BMKU 1412

BMCG 2312 – Manufacturing Process

It is possible to obtain this gear directly from natural?
Example of an Engineering Product
1. Aeroplanes – what are they made of?
Apa bahan-bahan diguna untuk membuatnya?
2. Twin Tower Petronas – What is this building
composed of?
Bangunan ni terdiri daripada apa?
What can you say?

Most of the product is made up of

several parts.
Each part has gone through a
series of manufacturing process.
Source: Automotive manufacturing solutions
 Machinery

Tooling

Power

Labor
Definition of manufacturing term

Takrifan terma pembuatan

What would be the consequences if the manufacturing process did not exist in the world?
Based on your understanding, why is
manufacturing process so important for a country
like Malaysia.
Product
Raw materials Manufacturing
What would happen if the manufacturing
Process Profit process did not exist in this world?
How does the manufacturing process
contribute to the prosperity of a country?

1) Technology – 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 the assembly of multiple parts to make products.
 Manufacturing
2) Economic – manufacturing is the Process
transformation of materials into items of
Value
greater value by means one or more added

processing involve. Therefore,

manufacturing is “added value” to the
Starting Material in Processed
material. material processing material
 Raw Material(s) Process(es) Products
• STEEL • TYPE OF • PROCESSES • SUBTRACTIVE PROCESSES
MANUFACTURING • FORMING AND SHAPING • CONTINOUS PROCESS
OPERATION AND • NET SHAPE PROCESS
LAYOUT
• ADDITIVE PROCESS
• JOINING PROCESS
QUALITY AND METROLOGY

SUSTAINABLE MANUFACTURING
 DEVELOPMENT
PRODUCT
INPUT FROM COMMENTS
CUSTOMERS INPUT FROM FROM
SUPPLIERS CUSTOMER

PRODUCT PRODUCT
PROJECT PROPOSAL PROJECT PLANNING DESIGN
MANUFACTURE LAUNCH
 PLANNING
TEAM

PRODUCT
DESIGN TEAM
ENGINEERING/PRODUCTION
TEAM

Who ARE involve in manufacturing PROCESS?

CUSTOMERS PLANNING ENGINEERING/
SUPPLIERS
PRODUCTION
New feature
Quantity to produce Does the design can fit the
Destination market current equipment
Production location Need new machine?
Product life
What are the tasks of
Similar competitor model planning department
What are the tasks of
engineering department?
What are the tasks of product
design team?

Translate planning design

Into manufacturable
design

Why concurrent engineering is important?

Traditional “waterfall” or sequential development vs. Iterative
development method in Concurrent Engineering
Distinguish between sequential development and iterative development methods.
PLANNING TEAM PRODUCT DESIGN ENGINEERING/PR
TEAM ODUCTION TEAM
DESIGN MATERIAL EXTERNAL REGULATIONS
• Size and shape of the final product • Material to be used (type and basic • Environment and
and raw material properties) • safety
• Geometry complexity • Castability/ weldability/Machinability
• parts with thin cross-sections
QUALITY MACHINES AND TOOLS
cannot be cast properly; complex
• Dimensional accuracy (tolerances) • Availability of machines
parts cannot be formed easily.
required and equipment
• Surface finish required -additional • Flexibility to change the
COST operations: grinding, polishing design at any time
• Economics (cost) of tooling, (better finish but more expensive!)
capital, scrap rate etc
• Operational and Cost QUANTITY If you're given product A and your boss asks you to
considerations: • Number of parts or products required choose the appropriate manufacturing process for
producing it, what factors would you consider?
• Design and cost of tooling and
• desired production rate
Explain the relationship between the design of a product and the
TIME FRAME choice of manufacturing process.
Explain the relationship between the cost and the choice of
• Lead time required to manufacturing process.
begin production Explain the relationship between the material and the choice of Additional reading
manufacturing process. https://writepass.com/journal/2016/08/factors-that-affect-
selection-of-manufacturing-process-design-at-apple-inc/
Extrusion
An industry refers to a specific category or sector of
economic activity where businesses and organizations are
involved in producing goods, providing services, or both,
that are related or similar in nature. Industries typically
group together companies that are engaged in similar types
of production, trade, or services. For example, the
automobile industry includes companies that manufacture
cars, while the entertainment industry encompasses
businesses related to film, music, and media. Industries are
a fundamental part of the economy and play a crucial role in
the production and distribution of goods and services
 Industries can be classified as:
Give an example of a finished product. Explain the
series of processes that turn raw materials into a
finished product within the primary, secondary, and
tertiary industries
What is a primary industry, and can you provide an example?Take the outputs of the
What is a secondary industry, and can you provide an example?
What is a tertiary industry, and can you provide an example?primary industries and
Those that CULTIVATE CONVERT them into
AND EXPLOIT natural consumer and
resources; capital goods.

Constitute with
•Aerospace SERVICE SECTOR of
PRIMARY INDUSTRY

•Agriculture •Automotive •Banking

•Forestry the economy.

