Essential Manufacturing

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

About the Author :
GORDON MAIR has carried out teaching, research, and consulting in the Department of Design, Manufacture, and Engineering Management at the University of Strathclyde for almost four decades. He is also a Chartered Engineer, Fellow of the Institution of Engineering and Technology, and Fellow of the Higher Education Academy. His teaching has covered the broad spectrum of manufacturing including its technology, management, and implications for product design. His research interests and publications are in the areas of manufacturing automation and robotics, telepresence, multisensory and multimodal displays, and all aspects of the interaction between humans, products and the environment. He has been a consultant to industry for production engineering, advanced manufacturing technology and operations management projects. He has also served as an expert to the European Commission for various multinational project assessments and reviews.