Manufacturing Technology (ME461) Lecture1

7/25/2019 Manufacturing Technology (ME461) Lecture1

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ME-461, Manufacturing

Technology, Lecture 1Date: 20/05/2016

Intructor: !hantanu"hattacharya



Manufacturing !yte#$%%roach

Definition of Manufacturing Technology:

•Manufacturing technology provides the tools that enable production of all

manufactured goods. These master tools of industry magnify the effort of

individual workers and give an industrial nation the power to turn raw materials

into the affordable, quality goods essential to today’s society.•Manufacturing technology provides the productive tools that power a growing,

stable economy and a rising standard of living. Thus manufacturing process reallyrepresents adding value to a raw material and creation of wealth.

Manufacturing

Facility AddValueInputOutput

Replenish

Wealth

Manufacturing

Syste

coprising ofanufacturing

processes

Sales

fluctuations

Ra! aterials cost and

a"aila#ility

$usiness

en"ironent

Social %ressure

Resources and

plans

%roduction rate&

'uality and

deli"ery

%rofit

Reputation

Manufacturing

%rocess is the (ey

to !ealthgeneration



Manufacturing Enter%rie• For a anufacturing enterprise of the t!enty first century #usiness en"ironent

the customer is the king)•The #usiness en"ironent is characteri*ed ainly #y products of increasing

variety and lower demand)•This has led to the epo!erent of +ustoer indi"idualis as a central thee

of all #usinesses)•This necessitates the anufacturing of highly custoi*ed products soeties

custoi*ed to the needs and necessities of indi"idual custoers)

•,istorically the 1970’s !ere dominated by the cost of product as a ain le"er

to o#tain copetiti"e supreacy)•-ater 1980’s were dominated by the low cost, high performance, high

quality product)

•+urrently& the customer takes high quality and low cost to be granted and isore focused to other factors li(e:

1!inding out his e"act product e"pectation and requirement

#customi$ation%

&'educed delivery lead times

()nvironmental issues like reduced waste generation etc



Manufacturing Enter%rie

• !o the current focus of any #anufacturing enter%rie i todevelop a mechanism to understand the customerneeds and develop internal mechanisms to respondto the changing needs quickly an& ine'%eni(ely)

• !o #ot of the factorie follo* the reverse direction

thinking that build products from customer needsand expectations)

• In other *or& *e can ay that a future ucceful#anufacturing organi+ation *ill e a virtual corporationthat i instantaneously responsive to customerneeds) In&utry conortiu# on t*enty .rt century#anufacturing , ol&#an an& rie



Manufacturing Enter%rie• We (no! ho! the "arious

functional organs of any

manufacturing enterprisesuch as finance, sales and

marketing, design and

manufacturing and human

resources recei"es feed#ac(

a#out product& product

attri#utes and ar(et

segents)

• That is also one of the

reasons !hy custoer plays a

pi"otal role)

• +orporate o#.ecti"es such as growth in market share, profitability,

workforce stability, and other financial measures associated !ith any

anufacturing enterprise emanate from the study of the market place)



hat can #ar3eting i&entify *hich *oul&hel% the #anufacturing enter%rie

• Range of products, product market segment, product ideas tosatisfy customer needs.

• an a co#%any &eli(er the 3in& of %ro&uct nee&e& to atify theor&er *inning criteria uch a cot, uality, lea& ti#e an& o on

• The an*er to thi uetion *oul& lie in product design and

manufacturing *hich e'%lore the (ariou &eign an& %roce o%tiona *ell a aee the infratructure to ee if they can atify theor&er *inning criteria)

• 7(iouly , the human resources, technology, nance, andbusiness processes in the co#%any %lay a #a8or role in an*eringthi uetion an& their interaction *ith #anufacturing i (ery

i#%ortant)• !o, a #anufacturing trategy i really a collaorati(e &eciion #a3ing

that houl& ati.e e(eryo&y9 nee& an neceitie an& i alo a*ay to achie(e congruence et*een corporate strategy, marketinggoals and manufacturing capabilities of an enter%rie)



