An introduction to the manufacturing industry
Essential Manufacturing provides a comprehensive introduction to the wide breadth of the manufacturing industry.
There is a need for all engineering and business students to understand the importance and context of the manufacturing industry. An engineer should have a well rounded appreciation of all aspects of the industry they work in, including manufacturing. This is evidenced by professional bodies expecting all accredited engineering courses to provide students with a background that allows them to see their own specific discipline in context. Similarly, business students will often find themselves dealing in some way with manufactured products or even be directly involved in manufacturing operations management. This book will cover the full spectrum of the manufacturing industry to provide a holistic appreciation of the topic but with enough detail to be of practical use.
The book begins with an introduction to the manufacturing industry, its history, and some important manufacturing concepts. The materials used in manufacturing and how they are produced are covered. This is followed by a more detailed description of the more common manufacturing processes, their application, and the types of automation used in the manufacturing industry. Consideration is then given to the important aspects of manufacturing operations management and production planning and control, work study, and manufacturing economics. How to maintain quality in the manufacturing process, including metrology, is examined and this is followed by human factors in manufacturing. Finally, a speculative look at the future of manufacturing is included.
Key features:
- Takes a self-contained approach.
- Includes review questions.
- Suitable as an introduction for more advanced study.
- Satisfies the requirements of college and first and second year university engineering courses.
The book provides a comprehensive, concise introduction to the manufacturing industry for engineering and management students.
Table of Contents
Preface xv
Part I Introduction 1
1 Introduction 3
1.1 Wealth and Prosperity 4
1.2 Manufacturing Industry 5
1.3 Manufacturing as a Stimulant 7
1.4 The Supply Chain 8
1.5 Conclusion 9
Review Questions 10
2 Manufacturing History 11
2.1 Toolmaking Humans 11
2.2 The New Stone Age 12
2.3 The Bronze Age 13
2.4 The Iron Age 14
2.5 The Industrial Revolution 16
2.6 The Twentieth Century 21
2.7 The Twenty-First Century 24
Review Questions 25
3 Typical Manufacturing Industries 27
3.1 Introduction 27
3.2 Aerospace Industry 29
3.3 Automotive Industry 30
3.4 Shipbuilding and Marine Engineering 31
3.5 Electronics and Electronic Products 32
3.6 Household Appliances 32
3.7 Pharmaceutical Industry 33
3.8 Food Processing 33
3.9 Beverage Industry 34
3.10 Clothing Industry 34
3.11 Producer Goods 35
3.12 Materials and Chemicals Production 35
Review Questions 36
4 Designing for Manufacture 37
4.1 Introduction 37
4.2 Computer Aided Design, Virtual Reality and Augmented Reality 37
4.3 Design for X 38
4.4 The Product Life Cycle 39
4.5 The Design Process 40
4.6 Identifying the Market Need 41
4.7 The Product Design Specification 41
4.8 Concept Design 43
4.9 Detail Design 43
4.10 Prototyping 44
4.11 Production 44
4.12 Contributors to the Design 44
4.13 Some Principles of Product Design 45
4.14 Standardisation and Modularisation 46
4.15 A Design for Manufacture Example 47
4.16 Conclusion 50
Review Questions 50
5 Manufacturing Concepts 53
5.1 The Manufacturing System 53
5.2 Lean Manufacturing and Added Value 55
5.3 Integrating the Effort 56
5.4 The Formal Organisation 60
5.5 Types of Manufacture 63
5.6 Types of Manufacturing Equipment 66
Review Questions 67
Part II Manufacturing Materials 69
6 Materials for Manufacture 71
6.1 Introduction 71
6.2 The Structure of Metals 72
6.3 Plastics 79
6.4 Ceramics 82
6.5 Composites 83
6.6 Properties and Testing of Materials 83
6.7 Conclusion 88
Review Questions 88
7 Materials Production 91
7.1 Introduction 91
7.2 Ferrous Metals Production 91
7.3 Non-Ferrous Metals Production 95
7.4 Forms of Material Supply 97
7.5 The Primary Production of Plastics 98
Review Questions 100
Part III Manufacturing Processes 101
8 Casting 103
8.1 Introduction 103
8.2 Ingot Casting 103
8.3 Continuous Casting 104
8.4 Sand Casting 105
8.5 Centrifugal Casting 107
8.6 Shell Moulding 107
8.7 Full Mould Process 108
8.8 Investment Casting 109
8.9 Die Casting 110
8.10 Defects in Castings 112
8.11 Cleaning of Castings 112
8.12 When to Use Casting 113
Review Questions 113
9 Cutting Processes 115
