ME20026: Manufacturing Operations and
Technology Notes:
INTRODUCTION:
Definition of Manufacturing:
Traditional Value orientated
Definition Process of converting raw materials Value adding activity
into products using resources
subject to regulations and policies
Flowchart
Manufacturing Industries:
Primary Secondary Tertiary
Definition Exploit natural Convert outputs of Provide services
resources primary industries into
products
Manufacturing Processes and Operations:
Range of activities that must be carried out to convert raw material to the final product:
• Processing and assembly
• Material handling
• Inspection
• Operations management
o Strategy
▪ Understand the aims of the manufacturing company
• Allows performance of the operation to be planned and monitored
at different levels of the enterprise
▪ Develop operations strategy
• Guides minute-by-minute decision making towards company’s long
term goals
o Design
▪ Determines functionality, physical form, shape, composition and software
components of the produced services and products
▪ Processes to do these
1
, o Planning and control
▪ Decided what manufacturing resources should be doing at any given time
o Improvement
▪ Continuous improvement to ensure company remains competitive in the
long run
Production Facilities:
Production quantity:
• Low volume production
o 1 to 100 units
• Medium volume production
o 100 to 10,000 units
• High volume production
o More than 10,000 units
Product Variety:
• Number of different product designs and types that are produced in a factory
• Inverse correlation between variety and quantity in factories
• Types of production facilities
o Low volume production
▪ Job shop
o Medium volume production
▪ Batch production
▪ Cellular manufacturing
o High volume production
▪ Mass production
Product and Part Complexity:
For an assembled product let
• P = product variety
• Q = production quantity
• 𝑛𝑝 = number of parts per product
• 𝑛𝑜 = number of operations required to make the parts
𝑷
𝒏𝒑𝒇 = ∑ 𝑸𝒋 𝒏𝒑𝒋
𝒋=𝟏
If all parts are produced in a factory, the total number of operations is given by:
𝑷 𝑸
𝒏𝒐𝒇 = ∑ 𝑸𝒋 𝒏𝒑𝒋 ∑ 𝒏𝒐𝒋𝒌
𝒋=𝟏 𝒌=𝟏
• 𝑛𝑜𝑓 = total number of operations performed by the factory in a year
o Important since it provides a numerical value for the level of activity in the factory
• 𝑛𝑜𝑗𝑘 = number of processing operations for each part k
• 𝑛𝑝𝑗 = number of parts in product j
2
,If we assume that
• Product designs P are produced in equal numbers Q
• All products have same number of components 𝑛𝑝
• All components require an equal number of operations 𝑛𝑜
𝒏𝒐𝒇 = 𝑷𝑸𝒏𝒑 𝒏𝒐
Limitations and Capabilities of a Manufacturing Plant:
• Refers to the technical and physical limitations of a manufacturing firm and each of its plants
• Main factors in determining capability
o Technological processing capability
▪ Technologies that are available to the factory
▪ Nb sometimes lack of expertise rather that physical availability limits a
manufacturing company
o Physical product limitations
▪ Size and weight limitations for most machines and material handing devices
that limit a manufacturing plant
o Production capacity
▪ This limit is a result of capacity planning for the factory
MANUFACTURING PROCESS SELECTION:
Classification of Manufacturing Processes:
Transformative process
• Mass of part remains the same throughout process
Subtractive process
• Mass reduces during process
Additive Process
• Mass increases during process
Transformative manufacturing processes:
Casting Processes Forming Processes Plastic Processing Surface processes
Sand casting Forging Injection moulding Thermal hardening
Shell moulding Rolling Reaction injection Shot peening
Gravity die casting Drawing moulding
Pressure die casting Cold forming Compression
Centrifugal casting Cold heading moulding
Investment casting Swaging Resin transfer
Ceramic mould casting Superplastic forming moulding
Plaster mould casting Sheet metal shearing Vacuum forming
Squeeze casting Sheet metal forming Blow moulding
Spinning Rotational moulding
Metal injection Continuous extrusion
moulding
Continuous extrusion
Subtractive manufacturing processes
• Machining
3
, • Electrical discharge machining
• Electrochemical machining
• Electron beam machining
• Laser beam machining
• Chemical machining
• Ultrasonic machining
• Abrasive jet machining
Additive manufacturing processes
• Powder metallurgy • Chemical vapour deposition
• Contact moulding • Physical vapour deposition
• Pultrusion • Electroless nickel
• Stereolithography • Electroplating
• 3D printing • Hot dip coating
• Selective laser sintering • Thermal spraying
• Laminated object manufacturing • Welding
• Fused filament fabrication • Brazing
• Carburising • Soldering
• Nitriding • Thermoplastic welding
• Ion implantation • Adhesive bonding
• Anodising • Mechanical fastening techniques
• Chromating
Manufacturing Cost Estimating:
𝑪𝒐𝒔𝒕 = 𝑫𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕 + 𝑰𝒏𝒅𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕
• Direct Cost
o Spent directly on making product
o Scales linearly with quantity produced
• Indirect cost
o All costs that cannot be directly attributed to a specific product
o Manufacturing
▪ Rent ▪ Transport
▪ Rates ▪ Safety
▪ Heat ▪ Computer network
▪ Light ▪ Stores
▪ Power ▪ Production control
▪ Management staff ▪ Quality control
▪ Maintenance ▪ Production
▪ Depreciation engineering
▪ Cleaning
o Business
▪ Research
