MM206E Manufacturing Processes

Gazi University, Faculty of Engineering

Mechanical Engineering Department

Elmas Salamcı, Rahmi Ünal, Yusuf Usta

FUNDAMENTALS OF MODERN MANUFACTURING - 4th Ed.

Mikell P. Groover

Pages: 1-24
 INTRODUCTION AND
OVERVIEW OF MANUFACTURING

1. What is Manufacturing?
2. Materials in Manufacturing
3. Manufacturing Processes
4. Production Systems
5. Organization of the Book

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Manufacturing?

• The word manufacture is derived from two Latin words, manus

(hand) and factus (make); the combination means made by hand.
• The English word manufacture is several centuries old, and ‘‘made by
hand’’ accurately described the manual methods used when the
word was first coined.
• Most modern manufacturing is accomplished by automated and
computer-controlled machinery.

• The words manufacturing and production are often used

interchangeably.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
• As a field of study in the modern context, manufacturing can be
defined two ways, one technologic and the other economic.

• Technologically, manufacturing is the application of physical and

chemical processes to alter the geometry, properties, and/or
appearance of a given starting material to make parts or products;
manufacturing also includes assembly of multiple parts to make
products.

The processes to accomplish manufacturing involve a combination of

machinery, tools, power, and labor, as depicted in Figure 1.1(a)
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
• Economically, manufacturing is the transformation of materials into items of greater
value by means of one or more processing and/or assembly operations, as depicted in
Figure 1.1(b).
• The key point is that manufacturing adds value to the material by changing its shape or
properties, or by combining it with other materials that have been similarly altered.
• The material has been made more valuable through the manufacturing operations
performed on it.
• When iron ore is converted into steel, value is added. When sand is transformed into
glass, value is added. When petroleumis refined into plastic, value is added. And when
plastic is molded into the complex geometry of a pation chair, it is made even more
valuable.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
MANUFACTURING INDUSTRIES AND PRODUCTS

• Manufacturing Industries: Industry consists of enterprises and

organizations that produce or supply goods and services. Industries
can be classified as primary, secondary, or tertiary.
• Primary industries cultivate and exploit natural resources, such as
agriculture and mining.
• Secondary industries take the outputs of the primary industries and
convert them into consumer and capital goods. Manufacturing is the
principal activity in this category, but construction and power utilities
are also included.
• Tertiary industries constitute the service sector of the economy. Alist
of specific industries in these categories is presented in Table 1.2.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
Manufactured Products: Final products made by the manufacturing
industries can be divided into two major classes: consumer goods and
capital goods.

• Consumer goods are products purchased directly by consumers, such

as cars, personal computers, TVs, tires, and tennis rackets.

• Capital goods are those purchased by companies to produce goods

and/or provide services. Examples of capital goods include aircraft,
computers, communication equipment, medical devices, trucks and
buses, railroad locomotives, machine tools, and construction
equipment.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Production Quantity, Q

Production quantity refers to the number of units produced annually of

a particular product type.

Annual production quantities can be classified into three ranges:

Production range Annual Quantity Q
Low production 1 to 100 units
Medium production 100 to 10,000 units
High production 10,000 to millions of

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Product Variety, P
Product variety refers to different product designs or types that are
produced in the plant.
 Different products have different shapes and sizes;
• they perform different functions
• they are intended for different markets
• some have more components than others;

The number of different product types made each year in a

factory can be counted
When the number of product types made in the factory is
high, this indicates high product variety.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
P versus Q in Factory Operations

Figure 1.2 P-Q Relationship

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 More About Product Variety
Although P is a quantitative parameter, it is much less exact than Q
because details on how much the designs differ is not captured
simply by the number of different designs.

 Soft product variety - small differences between products, e.g.,

between car models made on the same production line, with many
common parts among models
 Hard product variety - products differ substantially, e.g., between a
small car and a large truck, with few common parts (if any)

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Manufacturing Capability

A manufacturing plant consists of processes and systems (and people,

of course) designed to transform a certain limited range of materials
into products of increased value.

