ME144 - INDUSTRIAL PROCESSES

Prepared By:

Engr. Estelito V. Mamuyac

11 June 2014

Week-1.0 Introduction 2014-2015 / 1T

INDUSTRIAL PROCESSES

• Industrial processes are procedures involving chemical or

mechanical steps to aid in the manufacture of an item or

items, usually carried out on a very large scale.

• Industrial processes are the key components of heavy

industry.

• An industrial process alters materials or substances.

• Some processes make the production of a rare material

vastly cheaper, thus changing it into a commodity; i.e. the

process makes it economically feasible for society to use the

material on a large scale.

COTTAGE INDUSTRY

• Some industries which are usually operated from large centralized

factories were cottage industries before the Industrial Revolution*.

• A cottage industry (also called the domestic system) is an industry

- primarily manufacturing — which includes many producers,

working from their homes, typically part time.

• The term originally referred to home workers who were engaged in

a task such as sewing, lace-making or household manufacturing.

• Business operators would travel around, buying raw materials,

delivering them to people who would work on them, and then

collecting the finished goods to sell, or typically to ship to another

market.

COTTAGE INDUSTRY

• One of the factors which allowed the Industrial Revolution to take

place in Western Europe was the presence of these business people

who had the ability to expand the scale of their operations.

• Cottage industries were very common in the time when a large

proportion of the population was engaged in agriculture, because

the farmers (and their families) often had both the time and the

desire to earn additional income during the part of the year (winter)

when there was little farming work to do.

• The use of the term has expanded, and is used to refer to any event

which allows a large number of people to work part time.

• For example, eBay is said to have spawned a cottage industry of people who

buy surplus merchandise, and sell it on their auction system.

HISTORY OF COTTAGE INDUSTRY

• Current applications of the term "cottage industry" include: A program,

process or practice that takes up lengthy and/or inordinate amounts of

time while detracting from the main task at hand.

• Cottage industries were the precursor to the factories that would

characterize the Industrial Revolution.

• Their formation was prompted largely by the enclosing of the common

lands.

• Common lands were lands set aside for the common people on which to

garden or graze their livestock.

• Over time the rich aristocrats enclosed the common lands, largely

without censure or punishment of any kind, leaving the poor people in a

major predicament.

HISTORY OF COTTAGE INDUSTRY

• Bear in mind that if one was not a land owner, highly skilled, or

highly educated there were few opportunities to make a good

living.

• Cottage industries were the solution that solved this problem and

saved many of the common people.

• Most of the work was carried out in the home and was often

combined with farming.

• The process of the cottage industry involved the entire family as

most work performed in the 18th century did.

• In fact the entire process moved from child to the mother then to

the father.

HISTORY OF COTTAGE INDUSTRY

• A good example for this type of cottage industry is the making of

cloth. There were three main stages to making cloth: carding,

spinning and weaving.

• Most cloth was made from either wool or cotton, but other

materials such as silk and flax were also used.

• The woven cloth was sold to merchants called clothiers who visited

the village with their trains of pack-horses.

• Some of the cloth was made into clothes for people living in the

same area.

• However, a large amount of cloth was exported.

HISTORY OF COTTAGE INDUSTRY

• The first process is called carding which was

usually done by children.

• This involved using a hand-card that removed and

untangled the short fibers from the mass.

• Hand cards were essentially wooden blocks fitted

with handles and covered with short metal spikes.

• The spikes were angled and set in leather.

• The fibers were worked between the spikes and, by

reversing the cards, scrapped off in rolls (cardings)

about 12 inches long and just under an inch thick.

HISTORY OF COTTAGE INDUSTRY

CARDING MACHINE

HISTORY OF COTTAGE INDUSTRY

• The second process was known as spinning and this was

performed by the mothers.

• The spinning of wool, cotton or flax was originally done by the spindle

and distaff.

• The distaff, a stick about 3 ft long, was held under the left arm, and

the fibers of wool drawn from it were twisted spirally by the forefinger

and thumb of the right hand.

• As the thread was spun, it was wound on the spindle.