9.1 Introduction 115
9.2 Sawing and Filing 115
9.3 Basic Principles of Machining 116
9.4 Machine Tools 121
9.5 Other Cutting Processes 129
Review Questions 130
10 Deformation Processes 133
10.1 Introduction 133
10.2 Rolling 134
10.3 Forging 136
10.4 Extrusion 138
Review Questions 139
11 Press working 141
Review Questions 145
12 Plastics Processing 147
12.1 Introduction 147
12.2 Extrusion 147
12.3 Blow Moulding 148
12.4 Calendering 149
12.5 Vacuum Forming 149
12.6 The Blown Film Process 150
12.7 Injection Moulding 151
Review Questions 157
13 Additive Manufacturing Processes 159
13.1 Introduction 159
13.2 Advantages of Additive Manufacturing 159
13.3 Disadvantages of Additive Manufacturing 160
13.4 General Types 160
Review Questions 170
14 Miscellaneous Metal working Processes 171
14.1 Electro discharge Machining 171
14.2 Electrochemical Machining 172
14.3 Chemical Machining 172
14.4 Ultrasonic Machining 173
14.5 High Energy Rate Forming 173
14.6 Powdered Metal Processes 174
14.7 Pipe and Tube Manufacture 175
14.8 Metal Finishing Processes 176
Review Questions 178
15 Manufacturing Processes in the Electronics Industry 181
15.1 Introduction 181
15.2 Semiconductor Component Manufacture 182
15.3 Clean Rooms 186
15.4 Printed Circuit Board Manufacture 187
15.5 Conclusion 193
Review Questions 193
16 Assembly and Joining 195
16.1 Introduction 195
16.2 Mechanical Fastening 195
16.3 Soldering 197
16.4 Brazing 198
16.5 Welding 199
16.6 Adhesive Bonding 208
Review Questions 210
17 Material and Process Selection 211
Part IV Manufacturing Automation 215
18 Manufacturing Automation - Introduction 217
18.1 Types of Automation 217
18.2 The Advantages of Automation 218
18.3 Typical Examples of Manufacturing Automation 220
Review Questions 222
19 The Building Blocks of Automated Systems 223
19.1 Cams 223
19.2 Geneva Mechanism 223
19.3 Transfer Systems 224
19.4 Conveyors 225
19.5 Limit Switches 225
19.6 Fluid Power Components 226
19.7 Electric Motors for Actuation 227
19.8 Feedback Devices 229
19.9 The Vibratory Bowl Feeder 231
19.10 Programmable Logic Controllers (PLCs) 232
19.11 Control of Automated Machines 233
Review Questions 234
20 Reprogrammable Automation 235
20.1 Industrial Robots 235
20.2 Reprogrammable Equipment Precision 242
20.3 Computer Numerical Controlled (CNC) Machine Tools 243
20.4 Automated Guided Vehicles (AGVs) 243
20.5 Reprogrammable Automation and Industrial Robot Safety 247
Review Questions 250
21 Machine Vision 253
21.1 Areas of Application of Artificial Vision 253
21.2 Vision System Components 254
21.3 Lighting 259
21.4 Some Further Application Examples 261
21.5 Conclusion 262
Review Questions 262
Part V Manufacturing Operations Management 263
22 Production Planning 265
22.1 Introduction 265
22.2 Plant Location 265
22.3 Plant Layout 267
22.4 Project Planning 270
22.5 Process Planning 275
Review Questions 278
23 Production Control 281
23.1 Introduction 281
23.2 Elements of Production Control 282
23.3 Material Requirements Planning 285
23.4 Manufacturing Resource Planning 288
23.5 Enterprise Resource Planning 289
23.6 Recognising Constraints 290
23.7 Just in Time Manufacture 291
Review Questions 295
24 Work Study 297
24.1 Introduction 297
24.2 Method Study 299
24.3 Work Measurement 306
24.4 Work Study As a Service to Management 309
Review Questions 311
25 Manufacturing Economics 313
25.1 Introduction 313
25.2 Costs for Decision Making 315
25.3 Investment Appraisal 320
25.4 Cost Analysis and Control 323
25.5 Conclusion 325
Review Questions 325
Part VI Maintaining Manufacturing Quality 327
26 Quality Defined - Quality Management and Assurance 329
26.1 Defining Quality 329
26.2 Quality Management 329
26.3 Organisation for Quality 331
26.4 The Cost of Quality 335
26.5 Conclusion 338
Review Questions 339
27 Metrology and Statistical Quality Control 341
27.1 Introduction 341
27.2 Metrology 342
27.3 Factory and Workshop Metrology 345
27.4 Surface Texture and Measurement 347
27.5 Statistical Quality Control (SQC) 349
Review Questions 352
Part VII Human Factors in Manufacturing 355
28 Human Factors in Manufacturing 357
28.1 Introduction 357
28.2 Job Satisfaction 357
28.3 Health and Safety 358
28.4 Ergonomics 364
28.5 Conclusion 374
Review Questions 375
Part VIII Conclusion 377
29 Introduction 379
29.1 Additive Manufacturing 379
29.2 Augmented Reality (AR) and Virtual Reality (VR) 380
29.3 Immersive Telepresence 381
29.4 Communications Technologies and the IoT 381
29.5 Cloud Computing 382
29.6 Big Data Analytics 383
29.7 Conclusion 383
Appendix A: SI prefixes and multiplication factors 385
Index 387
