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Introduction to Manufacturing

- Part 1-

Darrell Wallace

Youngstown State UniversityDepartment of Mechanical and

Industrial Engineering

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man·u·fac·ture (v)

1. To make or process (a raw material) into a finished product, especially by means of a large-scale industrial operation.

2. To make or process (a product), especially with the use of industrial machines.

Latin:Manus (hand) + factus (make)

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Evolution of Manufacturing Just as today, the historical evolution of

manufacturing occurred as an exchange between material technology and processing capability

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Prehistoric Periods Stone Ages (~10,000,000 – 2,000 BC)

Time period varied geographically Three periods:

Paleolithic (old stone age) Mesolithic (middle stone age) Neolithic (new stone age)

Stone age likely led to wooden tools

Bronze Age (~2500-500 BC) Iron Age (~1500 BC-1000 AD)

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Manufacturing as Craft and Art Prior to about 1800, nearly all

manufacturing was “craftsmanship.” All products made as “one-offs” No standardization or mass-production

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Industrial Revolutions Major periods of Industrial growth beginning

around 1800 and continuing through modern day Transfer of expertise from person to process Improvements in processes

Automation Machine Tools Power Sources Materials Processing

Improvements in Infrastructure

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Some Key Components of the Industrial Revolutions Consumerism Military Development and Transfer of Technology

Manufacturing Tools and Processes Raw material processing (Whitney, Bessemer) Vertical integration (combined spinning / weaving) Mass Production (interchangeability, assembly lines) Machine Tools (Maudslay)

Power sources Steam Engines (Newcomb / Watt) IC Engines Electric machinery

Infrastructure Transportation Communication

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Year: 2004

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Educational services,health care, and social

assistance

Professional andbusiness services

Government

Finance, insurance,real estate, rental, and

leasing

Manufacturing

Contribution to U.S. GDP ($Billions)

Source: U.S. Bureau of Economic Analysis

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U.S. Manufacturing Employment FiguresSince 2001, Manufacturing employment has decreased significantly. However, contribution to the GDP has remained basically steady during that period. How is this possible?

Source: U.S. Bureau of Labor Statistics

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U.S. Manufacturing Productivity

M anufacturing SectorProductivity Index Per Capita

1987-2004

70

80

90

100

110

120

130

140

150

160

170

1985 1990 1995 2000 2005

Ou

tpu

t (N

orm

aliz

ed t

o 1

00%

in 1

992)

Source: BLS

50 years to Double Output

10 years to Double Output

25 years to Double Output

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Recent Shifts in U.S. Manufacturing 2001 Marked a major shift toward increased

productivity Employment in the manufacturing sector has

decreased sharply, but production has not. Productivity is at an all-time high Low-value-added processes appear to be offset

by improvements in higher-margin production Demand for employment will likely continue to

shift from unskilled laborers to individuals who can contribute to higher productivity.

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Engineering Skills Valued in Modern Manufacturing Environment Process Expertise

Improve process efficiencies Bridge gap be between design technology and production

technology

Design Expertise Adapt designs to make them more manufacturable

Logistics and Process Flow Maximize efficiency throughout the manufacturing process

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Course Objectives Show the relationship of manufacturing to other

engineering pursuits

Familiarize you with the most common manufacturing processes and some fundamental analyses

Encourage you to consider the many processes by which each product you encounter is manufactured

Provide fundamental background for future work and education in manufacturing and related fields