• It consisted of a revolving wheel operated by treadle and a driving

spindle. this slow process of spinning was a tedious process that

remained unaltered until the invention of Spinning Jenny.

• The machine used eight spindles onto which the thread was spun

from a corresponding set of rovings. By turning a single wheel, the

operator could now spin eight threads at once.

HISTORY OF COTTAGE INDUSTRY

Modern top-whorl drop spindles

Spinning with a spindle (below) and distaff (above)

HISTORY OF COTTAGE INDUSTRY

• The last process was performed by the fathers or the men of

the household, this process was called the weaving.

• The weaving was done on a machine known as the handloom weaver

so weaving was also referred to as hand-looming.

• The handloom was devised about 2,000 years ago and was brought to

England by the Romans. The process consisted of interlacing one set

of threads of yarn (the warp) with another (the weft). The warp

threads are stretched lengthwise in the weaving loom. The weft, the

cross-threads, are woven into the warp to make the cloth.

• Like the process of spinning, weaving remained unchanged for a great

period of time. Then the twelfth child of a Yeoman farmer, John Kay

invented the flying shuttle, which enabled a weaver to knock the

shuttle across the loom and back again using one hand only.

HISTORY OF COTTAGE INDUSTRY

Weaving in ancient Egypt

An Indian weaver on a pegged loom

A Jacquard loom (mechanical loom, 1801)

A hand loom

HISTORY OF COTTAGE INDUSTRY

• Recently cottage industries have been encouraged by

environmental groups to preserve areas of the rainforest by aiding

the local tribes in a sustainable way.

• e.g., the Maisin tribe and others in Papua New Guinea is a notable

example to sustain the rainforest for future generations.

• In the Philippines, cottage industry is very much alive, especially in

the provinces. Typical of this industry are:

• Dress making

• Handcrafts and artcrafts

• Fine jewelry making

• Furniture and woodworks

MANUFACTURING

• Manufacturing, in its comprehensive sense, is the process of converting raw

materials into products.

• It is the production of goods for use or sale using labor and machines, tools,

chemical and biological processing, or formulation. The term may refer to a

range of human activity, from handicraft to high tech, but is most commonly

applied to industrial production, in which raw materials are transformed into

finished goods on a large scale.

• Manufacturing also involves activities in which the manufactured product,

itself, is used to make other products.

• Examples include large presses to shape sheet metal for appliances and car bodies,

machineries to make fasteners…such as bolts and nuts, and sewing machines to make

clothing.

• Other complex products, such as aircraft, household appliances or automobiles, are sold to

wholesalers, who in turn sell them to retailers, who then sell them to end users – the

"consumers".

MANUFACTURING

• The word manufacturing is derived from the Latin “manu

factus”, meaning made by hand. The word manufacture

first appeared in 1567, and the word manufacturing

appeared in 1683.

• The word product means something that is produced, and

the words product and production first appeared

sometimes during the 15th century.

• Manufacturing and production often are used

interchangeably.

MANUFACTURING – HISTORY & DEVELOPMENT

• In its earliest form, manufacturing was usually carried out by a single

skilled artisan* with assistants. Training was by apprenticeship. In

much of the pre-industrial world the guild system protected the

privileges and trade secrets of urban artisans.

• Before the Industrial Revolution, most manufacturing occurred in

rural areas, where household-based manufacturing served as a

supplemental subsistence strategy to agriculture (and continues to

do so in places). Entrepreneurs organized a number of

manufacturing households into a single enterprise through the

putting-out system.

• Toll manufacturing is an arrangement whereby a first firm with

specialized equipment processes raw materials or semi-finished

goods for a second firm.

MANUFACTURING ACTIVITIES

• Typical Manufacturing Activities

• Product Design

• Machinery and Tooling

• Process and Planning

• Materials

• Purchasing/procurement

• Manufacturing

• Production Control

• Support Services

• Marketing

• Sales

• Shipping

• Customer Services

MANUFACTURING ACTIVITIES

• Manufacturing activities should be responsive to several demands

and trends:

• A product must fully meet design requirements, product specs, and standards.

