direct sales. These companies, like Dell Computer and Amazon.com, eliminate the "middleman" in the distribution system and pass on lower costs to their customers.

Scientists and engineers are studying manufacturing in outer space. The weightless and pollution-free environment of space will be beneficial for many manufacturing processes.

Some sources suggest that in the 21st century, billions of dollars worth of pharmaceutical products and electronic equipment will be manufactured in space.

energy

Sources of energy in manufacturing include hydroelectric power, nuclear power, and the burning of fossil fuels such as petroleum products and coal. Today, as interest in renewable resources increases, some manufacturers are turning to solar power, wind power, and geothermal sources of energy.

statistical process control

Statistical methods are used to monitor and maintain the quality of a manufactured product. The method called statistical process control uses graphs known as control charts to monitor quality. The control chart helps workers determine why the output varies in a production operation.

Subtractive manufacturing

Subtractive manufacturing involves machines that subtract or remove material to make a finished product. A steel shaft is an example of subtractive manufacturing. The shaft started out as a thick metal cylinder. It was put in a lathe and steel was removed to get to the final shape. The CNC Router that you will use is an example of a subtractive manufacturing machine.

Additive manufacturing

The 3-D printer that you will use in this module is an example of additive manufacturing. It adds or deposits thin layers of plastic to produce a finished product. 3-D printers can be desktop versions but in the future they will be able to build structures as big as a house.

3-d printing with materials

The 3-D printer you are using can use a variety of polymeric or simply plastic materials. For your projects you are using a spool of ABS plastic the same material used in plastic pipe and some automotive parts. However, 3-D printing is not limited to plastics. Many companies specialize in using fine powdered metal to construct parts. This process is known as Direct Metal Laser Sintering (DMLS). DMLS is an additive rapid manufacturing (or 3-D Printing) process that builds three dimensional parts by using a laser to selectively sinter a powdered metal material. The term sintering means to heat and fuse the material together

Owner's of knowledge

The Industrial Revolution reached its peak in the early 1800s. At that time each machine had to be manually set up and run to process materials. The men doing the setting up and running were the owner's of the knowledge it took to run the machine. If they left the company or died, their knowledge left with them. Today, modern desktop equipment is digitally controlled. Digital control is the next key area of the Second Industrial Revolution. Computer software replaces the machine-shop skills that used to be required to run machinery.

Manufacturing processes produce goods that people need and want. These are the desired outputs. Most manufacturing systems also have undesired outputs. The brown haze that hangs over many cities is an example of undesired outputs. Many manufacturing processes give off carbon dioxide and liquid chemicals. Other processes produce scrap metals and wood wastes. These undesired outputs can't be avoided, but they can be kept to a minimum.

The challenge to manufacturers is to produce the maximum amount of desired outputs and the minimum amount of undesired outputs.

Product inspection takes place at three points during production. The first inspection point occurs when materials arrive at the manufacturing plant. Materials that pass inspection are moved to the plant for processing. The second inspection occurs during materials processing. All of the parts are periodically inspected. Faulty parts are removed from the assembly line before they can affect the quality of the final product. note_add

The final inspection takes place before the finished product is ready to market.

feedback

The manufacturing system uses the information provided by the control chart as feedback. This feedback provides information the system needs to regulate itself. It also helps the manufacturer make adjustments that bring production outputs back to an acceptable level of quality. Control charts may contain different types of data. Some charts monitor data such as weight, length, and temperature. Other charts measure the number of defects produced in an operation.

Selecting a container

The package container is selected based on the answers gathered in the analyzing process. Common types of packaging include bottles, bags, trays, and jars. These containers can be made from materials such as glass, paper, plastic, and metal. The shape of the container and the materials used are based on cost, availability, and ease of manufacturing. The product must also fit easily into the package.

