MATEPRO (Group Quiz 1 MODULE 1) Flashcards
What is Process?
A Process converts a material from one form to another adding value to it.
Manufactured goods are typically divided into 2 classes:
Producer goods
Consumer goods
The vast majority of objects around
us consist of numerous individual
pieces that are built and assembled
by a combination of processes called
[blank]
manufacturing
- bolts, nuts,
paper clips, etc. - Individual items
DISCRETE PRODUCTS
a roll of
aluminum foil, a spool of wire, metal or
plastic tubing
- cut into individual pieces
CONTINUOUS PRODUCTS
every individual products has a
certain value which starts with raw
materials subjected to a sequence of
processes
VALUE
Production of Steel in Asia
600-800 A.D.
First Industrial Revolution
1780-1850
Second Industrial Revolution
1947
Third Industrial Revolution
1960-Industry 4.0 (modern times)
- involves the creative and systematic prescription of the shape
and characteristics of an artifact to achieve specified objectives while
simultaneously satisfying several constraints. - 80% of the cost of product development and manufacture is
determined by the decisions made in the initial stages of design.
PRODUCT DESIGN
Traditional processes using the sequential methodology may
appear to be straightforward and logical; in practice, however, it is
wasteful of both time and resources.
THE DESIGN PROCESS
also called simultaneously engineering by which all relevant
disciplines (departments and personnel) are already simultaneously
involved even from the earliest stages of product design.
- to bring products to the market as rapidly as possible
CONCURRENT ENGINEERING
- a prototype is a physical
model of an individual component or
product - carefully reviewed for
possible modifications to the original
design, materials of production
method
Prototype Production
is done prior to full
scale/mass production to validate and
document the manufacturing processes
for the developed product
Pilot Production
- prototypes can now be made rapidly
and at low cost using various specialized
technologies and CAD/CAM - available for wide variety of materials
ranging from plastics and ceramics to metallic
materials - examples are: 3D Printing (Additive
manufacturing), laser cutting
RAPID PROTOTYPING
a software-based method that uses
advanced graphics and virtual-reality
environments to allow designers to view and
examine a part in detail
VIRTUAL PROTOTYPING (Simulation-based
design)
Is a major consideration in manufacturing because all
components, regardless of their size, eventually have
to be assembled into the final product
DIMENSIONAL TOLERANCE
In concurrent engineering, the
design and manufacture of
products are integrated with a
view toward optimizing all
elements involved in the [blank] of the product.
Life Cycle
Stages of life cycle:
- Product start-up
- Rapid growth of the
product in the marketplace - Product maturity
- Decline
[blank] is comprehensive approach to integrating the design process with
production methods, materials, process planning, assembly, testing, and quality
assurance
DESIGN FOR MANUFACTURE (DFM)
Experience has indicated that a product which is easy to assemble is usually
also easy to disassemble
- Assembly costs in manufacturing operations can be substantial, typically
ranging from 20 to 60% of the total product cost.
DESIGN FOR ASSEMBLY (DFA) and DISASSEMBLY (DSD)
- The design should take into account the concept that, for ease of access,
components that are most likely to be in need of servicing be placed, as much as
possible, at the outer layers of the product.
DESIGN FOR SERVICE (DFS)
“mistake proofing” or “inadvertent error
prevention”
*Is the use of any automatic device or method that
either makes it impossible for an error particularly
human error to occur
POKA-YOKE
to increase product value,
reduce cost, reduce material usage.
Process development
is the economic term for making goods
and services available to satisfy human wants. It implies
creating value by applying useful mental or physical labor.
Manufacturing
A [blank] adds value to raw materials and
ultimately converts them to finished products, often using
machines or machine tools.
manufacturing process
The [blank] is a collection of operations
and processes used to obtain a desired product or
component.
manufacturing system
The entire company is the [blank]
production system
*Injection molding, die casting, progressive
stamping, milling, arc welding, painting,
assembling, testing, pasteurizing, homogenizing,
and annealing.
basic manufacturing processes
A [blank] is an assembly of related
mechanisms on a frame or bed that together
produce a desired result.
machine tool
A [blank] may do a single process or
multiple processes, or it may manufacture an
entire component.
machine tool
An [blank] is a distinct action performed to produce a
desired result or effect.
operation
is the manufacture of a product from pieces
such as parts, components, or assemblies. Examples of
fabricated products are spoons, nails, cars, etc.
Fabricating
refers to the manufacture of a product by
continuous means. Examples of processed products are
food, chemical and pharmaceutical products.
Processing
usually refers to the manufacture of a
product wherein the tools and the workers are the ones
who are usually brought to the product site. Examples
include buildings and highways.
Construction
- Designs the product.
- Should know what the product is supposed to do.
- Should know what environment/operating conditions
the product will be exposed to
Design engineer
- Selects the tools, machines, and processes that will be
used to manufacture the product designed by the
design engineer. - The manufacturing process is usually the most hostile
environment the product will ever see its entire lifecycle.
Manufacturing engineer
- Has expertise in setup reduction, integrated quality control and
inspection devices, and reliability and maintenance of machines and
of people. - Does process time reduction activities, factory lay-out optimization
and tool uptime/downtime improvement. - Increases efficiency of the factory.
Industrial and Lean Engineer
- Selects and develops new materials for the product designed by the
design engineer.
Materials Engineer
- Similar
machines/tools are
grouped together. - Used by factories
manufacturing a
large variety of
products
Job Shop
- Used when the
product is difficult to
move (e.g. an
airplane) - Like a machine shop
in a garage at home. - Tools and machines
are at the sides, while
the product being
assembled is at the
middle.
Project Shop
- Used for mass
production of a small
variety of products. - Subsequent
manufacturing processes
are lined up. - There is only one flow
for the manufacturing
system.
Flow Shop
- Used in manufacturing
food and chemical
products. - Features efficient material
handling. - Products are usually
transported from one
manufacturing process to
another via a piping or a
conveyor.
Continuous Process
- This layout is a product of the lean-manufacturing concept.
- Related processes are grouped and laid-out together in a Ushape.
- Product is transported via a kanban link.
Linked-cell
These are the value-adding steps in a manufacturing system
ex.
* Casting/foundry/molding processes
* Forming or metalworking processes
* Machining (material removal) processes
* Joining and assembly
* Surface treatments (finishing)
* Rapid prototyping
* Heat treating
* Other
BASIC MANUFACTURING PROCESSES
refers to checking whether the
finished product meets a specific
benchmark/criteria after manufacturing.
* Is the color correct? Is the length, width, height
correct? Are there any physical defects?
Inspection
exposes the product to the actual
environment it will be exposed to after being
bought.
* Does the product do what it is supposed to do? Does
it taste right? Does it fulfill the promised
specifications?
Testing
Refers to the physical movement of the product during manufacturing
* Includes loading and unloading of the product from the machine/tool.
* Automating the material handling steps often reduce scrap and
increases throughput (units produced/hour).
Transportation
- Maintains the product’s quality between completion and use.
- This is what the customer first sees in the product.
- Can sometimes be more expensive than the product itself (e.g.
cosmetics and razor blades)
Packaging
- Must be minimized at all cases. Time lapses without any value added
to the product other than depreciation. - Automation is discouraged. Cost of storage must be minimized.
Storage
