Transcript Slide 1

Introduction to
Manufacturing
- Part 1Darrell Wallace
Youngstown State University
Department of Mechanical and
Industrial Engineering
2
man·u·fac·ture (v)
1.
2.
To make or process (a raw material) into
a finished product, especially by means of
a large-scale industrial operation.
To make or process (a product),
especially with the use of industrial
machines.
Latin:
Manus (hand) + factus (make)
3
Evolution of Manufacturing

Just as today, the historical evolution of
manufacturing occurred as an exchange
between material technology and
processing capability
4
Prehistoric Periods

Stone Ages (~10,000,000 – 2,000 BC)


Time period varied geographically
Three periods:






Paleolithic (old stone age)
Mesolithic (middle stone age)
Neolithic (new stone age)
Stone age likely led to wooden tools
Bronze Age (~2500-500 BC)
Iron Age (~1500 BC-1000 AD)
5
Manufacturing as Craft and Art



Prior to about 1800, nearly all
manufacturing was “craftsmanship.”
All products made as “one-offs”
No standardization or mass-production
6
Industrial Revolutions

Major periods of Industrial growth
beginning around 1800 and continuing
through modern day


Transfer of expertise from person to process
Improvements in processes





Automation
Machine Tools
Power Sources
Materials Processing
Improvements in Infrastructure
7
Some Key Components of the
Industrial Revolutions



Consumerism
Military
Development and Transfer of Technology

Manufacturing Tools and Processes





Power sources




Raw material processing (Whitney, Bessemer)
Vertical integration (combined spinning / weaving)
Mass Production (interchangeability, assembly lines)
Machine Tools (Maudslay)
Steam Engines (Newcomb / Watt)
IC Engines
Electric machinery
Infrastructure


Transportation
Communication
8
Year: 2004
Manufacturing
Finance, insurance,
real estate, rental, and
leasing
Government
Professional and
business services
Educational services,
health care, and social
assistance
0
500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Contribution to U.S. GDP ($Billions)
Source: U.S. Bureau of Economic Analysis
9
U.S. Manufacturing Employment Figures
Since 2001, Manufacturing employment has decreased significantly. However,
contribution to the GDP has remained basically steady during that period. How
is this possible?
Source: U.S. Bureau of Labor Statistics
10
U.S. Manufacturing Productivity
Manufacturing Sector
Productivity Index Per Capita
1987-2004
170
10 years to
Double
Output
Output (Normalized to 100% in 1992)
160
150
25 years to
Double
Output
140
130
120
110
50 years to
Double
Output
100
90
80
70
1985
1990
1995
2000
2005
11
Source: BLS
Recent Shifts in U.S. Manufacturing





2001 Marked a major shift toward increased
productivity
Employment in the manufacturing sector has
decreased sharply, but production has not.
Productivity is at an all-time high
Low-value-added processes appear to be offset
by improvements in higher-margin production
Demand for employment will likely continue to
shift from unskilled laborers to individuals who can
contribute to higher productivity.
12
Engineering Skills Valued in Modern
Manufacturing Environment

Process Expertise



Design Expertise


Improve process efficiencies
Bridge gap be between design technology and production
technology
Adapt designs to make them more manufacturable
Logistics and Process Flow

Maximize efficiency throughout the manufacturing process
13
Course Objectives

Show the relationship of manufacturing to other
engineering pursuits

Familiarize you with the most common manufacturing
processes and some fundamental analyses

Encourage you to consider the many processes by
which each product you encounter is manufactured

Provide fundamental background for future work and
education in manufacturing and related fields
14