ManufacturingManufacturing

What is manufacturing?What is manufacturing?

• Dictionary.com defines it as:Dictionary.com defines it as:– the making of goods or wares by the making of goods or wares by

manual labor or by machinery, manual labor or by machinery, especially on a large scale especially on a large scale

Characteristics of Mass Characteristics of Mass ProductionProduction

• Precision measurementPrecision measurement• StandardizationStandardization• InterchangeabilityInterchangeability• SynchronizationSynchronization• ContinuityContinuity

Characteristics in choosing Characteristics in choosing they type of manufacturingthey type of manufacturing

• Volume to be producedVolume to be produced• Availability of necessary inputsAvailability of necessary inputs• Types of products to be madeTypes of products to be made• Life cycle or durability of a productLife cycle or durability of a product• Production philosophy of the Production philosophy of the

organizationorganization

Types of manufacturingTypes of manufacturing

1.1. Continuous ManufacturingContinuous Manufacturing

2.2. Intermittent (batch) manufacturingIntermittent (batch) manufacturing

3.3. Custom manufacturing Custom manufacturing

4.4. Just-in-time (JIT) (kanban) Just-in-time (JIT) (kanban) manufacturingmanufacturing

Continuous Continuous ManufacturingManufacturing

– Produces a large # of identical Produces a large # of identical products.products.

– Narrow production line (company Narrow production line (company makes only one product)makes only one product)

– Examples: TVs, radios, refrigerators, Examples: TVs, radios, refrigerators, food, and utensils.food, and utensils.

– Requires workers to be specialized at Requires workers to be specialized at their jobstheir jobs

Intermittent (batch) Intermittent (batch) manufacturingmanufacturing

– Company has a large inventoryCompany has a large inventory– Chosen for medium length production Chosen for medium length production

runs of a wide variety of products.runs of a wide variety of products.– Set-up and tooling are changed often Set-up and tooling are changed often

because of modificationsbecause of modifications– Advantage: same production line may Advantage: same production line may

be used for different productsbe used for different products– Examples: holiday candy, musical Examples: holiday candy, musical

instruments, and house paint.instruments, and house paint.

Custom manufacturing Custom manufacturing

– Produces one or just a few products at Produces one or just a few products at a timea time

– Each product is uniqueEach product is unique– Problem solving and trouble shooting Problem solving and trouble shooting

are necessary skillsare necessary skills– Prices of final product is quite highPrices of final product is quite high– Examples: large yachts, airplanes, Examples: large yachts, airplanes,

custom tools, jewelry, pottery, custom custom tools, jewelry, pottery, custom furniture and signs.furniture and signs.

Just-in-time (JIT) (kanban) Just-in-time (JIT) (kanban) manufacturingmanufacturing

– Can be applied to the different types Can be applied to the different types of manufacturingof manufacturing

– Key goals: reduce the inactive Key goals: reduce the inactive inventory and cut lot sizesinventory and cut lot sizes

Departments in IndustryDepartments in Industry

1.1. ManagementManagement

2.2. EngineeringEngineering

3.3. ProductionProduction

4.4. MarketingMarketing

5.5. FinancesFinances

6.6. Human resourcesHuman resources

ManagementManagement

– Makes sure all the departments work Makes sure all the departments work togethertogether

– Make company policies and then makes Make company policies and then makes sure the other departments follow themsure the other departments follow them

– Ranked in a hierarchical orderRanked in a hierarchical order– Duties include:Duties include:

• PlanningPlanning• OrganizingOrganizing• DirectingDirecting• ControllingControlling• EvaluatingEvaluating

EngineeringEngineering

– Designs, produces, and tests the first Designs, produces, and tests the first model of a new product (prototypes).model of a new product (prototypes).

– They conduct tests and experimentsThey conduct tests and experiments– Most departments have a research Most departments have a research

and development teamand development team– Types of engineers include:Types of engineers include:

• ManufacturingManufacturing• Quality controlQuality control• DesignDesign• MethodsMethods

ProductionProduction

– Sets up and uses the tools and Sets up and uses the tools and machine to make the product.machine to make the product.

– Management worker, the supervisor, Management worker, the supervisor, is in chargeis in charge

– Divided into skilled, semi-skilled, and Divided into skilled, semi-skilled, and unskilled laborunskilled labor

MarketingMarketing

– Conducts market research and Conducts market research and advertises, packages, sells, and advertises, packages, sells, and distributes the productdistributes the product

– Department includes: statisticians, Department includes: statisticians, advertisers, package designers, advertisers, package designers, salespeople, and shipping workers.salespeople, and shipping workers.

FinancesFinances

– Keeps track of all income and Keeps track of all income and expenditures.expenditures.

– Expenditures include: payroll, material Expenditures include: payroll, material costs, utility costs, and buying and costs, utility costs, and buying and maintaining tools, equipment, and maintaining tools, equipment, and machines.machines.

– Department includes: accountants, Department includes: accountants, bookkeepers, and other record bookkeepers, and other record keepers.keepers.

Human ResourcesHuman Resources

– Responsible for:Responsible for:• RecruitingRecruiting• NegotiatingNegotiating• TrainingTraining• Health and SafetyHealth and Safety

– Maintains safe environment by the Maintains safe environment by the Occupational Safety and Health administration Occupational Safety and Health administration (OSHA)(OSHA)

• Public Relations.Public Relations.

Material ProcessingMaterial Processing

• Primary Manufacturing ProcessesPrimary Manufacturing Processes• Secondary Manufacturing Secondary Manufacturing

ProcessesProcesses• Finished producFinished produc

Primary Manufacturing Primary Manufacturing processesprocesses

• all materials must change from their all materials must change from their raw state to a more useful form for raw state to a more useful form for secondary manufacturing.secondary manufacturing.

– Obtaining raw materialsObtaining raw materials– Refining materials- separates the useful Refining materials- separates the useful

part from the unwanted and less useful part from the unwanted and less useful materialsmaterials

• Mechanical refiningMechanical refining• Chemical refiningChemical refining• Thermal refiningThermal refining

– Manufacturing standard materialsManufacturing standard materials

Secondary Manufacturing Secondary Manufacturing processesprocesses

• Separating toolsSeparating tools• Forming toolsForming tools• Combining toolsCombining tools• Other toolsOther tools• ComputersComputers

Separating toolsSeparating tools

• remove part of the original remove part of the original material and leave the required material and leave the required size and shape size and shape

• Chip removalChip removal– Drills and bitsDrills and bits– Saw bladesSaw blades– CuttersCutters– Files, grinders, and abrasive papers.Files, grinders, and abrasive papers.

• Shearing tools (shears, chisels, and Shearing tools (shears, chisels, and punches)punches)

Forming toolsForming tools

• Casting toolsCasting tools• Compressing and stretching toolsCompressing and stretching tools• Conditioning toolsConditioning tools

Combining toolsCombining tools

• Coating toolsCoating tools• Bonding toolsBonding tools• Mechanical fastening toolsMechanical fastening tools

Other toolsOther tools

• MeasuringMeasuring• Holding-Clamps and pliersHolding-Clamps and pliers• Positioning-Jigs and fixturesPositioning-Jigs and fixtures• Transporting machinesTransporting machines