INDUSTRY
SECONDARY

TERTIARY INDUSTRY
•Beverages •Communications
•Fishing •Building materials •Education
•Livestock •Chemicals •Entertainment
•Quarries •Computers •Financial services
•Mining •Consumer appliances •Health and medical
•Petroleum •Electronics •Government
•Equipment •Hotel
•Food processing •Insurance
•Glass, ceramic •Restaurant
•Paper •Retail trade
•Pharmaceuticals •Tourism
•Plastics (shaping) •Transportation
•Textiles •Real estate
•Tire and rubber
•Wood and furniture
 11

• Manufacturing system can be defined as a transformation system in which a

product or service is created by working upon a set of inputs.

• Inputs are usually in the form of men, machine, money, materials etc. Production
systems are usually classified on the basis of product quantity and variety.

Intermittent Continuous
Project Mass
Batch
Jobshop What is manufacturing system?
1) Project – 1 to 10 units.
[Low production]
2) Job shop – 10 to 100 units.

3) Batch – 100 to 10,000 units. [Medium production]

4) Mass – Above 10,000 units. [High production]

List the type of manufacuring system

Explain the characteristics of each manufacturing system
Differentiate between the job shop, batch and mass manufacturing system.

@jurie 2007 – Lecture 1

 Above 10,000 units Continuous Production
System
Mass 100 to 10,000 units Intermitted Production
System
QUANTITY/VOLUME

High Batch 10 to 100 units

Product

Job shop 1 to 10 units

Medium
Project What is product quantity?
what is product quality?

Low

Plot the graph of product volume versus product variety for mass, batch, jobshop Product VARIETY
and project manufacturing system with an appropriate label.

Production quantity: number of unit produced annually of a particular product type.

Product variety: different product designs or types that are produced in the plant.
• Position – remains stationary
during the manufacturing
process

• Materials, people, machinery

are brought to the product
site.

• Based on customer
specifications.

• Example: bridge, building

construction, aircraft, ships,
locomotive.
 A job shop is a type of manufacturing process in which small batches of a variety
of custom products are made. In the job shop process flow, most of the products
produced require a unique set-up and sequencing of process steps.

 Low volume. Make-to-order

 Satisfies a market for nonstandard or
unique product.
 Layout – different machines with similar
functional are grouped together as
department.
 Require high skill levels labor – to
operate a variety of equipment
 A short duration activities to provide
custom goods.
 Example: Car workshop.
 Batch production produce or process any product in groups
called “batches”.
 Can produce a variety of products – opposed to a
continuous production process, or a one time production.
 Useful for industries that makes seasonal items/products
 Example: Similar standard items made periodically in
batches: bakery, paint, hand tools.
 Same facilities used to manufacture all the different items.

Batch Production Examples:

Baked goods
Clothing
Computer software
Die- or mold-making
Electrical goods
- Reduce initial capital outlay
- due to a single production line can be used to several products
- machines can be used more effectively, materials can be bought in bulk
- workers can specialize in that task.

- Requires very careful production planning & control – next batches; when, types.
- When switching to another batches – takes time (“down time”) – can cause loss of
output (low yield).
- Resulted “WIP” or create inventory/stock – increases costs such as inventory
cost, cost because of damage to stock.
The example production line (shown below) is that of an engineering company, manufacturing small steel
products such as hinges and locks. They manufacture batches of five hundred at a time. The workers are
unskilled and semi skilled. As each task is completed the item being manufactured is passed down the
production line to the next worker, until it is complete.
 Mass production often involves the assembly of a number of
sub-assemblies of individual components. Parts may be bought
from other companies.

 A.k.a flow production, repetitive flow

production
 Producing goods in large quantities at low cost
per unit and produce in a short period of time.
 Involved fewer labor cost and a faster rate of
production.
 Work piece is transfer automatically from one
machine to another.
 Example: Cola-cola drinks, light bulbs,
refrigerator, tv.
What is plant layout?
What is the main goal the plant layout?
Plant layout refers to an
optimum arrangement of
facilities including
personnel, operating
equipment, storage space,
material handling
equipment and all other
supporting services along Goal of Plant Layout
with the design of best To maximize the profit by arrangement of all the plant
structure to contain all facilities to the best advantage of total manufacturing of
these facilities”. the product.

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
 List the objectives of plant layout.

• Streamline the flow of materials through the plant. Optimal Space Utilization: Arrange equipment and
Facilitate the manufacturing process. workstations to maximize the use of available
space, minimizing wastage and congestion.

• Minimize materials handling and cost. Improved Workflow: Design the layout to facilitate
a smooth flow of materials, components, and

• Effective utilization of men, equipment and space.

information throughout the production process.

Enhanced Productivity: Organize the layout to

• Flexibility of manufacturing operations and

reduce material handling time, streamline
processes, and increase overall efficiency.

Increased Safety: Ensure that the layout minimizes

arrangements. hazards and provides a safe working environment
for employees.

• Provide for employee convenience, safety and Flexibility: Design the layout to accommodate
changes in production requirements, such as new

comfort. product lines or changes in production volume.