$ hitorical %er%ecti(e of Deign1) Deign an& #anufacturing are core acti(itie for reali+ing a #ar3etale

an& %ro.t #a3ing %ro&uct)

2) The .gure elo* ho* the e(olution of #echanical $D/$M yte#o(er the %at three &eca&e) $D technology e#erge& to facilitate

representation completeness. /) First there !as the de"elopent of 01D

drafting in 2345s !hich e6tended to /D

odels principaly initiated #y the

!irefrae #ased odeling systes)

,o!e"er& it !as not possi#le to

represent higher order geoetry data

such as surfaces)7) In 2385 surface #ased odels !ere

de"eloped !hich e"ol"ed surface data

for #oundary representations although

this !as not sufficient to represent solid

or "olue enclosure inforation)

9) All solid odeling schees ha"e an

inherent !ea(ness in that they pro"ide

a lo! le"el representation of parts in

ters of only pro"iding geoetric and

topological data constituting the odel

4) This led to a slightly higher order odeling of paraetric and "ariational design !hich

finally eerged as (no!ledge #ased engineering syste that captures a lot of additional

non geoetric product inforation li(e engineering rules& part dependences&anufacturing constraints etc)



Mo&ern #anufacturing

• De.nitionaly modern manufacturing is a series of interrelatedactivities and operations involving design, material selection,planning, production, quality assurance, management, andmarketing of discreet consumer and durable goods.

• Manufacturing can e classied into continuous and discreetproduct production %rocee an& *e *ill e %rinci%ally focuing onthe &icreet %ro&uction technology)

• The modern manufacturing being very sensitive to the customerwant and need and the market environment is a combination ofattributes of mass production and job shop production.

• !uch yte# ha(ing attriute fro# oth are 3no*n a exible

manufacturing systems.• They rely hea(ily on ! equipment, "#$%, R&'&(% and group

technology approaches *hich rely hea(ily on i#ilaritie in %art%ro&uction y (irtue of their &eign attriute an& #anufacturingfeature)



$ hitorical %er%ecti(e of#o&ern #anufacturing

• The conce%t of a factory an& %ro&ucti(ity i#%ro(e#ent i really attriute&to the father of #o&ern &ay econo#ic , a !cotih national "dam %mith*hoe fa#ou *or3 on the &i(iion of laor entitle&

An Inquiry into the Nature and Causes of the Wealth of Nations); *a oneof the .rt treatie in 1<<6 on #o&ern &ay econo#ic an& ca%itali#)

• De(elo%#ent of the =o* ae#ly line yte# for engine #anufacturing

y )enry *ord in ++- *a a giant lea% to*ar& the #o&ern &ay#anufacturing)

• !o#e other %hiloo%her li3e *rant #ilbreth *ho &e(elo%e& the conce%tof #otion tu&y an& eli#ination of *ateful #otion an& )enry #antt*ho &e(lo%e& a yte#atic gra%hing %roce&ure for %re%lanning,

che&uling of acti(itie an& %rogre re(ie* an& che&ule u%&ating)• In the area of #achine #.. evol developed a controller device in

+/0 that coul& recor& electrical ignal #agnetically an& %lay the# ac3to o%erate a #echanical #achine) $ no) of intereting &e(elo%#ent ha(eta3en %lace ince then in the area of #achine tool)

http://en.wikipedia.org/wiki/The_Wealth_of_Nations

http://en.wikipedia.org/wiki/The_Wealth_of_Nations



Machine: $ hitorical

er%ecti(e• The .rt ucceful nu#erical #achine tool *a &e(elo%e& at MIT un&er

a ucontract fro# aron or%oration, Michigan on $ir force fun&ing in1?50)

• $uto#atic tool changer an& in&e'ing *or3tale *ere a&&e& in 1?60)

• During thi %erio& the conce%t of D> &irect nu#eric control in *hiche(eral > #achine are lin3e& to a #ain co#%uter *a &e(elo%e&)

• ontrol yte# &e(elo%#ent in 1?<1 *a the ne't #iletone *hich lea&to the &e(elo%#ent of #icrocontroller controlle& > #achine alocalle& > #achine)