The three building blocks - materials, processes, and systems - are the
subject of modern manufacturing

 Manufacturing capability includes:

1. Technological processing capability
2. Physical product limitations
3. Production capacity

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 1. Technological Processing Capability
The technological processing capability of a plant (or company) is its
available set of manufacturing processes.
Certain plants perform machining operations, others roll steel billets
into sheet stock, and others build automobiles.

• A machine shop cannot roll steel,

• A rolling mill cannot build cars.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 2. Physical Product Limitations
• A plant with a given set of processes is limited in terms of the size and
weight of the products that can be accommodated.
Large, heavy products are difficult to move. To move these products
about, the plant must be equipped with cranes of the required load
capacity.
Smaller parts and products made in large quantities can be moved by
conveyor or othermeans.

Product size and weight affect:

• Production equipment
• Material handling equipment
 Production, material handling equipment, and plant size must be
planned for products that lie within a certain size and weight range.

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 3. Production Capacity
• Manufacturing capability is the production quantity that can be
produced in a given time period (e.g., month or year).
• This quantity limitation is commonly called plant capacity, or
production capacity, defined as the maximum rate of production
that a plant can achieve under assumed operating conditions.

 Operating conditions refer to number of shifts per week, hours per

shift, direct labor manning levels in the plant, and so on
 Usually measured in terms of output units, such as tons of steel or
number of cars produced by the plant
 Also called plant capacity

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Materials in
Manufacturing

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 In Addition: Composites
•Nonhomogeneous mixtures of the other three basic
types rather than a unique category

Figure 1.3 Venn

diagram of three
basic material types
plus composites

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Manufacturing Processes

• Two basic types:

1. Processing operations - transform a work material from one state
of completion to a more advanced state
• Operations that change the geometry, properties, or
appearance of the starting material
2. Assembly operations - join two or more components to create a
new entity

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Figure 1.4 Classification of manufacturing processes

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Shaping Processes – Four Categories
1. Solidification processes - starting material is a heated
liquid or semifluid
2. Particulate processing - starting material consists of
powders
3. Deformation processes - starting material is a ductile
solid (commonly metal)
4. Material removal processes - starting material is a
ductile or brittle solid

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Solidification Processes

• Starting material is heated sufficiently to transform it into a liquid or

highly plastic state.
 Examples: metal casting, plastic molding

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Particulate Processing

• Starting materials are powders of metals or ceramics

 Usually involves pressing and sintering, in which powders are first
compressed and then heated to bond the individual particles

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Deformation Processes

• Starting workpart is shaped by application of forces that exceed the

yield strength of the material
 Examples: (a) forging, (b) extrusion

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Material Removal Processes
• Excess material removed from the starting piece so what remains is the
desired geometry
 Examples: machining such as turning (a), drilling (b), and milling (c)

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Waste in Shaping Processes
• Desirable to minimize waste in part shaping
 Material removal processes are wasteful in unit operations, simply by
the way they work
 Most casting, molding, and particulate processing operations waste
little material
 Terminology for minimum waste processes:
• Net shape processes - when most of the starting material is
used and no subsequent machining is required
• Near net shape processes - when minimum amount of
machining is required

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Property-Enhancing Processes
• Performed to improve mechanical or physical properties of work
material

 Part shape is not altered, except unintentionally

• Example: unintentional warping of a heat treated part
 Examples:
• Heat treatment of metals and glasses
• Sintering of powdered metals and ceramics

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Surface Processing Operations

 Cleaning - chemical and mechanical processes to remove dirt,

oil, and other contaminants from the surface

 Surface treatments - mechanical working such as sand blasting,

and physical processes like diffusion

 Coating and thin film deposition - coating exterior surface of the

workpart

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Assembly Operations
Two or more separate parts are joined to form a new entity

Types of assembly operations:

1. Joining processes – create a permanent joint

Welding, brazing, soldering, and adhesive bonding

2. Mechanical assembly – fastening by mechanical methods

Threaded fasteners (screws, bolts and nuts); press fitting, expansion fits

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Production Systems

• People, equipment, and procedures used for the

combination of materials and processes that constitute
a firm's manufacturing operations
 A manufacturing firm must have systems and
procedures to efficiently accomplish its type of
production
 Two categories of production systems:
• Production facilities
• Manufacturing support systems
 Both categories include people (people make the
systems work)

