What is Manufacturing?

1
What is Manufacturing?

• Why do we study manufacturing?

2
What is Manufacturing?

• What is the importance of manufacturing in
  society?
• How does manufacturing affect your life?
• What is the importance of teamwork when
  completing a task?

3
Manufacture

• On a sheet of paper write your definition for the
  word
• Manufacture

4
Class Discussion

• What is your definition of Manufacturing?

5
Definition of Manufacturing

• Manufacturing is the transformation of materials
  into usable products.
• Derived from the Latin words manu factus, meaning
  made by hand.

6
Class Discussion

• Answer the following questions
• What is its purpose?
• What are its features and functions?
• What materials were used to make each part?
• What raw materials were used?
• How were the raw materials transformed?

7
How a pen is made

• The points - brass.
• Stainless steel all parts on some pens
• Brass the ink cartridge, the body, and the
  spring
• Aluminum the pen body
• Plastic the body, ink cartridge, cap, point top
• All pens are manufactured from various materials.
  The material composition is what determines the
  durability and cost to the consumer.

8
The Manufacturing Process

• All pens are made slightly different, but the
  main processes include
• Ink compounding
• Metal component formation
• Plastic component molding
• Piece assembly
• Packaging
• Labeling
• Shipping

9
Making the Ink

• Compounders (ink workers) follow a formula to
  make batches of ink.
• Raw materials are mixed together and can be
  heated or cooled to speed the mixing process.
• Larger quantity raw materials are pumped into the
  batch tank using computerized controls.
• Quality control checks are completed at various
  points in the mixing process.

10
Stamping and Forming

• The balls to the pen are typically supplied by an
  outside vendor (outsourced).
• The point of the pen is manufactured in the
  following steps
• Brass is inserted in stamping machines which cuts
  small discs.
• Small discs are softened and poured in a
  compression chamber. A steel ram presses the
  brass and a plunger forces it into a die cast
  mold. The excess metal is scraped off and the
  die is opened. The pen piece is removed. The
  pieces are put in a bath to remove oils used
  during the die process.
• The ball can then be inserted into the point
  cavity

11
Molding the Housing

• Plastic pieces of the pen are produced by
  extrusion or injection molding.
• Plastic is supplied as granules or powder and fed
  into a large hopper.
• Pen body and ink reservoir
• In an extrusion process, a large spiral screw
  forces the material through a heated chamber
  making it a thick flowing mass. It is then
  forced into a die, cooled, and cut.
• Caps, ends, and mechanical components
• Injection molding is used. Plastic is heated and
  converted and converted to a liquid that can be
  forcibly injected into a mold. After it cools
  and becomes a solid, the die is opened.

12
Ink Filling and Assembly

• Assembly takes place after the parts are formed.
  
• The ball point is attached to the ink reservoir.
  
• These pieces are sent on a conveyor to the
  injectors which fill the ink.
• The spring is placed on the barrel of the
  reservoir.

13
Final Assembly, Packaging, and Shipping

• The point and reservoir are placed in the main
  body of the pen.
• The caps and ends are assembled.
• Final decorations or coatings are completed.
• The pens are packaged
• Sales units are put in boxes, stacked on pallets,
  and shipped to the distributor.

14
Group Activity

• Examining a Manufactured Item
• The Problem
• You are and your team members are engineers with
  ABC Manufacturing. Your department head has
  asked you to examine a competitors product. You
  have 20 minutes to complete your investigation
  and file your report.

15
Working as a Team

• Before you begin, decide how you will work as a
  team
• Will each of you perform a single task?
• Will all of you share in every task?
• Will smaller groups perform individual tasks?
• Will one person disassemble or assemble while
  another records?

16
Your Examination

• Write a description of the product and how it is
  used. What is its approximate cost?
• Take apart the item. Identify the parts and
  materials each is made from. How do you think
  each part was made? (stamped, molded, etc.)
• Note each step you perform and any details that
  may be important such as how to hold a part.
  Number each part so they can be reassembled.
• Give a step-by-step description of how the item
  is assembled. You can make a sketch or assembly
  drawing.

17
Follow Up

• Was working with a team an effective way to work?
  Do you think you would have accomplished as much
  working alone?
• Were the methods that your team used successful?
• How did your team gather and share information?
  How was information communicated?
• What did you contribute to your team? Are you
  satisfied with what your team did? Would you do
  anything differently next time?
• How would you have assembled your item if there
  had been 10 of them? 10,000?
• How might the study of manufacturing benefit you?
  

18
Activity Time Manufacturing in History

• Using the internet, find 5 manufactured items
  during your specified time frame.
• 1850-1900, 1900-1930, 1940-1950, 1950-1960,
  1960-1970, 1980-1990, 1990-2000, 2000-current
• Create a PowerPoint presentation including the
  following (20 pts per invention)
• Picture of the invention (3pts)
• Date of invention (2pts)
• Purpose of invention (5pts)
• How did it change peoples lives? (10pts)