Cont…
• Cellular manufacturing is a process of manufacturing which is a
subsection of just-in-time manufacturing and lean manufacturing
encompassing group technology.
• The goal of cellular manufacturing is to move as quickly as possible,
make a wide variety of similar products, while making as little waste
as possible.
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4. Micro-Fabrication and Nanotechnology
• Products that are so miniaturized require special fabrication technologies.
❑ Micro-fabrication: refers the processes needed to make parts and products
whose features sizes are in the micrometer range (1 μm = 10-3 mm = 10-6m).
– Examples: ink-jet printing heads, compact discs (CDs and DVDs), and micro-
sensors used in automotive applications (e.g., air-bag deployment sensors).
❑ Nanotechnology: refers to materials and products whose feature sizes are in the
nanometer scale (1 nm = 10-3 mm = 10-6 mm = 10-9m), a scale that approaches the size of
atoms and molecules. Ultra-thin coatings for catalytic converters, flat screen TV monitors,
and cancer drugs are examples of products based on nanotechnology
Addis Ababa institute of Technology, SMiE, MEng 3191 86
5. Lean Production and Six Sigma
• These are two programs aimed at improving efficiency
and quality in manufacturing.
• They address demands by customers for products they
buy to be both low in cost and high in quality.
• Lean production: based on the Toyota Production System
developed by Toyota Motors in Japan. Its origins date from the
1950s and 1960s when Toyota began using unconventional
approaches to improve quality, reduce inventories, and
increase flexibility in its operations.
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Addis Ababa institute of Technology, SMiE, MEng 3191
Cont…
• Lean production can be defined simply as “doing more
work with fewer resources.”
✓ Fewer workers and less equipment are used to accomplish more
production in less time, and yet achieve higher quality in the final product.
• The underlying objective of lean production is the
elimination of various forms of waste, such as producing
defective parts, excessive inventories, and workers waiting.
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Addis Ababa institute of Technology, SMiE, MEng 3191
Cont…
• Six Sigma was started in the 1980s at Motorola Corporation
in the United States.
• Objective of six sigma: to reduce variability in the
company’s processes and products to increase customer
satisfaction.
• Six Sigma : a quality-focused program that utilizes
worker teams to accomplish projects aimed at improving
an organization’s operational performance.
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6. Environmentally Conscious Manufacturing
• The most important process in manufacturing process is material removal
processes, in which chips are removed from a starting workpiece to create
the desired part geometry.
• Another unavoidable aspect of manufacturing is that power is required to
accomplish any given process. Generating that power requires fossil fuels,
the burning of which results in pollution of the environment.
• At the end of the manufacturing sequence, a product is created that is
sold to a customer. Ultimately, the product wears out and is disposed of,
perhaps in some landfill, with the associated environmental degradation.
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Cont…
• Environmentally conscious manufacturing: refers to
programs that seek to determine the most efficient use of
materials and natural resources in production and
minimize the negative consequences on the environment.
• Other terms for these programs include green manufacturing and
sustainable manufacturing. They all boil down to two basic
approaches:
✓Design products that minimize their environmental impact
✓Design processes that are environmentally friendly.
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Cont…
• Product design is the logical starting point in environmentally
conscious manufacturing.
• Design for environment (DFE): the techniques that attempt to consider
environmental impact during product design prior to production.
• Considerations in DFE include:
➢ Selecting materials that require minimum energy to produce,
➢ Selecting processes that minimize waste of materials and energy,
➢ Designing parts that can be recycled or reused,
➢ Designing products that can be readily disassembled to recover the parts,
➢ Designing products that minimize the use of hazardous and toxic materials, and
➢ Giving attention to how the product will be disposed of at the end of its useful life.
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Cont…
• Approaches that can be applied to make plant operations
more environmentally friendly:
✓ Adopting good housekeeping practices—keeping the factory clean,
✓ Preventing pollutants from escaping into the environment (rivers and
atmosphere),
✓ Minimizing waste of materials in unit operations,
✓ Recycling rather than discarding waste materials,
✓ Using net shape processes,
✓ Using renewable energy sources when feasible,
✓ Maintaining production equipment so that it operates at maximum efficiency, and
✓ Investing in equipment that minimizes power requirements.
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Thank you!!