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Production Facilities

• The factory, production equipment, and material

handling systems
 Production facilities "touch" the product
 Includes the way the equipment is arranged in the
factory - the plant layout
 Equipment usually organized into logical groupings,
called manufacturing systems
• Examples:
 Automated production line
 Machine cell consisting of an industrial
robot and two machine tools

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Facilities versus Product Quantities
• A company designs its manufacturing systems and
organizes its factories to serve the particular mission of
each plant
 Certain types of production facilities are recognized as
the most appropriate for a given type of manufacturing:
1. Low production – 1 to 100
2. Medium production – 100 to 10,000
3. High production – 10,000 to >1,000,000
 Different facilities are required for each of the three
quantity ranges

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Low Production
• Job shop is the term used for this type of production
facility
 A job shop makes low quantities of specialized and
customized products
• Products are typically complex, e.g., space
capsules, prototype aircraft, special machinery
 Equipment in a job shop is general purpose
 Labor force is highly skilled
 Designed for maximum flexibility

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Medium Production

• Two different types of facility, depending on product variety:

Batch production
• Suited to hard product variety
• Setups required between batches
Cellular manufacturing
• Suited to soft product variety
• Worker cells organized to process parts without setups
between different part styles

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 High Production
 Often referred to as mass production
• High demand for product
• Manufacturing system dedicated to the
production of that product
 Two categories of mass production:
1. Quantity production
2. Flow line production

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Quantity Production

• Mass production of single parts on single machine or small numbers

of machines
 Typically involves standard machines equipped with special tooling
 Equipment is dedicated full-time to the production of one part or
product type
 Typical layouts used in quantity production are process layout and
cellular layout

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Flow Line Production

• Multiple machines or workstations arranged in sequence, e.g.,

production lines
 Product is complex
• Requires multiple processing and/or assembly operations
 Work units are physically moved through the sequence to complete
the product
 Workstations and equipment are designed specifically for the
product to maximize efficiency

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Manufacturing Support Systems

• A company must organize itself to design the processes

and equipment, plan and control production, and satisfy
product quality requirements
 Accomplished by manufacturing support
systems - people and procedures by which a company
manages its production operations
 Typical departments:
1. Manufacturing engineering
2. Production planning and control
3. Quality control

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
 Overview of Major Topics

• Figure 1.10 Overview of production system and major topics in

Fundamentals of Modern Manufacturing.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of
Modern Manufacturing 3/e
A spectacular scene in steelmaking is charging of a basic oxygen furnace,
in which molten pig iron produced in a blast furnace is poured into the
BOF. Temperatures are around 1650°C (3000 ° F).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
A machining cell consisting of two horizontal machining centers supplied by
an in-line pallet shuttle (photo courtesy of Cincinnati Milacron).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
A robotic arm performs
unloading and loading
operation in a turning
center using a dual gripper
(photo courtesy of
Cincinnati Milacron).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Metal chips fly in a high
speed turning operation
performed on a computer
numerical control turning
center (photo courtesy of
Cincinnati Milacron).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Photomicrograph of the cross section of multiple coatings of titanium
nitride and aluminum oxide on a cemented carbide substrate (photo
courtesy of Kennametal Inc.).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
A batch of silicon wafers enters a furnace heated to 1000°C (1800°F) during
fabrication of integrated circuits under clean room conditions (photo
courtesy of Intel Corporation).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Two welders perform arc
welding on a large steel
pipe section (photo
courtesy of Lincoln
Electric Company).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Automated dispensing of
adhesive onto component
parts prior to assembly
(photo courtesy of EFD,
Inc.).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Assembly workers on an
engine assembly line
(photo courtesy of Ford
Motor Company).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e
Assembly operations
on the Boeing 777
(photo courtesy of
Boeing Commercial
Airplane Co.).

©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of

Modern Manufacturing 3/e