Lecture notes Manufacturing Engineering

lecture notes and what is manufacturing engineering and management and what is industrial manufacturing engineering and what is advanced manufacturing engineering
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Dr.LeonBurns,New Zealand,Researcher
Published Date:21-07-2017
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ME 303 – Manufacturing Engineering Course Notes Prof. Dr. Ömer ANLAĞAN Prof. Dr. S. Engin KILIÇ Prof. Dr. A. Erman TEKKAYA Assoc. Prof. Dr. Melik DÖLEN Middle East Technical University Department of Mechanical Engineering Ankara 06531, TURKEYWhat is Manufacturing?  Meaning: Manufacture (of Latin origin) Manu→ Hand Fact→ Made/fashioned Manufactus→ Hand-made Design Manufacturing is the  Definition: making of the goods Materials Processes from raw materials into a suitable form. 2/22/2014 ME 303 - Section 01 1.1Definition of Manufacturing Manufacturing is a blend of art, science, and economics with very broad social implications. Three Pillars of Manufacturing  Scientific Sense  Engineering (Practical) Sense  Economic Sense 2/22/2014 ME 303 - Section 01 1.2Historical Developments  Manufacturing started some 6000 years ago.  Early humanbeings used sharp and strong materials as cutting tools and their bodies as machine tools.  Hands: Workpiece- and tool holding devices  Muscles: Actuators for primary and secondary motions  Eyes: Position transducers (sensors)  Brain: Control computer 2/22/2014 ME 303 - Section 01 1.3History (Cont’d)  First industrial revolution (1760-1830)  Introduction of the steam engine (replacement of muscle power)  Early mechanization 2/22/2014 ME 303 - Section 01 1.4History (Cont’d)  Second industrial revolution (1950-present)  Extensive use of electric power  Introduction of the computer and solid-state electronics (replacement of eyes and partly brain operations)  Development of new materials and manufacturing techniques 2/22/2014 ME 303 - Section 01 1.5Economic Role of Manufacturing  Prosperity of a nation is closely related to the capabilities of its manufacturing industry.  Even after the second industrial revolution, one cannot create wealth without manufacturing industry.  Competitiveness can be achieved through high level of productivity. Nations falling behind in this respect find their living standards gradually diminishing. 2/22/2014 ME 303 - Section 01 1.6Manufacturing and GNP USA Kuwait Japan Switzerland Germany Mexico Turkey Brazil Argentina India Pakistan Contribution of Bangladesh Manufacturing (%) 30 5 Gross National Product: Value of all goods and services produced in a national econony. 2/22/2014 ME 303 - Section 01 1.7 Log of GNPAutomation  Meaning: Automation (of Greek origin) Auto→ Self Matos→ Acting/moving Automation is a form of manufacturing in  Definition: which production, movement, and inspection are performed by self-operating machine without human intervention. The skill of a human operator is essentially transfered to a specialized machine. 2/22/2014 ME 303 - Section 01 1.8Automation (2)  Mechanization implies an operation being performed by a mechanical system (not by hand).  It is generally based on open- loop (no feedback) control strategy.  Ex: Use of a cam mechanism to move the cross-slide of a lathe. 2/22/2014 ME 303 - Section 01 1.9Automation (3)  Automation implies closed-loop control and adaptive control in an advanced context. Automation utilizes programmable devices with different flexibility.  Hard Automation constitutes control methods that require considerable effort to reprogram a certain machine for different operations.  Soft/Flexible Automation consists of control methods that allow easy reprogramming through simply changing the software. 2/22/2014 ME 303 - Section 01 1.10Spectrum of Specialization Manufacturing Engineering Application of science, engineering, technology, and economics to manufacture products of a quality, quantity, and cost competitiveness in the market place. Manufacturing Engineers Manufacturing Engineers Material Quality Process Tool Standarts Facility Material Quality Handling Control Process Tool Standarts Facility Engineers Engineers Engineers Engineers Handling Control Engineers Engineers Engineers Engineers Engineers Engineers Engineers Engineers 2/22/2014 ME 303 - Section 01 1.11Process Engineers Develop a logical sequence of manufacturing operations for each assembly and for the final assembly of all sub- assemblies into a finished product. Need a detailed knowledge of  Machining process  Forming process  Assembly process  Plant capabilities  Existing equipment 2/22/2014 ME 303 - Section 01 1.12Tool Engineers Provide proper tools for manufacturing. Following tools are commonly used in manufacturing industry:  Conventional Tools  Standard tools: Cutting tools, dies  Non-standard tools: Workpiece holding devices  Non-traditional Tools  Electro-discharge machining (EDM): electrodes  Laser 2/22/2014 ME 303 - Section 01 1.13Standards Engineers Synchronize the entire manufacturing process. For this purpose, they determine the time requirement for each operation and their sequences utilizing work standards and standard times. 2/22/2014 ME 303 - Section 01 1.14Material Handling Engineers  Plans for efficient transfer of materials from one point to another. They must avoid the following:  Disruption of production due to lack of batches  Unnecessary level of in-process stock  High degree of congestion 2/22/2014 ME 303 - Section 01 1.15Facility Engineers  Provide efficient equipment layout. They must avoid the following:  Higher material handling cost  Longer manufacturing time  High level of in-process stock  High degree of congestion in the process flow.  In some cases, facility engineers and material handling engineers combine in a single group called plant engineers. 2/22/2014 ME 303 - Section 01 1.16Quality Control Engineers Maintain the described level of product quality by employing a quality assurance system. Quality can be established at:  Product design stage  Design stage of production system  Production stage by inspection. 2/22/2014 ME 303 - Section 01 1.17Manufacturing Quality  Quality is defined at the design stage and is built into the product during manufacturing.  Design quality sets the specifications on the material and tolerances.  Manufacturing quality is the degree of comformity to the design specifications. 2/22/2014 ME 303 - Section 01 1.18Quality vs. Cost Quality ↑ Cost ↑ Demand ↓ Quality ↑ Quantity ↓ Cost ↑ 2/22/2014 ME 303 - Section 01 1.19

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