• The #a8or a&(antage of a > #achine *a in it aility to tore %art%rogra# an& alo interact *ith other controller or central co#%uter*hich le& to the &e(elo%#ent of &itriute& > yte# *herein e(eral

> #achine *oul& e connecte& to a central hot co#%uter)

• The %o*er of the > #achine *ere further enhance& in 1?@0 y#a3ing the# ca%ale of carrying hun&re& of tool, ha(ing #ulti%le%in&le an& controlling #o(e#ent u%to 6 a'i)



Material Aan&ling !yte#• Material han&ling i an integral %art of any #anufacturing

yte#)• Manufacturing yte# %erfor#ance can e igni.cantly

i#%ro(e& y uing co#%uter controlle& #aterial =o* , *hichre&uce *aiting ti#e an& *or3 in %roce in(entory co#%are&*ith #anual loa&ing an& unloa&ing an& #anual #aterialhan&ling yte#)

• To thi en& the &e(elo%#ent in =oor #ounte& an& o(er hea&roller con(eyor, tac3er crane an& auto#ate& gui&e& (ehicleha(e contriute& utantially to #ooth #aterial =o* infactory =oor)

• Through a yte# of L, co#%uter net*or3, #aterial han&ling

yte#, #aterial torage yte# an& #achine tool can eintegrate& to con.gure an auto#ate& #anufacturing yte#)



B7"7TI!

• The *or& *a atirically ue& for the .rt ti#e in the %layBou#9 Cni(eral Boot; *ritten y arel a%e3 in 1?21an& in&icate& force& laor)

• !ince then rootic ha really *itnee& a erie of

technological change)• The technology for the current generation of in&utrial

root *a &e(elo%e& i#ulataneouly y )) en*ar& inreat "ritain in 1?54 an& )) De(ol in Cnite& !tate)

• The .rt co#%uter ty%e root %rogra##ing language *a

&e(elo%e& a !tanfor& Beearch Intitute in 1?< *hereinthe language $L *a &e(elo%e&)

• >o*a&ay root are ue& for a (ariety of a%%lication li3e%ainting, *el&ing, #aterial han&ling an& ae#ly)



78ecti(e of thi coure

• The main goal of the ao(e collaborative decision i to formulate adesign and manufacturing plan *hich i %rinici%ally builtconsidering aspects li3e product and process denition andcapability, manufacturing planning and control, and factoryautomation strategies)

• In &oing o it i (ery i#%ortant to ha(e a thorough un&ertan&ing of the

concepts of design and manufacturing technology an&#anage#ent an& alo other functional areas like nance,marketing and sales, personal etc)

• The focu of thi coure *oul& e li#ite& to the &eign an&#anufacturing technologie enaling the functioning of a ucceful#anufacturing enter%rie)

• $ccor&ingly *e *oul& &icu o#e conce%t of omputer aideddesign, omputer aided process planning, omputer aidedmanufacturing, quality engineering, automated materialhandling, manufacturing planning and control, 1eanmanufacturing and *lexible manufacturing)

t



o% c to e co(ereo#%uter $i&e& Deign,

$D1) The ro&uct Deign roce

• role# i&enti.cation, reli#inary i&ea, re.ne#ent %roce,analyi %roce, &eciion %roce, I#%le#entation %roce

2) o#%uter $i&e& Deign

) $ rief hitory of $D

4) $D/$M yte#

• Mainfra#e ae& yte#, Minico#%uter ae& yte#,

or3tation ae& yte#, Microco#%uter ae& yte#

5) $D yte# In%ut-7ut%ut De(ice6) !election of $D/ $M yte#

<) o#%uter gra%hic an& tranfor#ation

• eo#etric tranfor#ation, ho#ogeneou re%reentation,o#%oition of tranfor#ation



To%ic to e co(ere&eo#etric Mo&eling

1) Intro&uction to geo#etric #o&eling)2) hy i 3no*le&ge of geo#etric Mo&eling >eceary