Other uses

The process flow chart is also used to study the existing system. After this chart is completed, the engineers examine it and ask questions such as: Are there any bottlenecks in the planned production system? Is each operation necessary, or can one be combined with others? What is the best order of operations? Can the operations be simplified? Is this the best way to organize the entire process? The goal of this process is to improve each operation and to make the entire production system as effective as possible. Therefore, the operations involved should be comfortable for workers. Easily accessible materials and parts, adequate lighting, and safety measures should be incorporated into the operations

Developing a New Product

The six major steps in product design are: Developing product ideas Determining product needs (based on customer requirements) Screening product ideas Designing and developing the product Specifying the product characteristics Obtaining approval for producing the product

cloud-based services

The third key area of the Second Industrial Revolution is the "cloud" You are using a cloud based program right now. Whether it is Apple's iCloud or Google Drive, the concept is the same. A place to store and retrieve digital files. 3-D files don't have to be turned into physical objects on your desk- top 3-D printer. In fact you may want to produce your design in metal using a Direct Metal Laser Sintering 3-D printer, a very expensive machine. However, online manufacturing services such as Shapeways and Solid Concepts can download your design file from the cloud, 3-D print the part in plastic, metal or ceramic and in a couple of days have your finished part back to you for inspection. There are also many companies that sell pre-drawn 3-D designs that you can purchase, download and print yourself. What these three areas: desktop, digital, and cloud mean to the individual designer and small business person is a fabrication chain from prototyping to mass production. What the Internet did to open news, music and movies to everyone, the Second Industrial Revolution is doing for manufacturing.

types of plant layout

The two types of plant layouts are process and product. In a process layout, all equipment that performs the same processes is grouped together, such as the welding department or painting department. In a product layout, all of the equipment needed to produce the same product is grouped together. Engineers communicate their plant layout designs with drawings, two-dimensional templates, and three-dimensional scale models.

Thomas edison

Thomas Alva Edison (February 11, 1847 - October 18, 1931) was an American inventor and a pretty good businessman. He invented many devices that we use today and greatly influenced life around the world. Some of his inventions include the phonograph, the motion picture camera, and a long-lasting, practical electric light bulb. He was one of the first inventors to apply the principles of large-scale teamwork and mass production to the process of invention, and because of that, he is often credited with the creation of the first industrial research laboratory. Thomas Edison was also very involved in the formation of an electrical manufacturing company in 1892. You might have heard of it. It's called GE or General Electric.

Time

Time is a valuable resource within a manufacturing system. It takes time to plan, design, and manufacture a product. In today's extremely competitive economy, time is becoming an important resource. New machines and time compression technologies, such as lean manufacturing, are reducing the time it takes to design and produce products. Thus, the cost of manufactured goods are reduced.

knowledge

To design and operate a manufacturing system requires knowledge. The system must include knowledge for the design and production of products, the communication of information, and the transportation and marketing of products. Additionally, outcomes of the system must be evaluated, and the system must change as a result of the feedback. This requires knowledge on the part of employees. In other words, knowledge resides in the employees, as well as in records, manuals, films, tapes, databases, and other sources.

Two Approaches

Two approaches are used to develop products. A company that matches the new product to its equipment, the skills of its employees, and its marketing systems uses the production approach. A company that focuses on what customers want uses a marketing approach. Most industrial products are developed from the marketing approach. Machines and equipment are designed to meet customer demands.

computer control

Using computers to run machines dramatically lowers the barrier to entry for turning ideas into prototypes. Because today's designs start on screen within CAD programs they exist as digital files that can easily be shared and modified. The online sharing and collaboration culture turns what would have once been a solo effort into community projects.

quality assurance

When you buy a product, you expect it to work as advertised. In manufacturing, the term "quality" means that the product meets the stated design standards. Profitable products work well and are free of defects.

what is a good design

With a well-designed layout, workers such as machinists and assemblers use material processing machines with a minimum of movement. The processes should flow without bottlenecks (areas where work is backed up). Materials handlers should be able to move supplies quickly and safely. In addition, the work environment must meet Occupational Safety and Health Administration (OSHA) safety standards. These government-sponsored workplace safety standards were established to create safe working environments.