• A product must be manufactured by the most economical and environmentally friendly

methods.

• Quality must be built into the product at each stage, from design to assembly, rather

than relying on quality testing after the product is manufactured.

• In the highly competitive environment of today, production methods must be

sufficiently flexible to respond to changing market demands, types of products,

production rates, production quantities, and to provide on-time delivery to the

customer.

• Continuous developments in materials, production methods, and computer integration

of both technological and managerial activities in a manufacturing organization must be

evaluated constantly with a view to their appropriate, timely, and economical

implementation.

MANUFACTURING ACTIVITIES

• Manufacturing activities ……demands and trends (cont’d.):

• Manufacturing activities must be viewed as a large system, all

parts of which are interrelated to varying degrees. Such

systems can now be modeled in order to study the effect of

factors such as changes in the market demands, product design,

materials, and production methods on product quality and cost.

• The manufacturer must work with the customer for timely

feedback for continuous product improvement.

• A manufacturing organization constantly must strive for higher

levels of productivity, defined as the optimum use of all its

resources such as materials, machines, energy, capital, labor,

and technology; output per employee per hour in all phases

must be maximized.

FLOW SCHEMATIC DIAGRAM

PCB Manufacturing (Fabrication)

MANUFACTURING SCHEMATIC FLOW DIAGRAM

PCB Manufacturing (Fabrication)

MANUFACTURING SCHEMATIC FLOW DIAGRAM

Car Wheels Manufacturing

PROCESS SCHEMATIC FLOW DIAGRAM

Synthetic Fuel from End of Life Plastics

PROCESS SCHEMATIC FLOW DIAGRAM

MANUFACTURING SCHEMATIC FLOW DIAGRAM

HELPFUL INFORMATION

• Industrial Revolution

• The Industrial Revolution was the transition to new manufacturing processes that occurred in the period from about 1760 to some time between 1820 and 1840. This transition included going from hand production methods to machines, new chemical manufacturing and iron production processes, improved efficiency of water power, the increasing use of steam power and development of machine tools. The transition also included the change from wood and other bio-fuels to coal. The Industrial Revolution began in Great Britain and within a few decades had spread to Western Europe and the United States.

• The Industrial Revolution marks a major turning point in history; almost every aspect of daily life was influenced in some way. Most notably, average income and population began to exhibit unprecedented sustained growth. In the words of Nobel Prize winner Robert E. Lucas, Jr., "For the first time in history, the living standards of the masses of ordinary people have begun to undergo sustained growth ... Nothing remotely like this economic behavior is mentioned by the classical economists, even as a theoretical possibility”.

HELPFUL INFORMATION

• Artisans

• An artisan or artisan (from French: artisan, Italian: artigiano) or craftsman

(craftsperson), is a skilled manual worker who makes items that may be

functional or strictly decorative, including furniture, sculpture, clothing,

jewelry, household items and tools or even machines such as the

handmade devices of a watchmaker.

• Artisans practice a craft and may through experience and aptitude reach

the expressive levels of an artist.

• Artisans were the dominant producers of consumer products prior to the

Industrial Revolution. According to classical economics theory, the division

of labor occurs with internal market development. However, according to

economist John Hicks merchants and artisans originated as servants to the

rulers.

HOMEWORK

o Read the Industrial Revolution and discuss its significance in the industrial world.

REFERENCES

• Textbook

• George T. Austin, (1984), Shreve’s Chemical Processes Industries, 5th Ed. (McGraw-Hill)

• Kalpakjian, Serope; Steven Schmid (August 2005). Manufacturing, Engineering & Technology.

Prentice Hall. pp. 22–36, 951–988.

• Web

• http://en.wikipedia.org/wiki/List_of_industrial_processes

• http://en.wikipedia.org/wiki/Cottage_industry#Cottage_industry

• http://en.wikipedia.org/wiki/Manufacturing

• www.intelorg.com.sg/Alloy%20Wheel%20Projects.htm

• www1.eere.energy.gov