) eo#etric Mo&eling $%%roache

4) irefra#e Mo&eling

• Li#itation of *irefra#e #o&eling, irefra#e Entitie,

$nalytic cur(e, Be%reentation of cur(e, >on%ara#etricre%reentation of cur(e, ara#etric re%reentation ofcur(e, !ynthetic cur(e, ara#etric re%reentation of!ynthetic cur(e, Aer#ite cuic %line, "e+ier cur(e, "-!%line, Botational "-!%line an& non unifor# rotational "-

!%line cur(e, ur(e #ani%ulation)5) !urface #o&eling

• !urface entitie, urface re%reentation



o#%uter $i&e& roce

lanning1) 7(er(ie* of #anufacturing %rocee

• Turning 7%eration, Drilling 7%eration, Milling 7%eration, rin&ing7%eration

2) hat i roce lanning

) "aic te% in &e(elo%ing a roce lan

• $nalyi of %art reuire#ent, !election of Ba* *or3-%iece,Deter#ining #anufacturing o%eration an& their euence,election of #achine tool, !election of tool, *or3-hol&ing &e(ice,in%ection eui%#ent etc), &eter#ining #achining con&ition an&#anufacturing ti#e)

4) The %rinci%le %roce %lanning a%%roache

• Manual e'%erience ae& %lanning #etho&, co#%uter ai&e&%roce %lanning #etho&)

5) Fariant an& generati(e %roce %lanning yte#)

6) Geature recognition in co#%uter ai&e& %roce %lanning



o% c o e co(ere$uto#ate& #aterial han&ling an& torage

yte#1) hat i a #aterial han&ling yte#

2) rinci%le of #aterial han&ling

) Material Aan&ling Eui%#ent

4) $uto#ate& ui&e& Fehicle !yte#

• The co#%onent of an $F!, The ty%e of $F!, $F! ui&ance!yte#, $F! teering control, $F! routing, $F! control

yte#, Interface *ith other !uyte#, $F! loa& tranfer, $F!&eign feature, !yte# &eign of auto#ate& gui&e& (ehicleyte#, a&(antage of $F! o(er other #aterial han&lingyte#, a%%lication of $F!)

5) $uto#ate& torage an& retrie(al yte#

• Gunction of torage yte# an& &e.nition of $!/B!

• $!/B! co#%onent an& ter#inology ue&

• hy an $!/B! ,Ty%e of $!/B!, Deign of $!/B!

6) on(eyor)



To%ic to e o(ere&Huality Engineering

• Huality engineering, !tatitical roce ontrolan& auto#ate& in%ection yte#:

1)Cn&ertan&ing the #eaning of Huality)

2)Di#enion of Huality)

)Huality ot re(ention cot, $%%raial cot,Internal failure cot, E'ternal failure cot

4)Gra#e*or3 for uality i#%ro(e#ent)

5)Gailure #o&e eect analyi)

6)I#%ro(ing %ro&uct uality &uring the %ro&uction%hae)<)$uto#ate& In%ection on-line/ in- %roce an&

%ot %roce in%ection #etho&)



Ja%anee Manufacturing

!yte#• Jut in Ti#e #anufacturing yte#1) Toyota %ro&uction yte#: $n o(er(ie* co#%onent of the Toyota ro&uction yte#,

Three M9

2) ull (eru uh yte#)

) Ty%e of anan *ith&ra*al 3anan, %ro&uction 3anan, =o* of *ith&ra*al an&%ro&uction 3anan an& their interaction, %recon&ition for o%erating 3anan

4) anan %lanning an& control #o&el &eter#ining the nu#er of 3anan: a

&eter#initic #o&el, a %roailitic cot #o&el for &eter#ining o%ti#al nu#er of3anan, relationhi% et*een JIT #anufacturing, etu% ti#e an& cot)

5) !ignal anan , E'%re 3anan, E#ergency 3anan, through 3anan)

6) Le(el che&ule for #i'e& #o&el ae#ly line a #athe#atical #o&el to otain le(elche&ule)

<) $lternate JIT yte# %erio&ic %ull yte#, contant *or3 in %roce yte#, long %ullyte#)