▪ Design
▪ Development
▪ Sales
▪ Marketing
4
Technology Notes:
INTRODUCTION:
Definition of Manufacturing:
Traditional Value orientated
Definition Process of converting raw materials Value adding activity
into products using resources
subject to regulations and policies
Flowchart
Manufacturing Industries:
Primary Secondary Tertiary
Definition Exploit natural Convert outputs of Provide services
resources primary industries into
products
Manufacturing Processes and Operations:
Range of activities that must be carried out to convert raw material to the final product:
• Processing and assembly
• Material handling
• Inspection
• Operations management
o Strategy
▪ Understand the aims of the manufacturing company
• Allows performance of the operation to be planned and monitored
at different levels of the enterprise
▪ Develop operations strategy
• Guides minute-by-minute decision making towards company’s long
term goals
o Design
▪ Determines functionality, physical form, shape, composition and software
components of the produced services and products
▪ Processes to do these
1
, o Planning and control
▪ Decided what manufacturing resources should be doing at any given time
o Improvement
▪ Continuous improvement to ensure company remains competitive in the
long run
Production Facilities:
Production quantity:
• Low volume production
o 1 to 100 units
• Medium volume production
o 100 to 10,000 units
• High volume production
o More than 10,000 units
Product Variety:
• Number of different product designs and types that are produced in a factory
• Inverse correlation between variety and quantity in factories
• Types of production facilities
o Low volume production
▪ Job shop
o Medium volume production
▪ Batch production
▪ Cellular manufacturing
o High volume production
▪ Mass production
Product and Part Complexity:
For an assembled product let
• P = product variety
• Q = production quantity
• 𝑛𝑝 = number of parts per product
• 𝑛𝑜 = number of operations required to make the parts
𝑷
𝒏𝒑𝒇 = ∑ 𝑸𝒋 𝒏𝒑𝒋
𝒋=𝟏
If all parts are produced in a factory, the total number of operations is given by:
𝑷 𝑸
𝒏𝒐𝒇 = ∑ 𝑸𝒋 𝒏𝒑𝒋 ∑ 𝒏𝒐𝒋𝒌
𝒋=𝟏 𝒌=𝟏
• 𝑛𝑜𝑓 = total number of operations performed by the factory in a year
o Important since it provides a numerical value for the level of activity in the factory
• 𝑛𝑜𝑗𝑘 = number of processing operations for each part k
• 𝑛𝑝𝑗 = number of parts in product j
2
,If we assume that
• Product designs P are produced in equal numbers Q
• All products have same number of components 𝑛𝑝
• All components require an equal number of operations 𝑛𝑜
𝒏𝒐𝒇 = 𝑷𝑸𝒏𝒑 𝒏𝒐
Limitations and Capabilities of a Manufacturing Plant:
• Refers to the technical and physical limitations of a manufacturing firm and each of its plants
• Main factors in determining capability
o Technological processing capability
▪ Technologies that are available to the factory
▪ Nb sometimes lack of expertise rather that physical availability limits a
manufacturing company
o Physical product limitations
▪ Size and weight limitations for most machines and material handing devices
that limit a manufacturing plant
o Production capacity
▪ This limit is a result of capacity planning for the factory
MANUFACTURING PROCESS SELECTION:
Classification of Manufacturing Processes:
Transformative process
• Mass of part remains the same throughout process
Subtractive process
• Mass reduces during process
Additive Process
• Mass increases during process
Transformative manufacturing processes:
Casting Processes Forming Processes Plastic Processing Surface processes
Sand casting Forging Injection moulding Thermal hardening
Shell moulding Rolling Reaction injection Shot peening
Gravity die casting Drawing moulding
Pressure die casting Cold forming Compression
Centrifugal casting Cold heading moulding
Investment casting Swaging Resin transfer
Ceramic mould casting Superplastic forming moulding
Plaster mould casting Sheet metal shearing Vacuum forming
Squeeze casting Sheet metal forming Blow moulding
Spinning Rotational moulding
Metal injection Continuous extrusion
moulding
Continuous extrusion
Subtractive manufacturing processes
• Machining
3
, • Electrical discharge machining
• Electrochemical machining
• Electron beam machining
• Laser beam machining
• Chemical machining
• Ultrasonic machining
• Abrasive jet machining
Additive manufacturing processes
• Powder metallurgy • Chemical vapour deposition
• Contact moulding • Physical vapour deposition
• Pultrusion • Electroless nickel
• Stereolithography • Electroplating
• 3D printing • Hot dip coating
• Selective laser sintering • Thermal spraying
• Laminated object manufacturing • Welding
• Fused filament fabrication • Brazing
• Carburising • Soldering
• Nitriding • Thermoplastic welding
• Ion implantation • Adhesive bonding
• Anodising • Mechanical fastening techniques
• Chromating
Manufacturing Cost Estimating:
𝑪𝒐𝒔𝒕 = 𝑫𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕 + 𝑰𝒏𝒅𝒊𝒓𝒆𝒄𝒕 𝑪𝒐𝒔𝒕
• Direct Cost
o Spent directly on making product
o Scales linearly with quantity produced
• Indirect cost
o All costs that cannot be directly attributed to a specific product
o Manufacturing
▪ Rent ▪ Transport
▪ Rates ▪ Safety
▪ Heat ▪ Computer network
▪ Light ▪ Stores
▪ Power ▪ Production control
▪ Management staff ▪ Quality control
▪ Maintenance ▪ Production
▪ Depreciation engineering
▪ Cleaning
o Business
▪ Research
▪ Design
▪ Development
▪ Sales
▪ Marketing
4