Reduced Costs: Optimize the layout to minimize

• Minimize investment in equipment. production costs, including material handling,
inventory, and labor costs.

• Minimize overall production time. Improved Quality: Create a layout that allows for
better quality control and reduces the risk of errors
or defects.
• Maintain flexibility of arrangement and operation. Employee Morale: Consider the layout's impact on
employee satisfaction and morale, aiming for a
comfortable and efficient working environment

https://www.wisdomjobs.com/e-university/production-and-operations-management-tutorial-295/plant-layout-9479.html
 List the principles of the plant layout
Principles of Explain each principle of the plant layout
Plant Layout

Safety,
Minimum Minimum Cubic space Maximum
Integration security, and Flow
Distance handling utilization flexibility
satisfaction

A good The total Workers Reduces A good Materials to Can be

layout distance safety and the layout is move in altered
integrates travelled by satisfaction material one that forward without much
men, the men and and handling to utilizes both direction cost and
materials, materials safeguards the horizontal towards the time, i.e.,
and should be the plant minimum and vertical completion future
machines in minimum and space. Also stage requirements
order to get and as far as machinery the height
the optimum possible against fire,
utilization of straight line theft, etc.
resources movement
and should be
maximum preferred
effectiveness.
 Flow Line Functional
Fixed Position Cellular
(Product) (Process)

 Fixed position Layoutproject Map the type of plant layout to the type of
manufacturing system.
 Product LayoutMass Production
 Process LayoutBatch/jobshop
 Cellular LayoutHybrid

http://slideplayer.com/slide/3715352/
 PROJECT

1. Fixed position layout List the criteria of fixed position layout? and illustrate it in sketching
List the criteria of Process layout? and illustrate it in sketching
List the criteria of Product layout? and illustrate it in sketching
Fixed Position Layout This is also called the project type of layout.
• The material, or major components remain in a fixed location and tools, machinery, men and other
materials are brought to this location.
• Suitable when one or a few pieces of identical heavy products (huge) are to be manufactured and when
the assembly consists of large number of heavy parts, the cost of transportation of these parts is very high
and take a long time to produce.
Process layout is recommended for batch production.
• Machines performing similar type of operations are
BATCH
grouped at one location in the process layout e.g., all
lathes, milling machines, etc. are grouped in the shop
will be clustered in like groups (according to
functions)

• The flow paths of material through the facilities from

one functional area to another vary from product to
product.

• Usually the paths are long and there will be

possibility of backtracking.

• Process layout is normally used when the production

volume is not sufficient to justify a product layout.

• Typically, job shops employ process layouts due to

the variety of products manufactured and their low
production volumes.
 MASS

In this type of layout, machines and • Machines and equipment are positioned
auxiliary services are located along a flow line.
according to the processing • Several flow lines may come together to
sequence of the product. feed the final assembly line.
• Product passes from workstation to
Plant arrangement to facilitate another workstation along the flow line.
material processing in the same • Special purpose machines are used which
order. perform the required function quickly and
reliably.
Suitable for mass production system • High level of machine and manpower
as , the facilities can be arranged to utilization
achieve efficient flow of materials • Need to categorize operations to ensure
and lower cost per unit. equal processing time at all work stations
(line balancing).
When Applicable
When the volume of production
Product A
of a product is high such that a L L M D
separate production line to
manufacture it can be justified. Product B
L M M D
In a strict product layout,
machines are not shared by Product C
L G G D
different products. Therefore,
the production volume must be
sufficient to achieve satisfactory
utilization of the equipment.

A typical product layout is

shown in the following figure.
Advantages
• Reduced work handling leads to short
cycle time/piece.
• Less WIP
• Simple planning and control.
• Reduced labor skill.
• Good space utilization.

Disadvantages
• Limited flexibility
• Machine breakdown causes major
problem
• High setting up cost.
• Uses expensive special purpose machine
 Plant divided into groups or cells in a small unit (individual cell), consisting of one to several
workstations.

 A w/station can contains either one machine (known as a single machine cell), or several machines
(known as a group machine cell) with each machine performing a different operation on the part.

 Cells can process a complete family of parts – need to form families of products.

 The flow among the equipment in the cells can vary depending on the composition of parts within
the part family.

 Good example for the implementation of the concept of group technology.

 The machines at w/stations can be modified, retooled, and regroup for different product lines
within the same family of parts.

 Consist of two subsections which is Just-in-Time (JIT) and Lean Manufacturing

Group technology or GT is a manufacturing technique in which
parts having similarities in geometry, manufacturing process
and/or functions are manufactured in one location using a small
number of machines or processes.
 Relate to quantity &
Plant layout variety of product

Type of
Nature of manufac Tech
work operation
involved
Classificati Definition
Definition 1. manufac definition
on
2. How to select the
Intro to right
Industry
Manufac Econ process
classification
3. Type of manufac
Select
process
People operations
Example involve 4. Plant layout
Factors to
consider
Roles