@) Jut in ti#e %urchaing)

?) Total uality control an& JIT TH re%oniilitie, rinci%le of Huality, Huality culture

10)"arrier to JIT i#%le#entation)

11)otential ene.t of JIT i#%le#entation)

i &



To%ic to e o(ere&Manufacturing %lanning an& control yte#

1) $ aic fra#e*or3 for a #anufacturing %lanning an& ontrol yte#)

2) De#an& #anage#ent &e#an& forecating

) $ggregate %ro&uction %lanning a #athe#atical #o&el)

4) Mater %ro&uction che&ule)

5) Bough cut ca%acity %lanning)

6) Material reuire#ent %lanning %ro&uct tructure an& ill of #aterial,

In&e%en&ent (eru &e%en&ent &e#an&, %art e'%loion, groreuire#ent of co#%onent ite#, o##on ue ite#, on han& in(entory,che&ule& recei%t an& net reuire#ent)

<) MB lot i+ing)

@) a%acity %lanning)

?) 7r&er releae)

10)!ho% =oor control ar co&e yte# for ho% =oor, o%eration che&uling, 8o euencing an& %riority rule, co#%arion of (ariou che&uling rule

(a ua on r er a an



(a ua on r er a anMetho&

E(aluation riteria:

1 Mi&ter#, Ginal e'a#ination an& Ter# %a%er)

%.!o. riteria

1 Mi&ter# 0 #ar3

2 Ginal E'a# 40 #ar3

Ter# %a%er 0 #ar3

Total Lecture Aour K 40 to e hare& y Dr)Ba#3u#ar an& Dr) !hantanu "hattacharya



I#%ortant %oint

•$tten&ance in clae i (ery

i#%ortant for continuity ofun&ertan&ing) To%ic &icue& arerelate& an& un&ertan&ing of one

to%ic #ay &e%en& on %rior learntto%ic an& *hate(er i co(ere& in thecla *oul& e thoroughly e(aluate&

in the ter# %a%er)•>o &u%lication of each other *or3 i%er#iile in aign#ent) ra&ing*ill e &one ae& on originality ofthe an*er a er intructor



"oo3 an& reference

• Computer integrated design and manufacturing,

Nanua Singh, John Wiley and sons, Inc.

• “Statistical Quality Control” by Eugene L. Grant and

Richard S. Leavenworth, Tata cgraw !ill"ublishing Co#$any Li#ited, %ew &elhi.

• “Ele#entary Statistical Quality Control”, 'rving (.

)urr, arcel &e**er 'nc.



o#%uter ai&e& &eign

• $ large no) of factor are re%onile for theucce of any engineering organi+ation)

• Engineering &eign of %ro&uct an& %rocee i

one of the #ot critical factor for ucce)• Cn&ertan&ing of the &eign %roce an& the

co#%uter ai&e& &eign tool $D i reuire& toreali+e a %ro&ucile %ro&uct &eign)

• o#%uter gra%hic %lay an i#%ortant role inthe %ro&uct &e(elo%#ent %roce y generating%reenting an& #ani%ulating geo#etric #o&el)



$D/$M yte#• $ *i&e (ariety of $D/$M yte# are currently a(ialale)

• Eentially a $D yte# co#%rie of three #a8or

co#%onent: Aar&*are, *hich inclu&e co#%uter an&in%ut/out%ut &e(ice, a%%lication oft*are, an& theo%erating yte# oft*are)

• The o%erating yte# oft*are act a the interfaceet*een the har&*are an& the $D a%%lication oft*are

yte#) • The classification schee !e use in thissection is #ased on hard!are of the syste)

•More specifically& !e classify systes #y the

host coputer that dri"es the syste)

•enerally& +AD;+AM systes are classifiedinto four types:

2)Mainfrae $ased systes

0)Minicoputer #ased systes

/)Wor(station #ased systes

7)Microcoputer #ased systes



In%ut out%ut &e(ice

I t & ti t t i



Intro&uction to eo#etric Tranfor#ation

• o#%uter gra%hic %lay an i#%ortantrole in the %ro&uct &e(elo%#ent %rocey generating, %reenting, an&#ani%ulating geo#etric #o&el of o8ect)

• During the %ro&uct &e(elo%#ent %roce,for %ro%er un&ertan&ing of &eign, it ineceary not only to generate geo#etric#o&el of o8ect ut alo to %erfor# uch#ani%ulation on thee o8ect arotation, tranlation an& caling)



tranfor#ation

• Eentially, co#%uter gra%hic i concerne& *ith

generating, %reenting an& #ani%ulating #o&el ofan o8ect an& it &ierent (ie* uing co#%uterhar&*are, oft*are an& gra%hic &e(ice)

• Cually the nu#erical &ata generate& y a co#%uterat (ery high %ee& i har& to inter%ret unle onere%reent the &ata in gra%hic for#at an& it i e(enetter if the gra%hic can e #ani%ulate& to e(ie*e& fro# &ierent i&e, enlarge& or re&uce& ini+e)

• eo#etric tranfor#ation i one of the aictechniue that i ue& to acco#%lih thee gra%hicfunction in(ol(ing cale change, tranlation toanother location or rotating it y a certain angle toget a etter (ie* of it)



eo#etric Tranfor#ation

• T*o &i#enional tranfor#ation:



2-D tranfor#ation

<6aple : In the figure a#o"e& suppose the initial coordinates of "ertices A&$&+ are

=2&/>& =7&9>& and =9&/)9>& respecti"ely) Deterine the coordinates of ne! "ertices A?& $?

and +? after translating the triangle #y a distance D@ 8& 10BT =!here T represents

transpose>) Verify that the lengths of the edges of the triangle are unchanged)



2-D tranfor#ation

2 D tranfor#ation



2-D tranfor#ation• !caling

<6aple: Fro the figure on the right& sho! that

the length of the edge A?$? is e'ual to three ties

that of A$ after scaling the o#.ect uniforly #y

factor /)

2 D t f ti



2-D tranfor#ation'otation*

Rotation in 0D space is defined as o"ing

any point =6&y> of an o#.ect to a ne! position

#y rotating it through a gi"en angle C a#out

soe reference point) %ositi"e angles are

easured countercloc(!ise fro 6 to y) The

atheatical e6pression for the rotating

transforation is not as o#"ious as the

forulas for translation and scaling



-Botation

<6aple: Deterine the ne! position of

o#.ect A placed on a round holding ta#leafter the ta#le has #een rotated #y /9 deg)

Solution:

D tranfor#ation



-D tranfor#ation• -D tranfor#ation are i#ilar to 2-D tranfor#ation in oth &e.nition

an& &eri(ation) e %ro(i&e -D tranfor#ation in #atri' for# afollo*:

(ranslation: In thi cae *e tranlate a %oint F',y,+ y &', &y, &+ to%oint F9'9,y9, +9) Thi can e e'%ree& in #atri' for# a

Ao#ogeneou



Ao#ogeneoutranfor#ation

• $lthough the 2D an& D tranfor#ation

%reente& in the %re(iou ection ha(eo(iou geo#etric #eaning it i not ecient orecono#ical to i#%le#ent the# on a co#%uter)

• Thi i ecaue tranlation in(ol(e thea&&ition of #atrice *herea caling an&rotation in(ol(e #ulti%lication)

• It i ho*e(er %oile to i#%le#ent a che#ein(ol(ing only #ulti%lication *hich *oul&i#%lify the tranfor#ation %roce)



Tranfor#ation

i i f



o#%oition of Tranfor#ation

• In %ractice, erie of tranfor#ation #ay ha(e toe a%%lie& to an o8ect)

• The techniue for co#ining erie oftranfor#ation are (ery ueful in thee cae)

• The .nal %roce of co#%oition i acco#%lihe&y #ulti%lying AN #atri' of (ariou co#%oition)

The %roce i alo 3no*n are co#%oun&ing orconcatenation of AN)

V?@ ,nB ,n12B ) ,2B V

Where n refers to the nth transforation in se'uence)

Manufacturing Technology (ME461) Lecture1

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