ME383 Modern Manufacturing Practices

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ME 383Modern Manufacturing Practices
Lecture Note 1 Introduction Dr. Y.B.
Guo Mechanical Engineering The University of
Alabama
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Instructor

• Dr. Y.B. Guo
• HR 261, 348-2615
• yguo_at_eng.ua.edu
• http//unix.eng.ua.edu/yguo
• Office Hours Mon 400-500 PM or
• by Appointment

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TA

• Hardik M. Singh
• HR 285
• hmsingh_at_bama.ua.edu

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Pre and Corequisites

• Prerequisites DR 133
• Corequisites AEM 250 (Mechanics of Materials)
  MTE 271 (Engineering Materials)
• Required for ME, MFGE, IE

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Notes, Textbook, and References

• Lecture Notes http//unix.eng.ua.edu/yguo/me383/
  
• Text Manufacturing Processes for Engineering
  Materials, 5th edition, S. Kalpakjian and S.R.
  Schmid, Prentice Hall, 2006
• References
• Manufacturing Processes and Equipment, G. Tlusty,
  Prentice-Hall, 2000
• Materials and Processes in Manufacturing, 8th
  ed., E.P. DeGarmo, J.T. Black, R.A. Kohser,
  Wiley, 1997
• Fundamentals of Modern Manufacturing Materials,
  Processes, and Systems, M.P. Groover,
  Prentice-Hall, 1996

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Enrollment

• ME383 Lec MW 10pm - 150pm, HR 252
• ME283/Sec1 M 200-600 pm Rm. 1213 (machine
  shop) Shelton State Community College 9500
  Old Greensboro Rd.
• Instructor Mr. M. Boshell
• ME283/Sec2 Dr. Greene Cgreene_at_eng.ua.edu
• Mandatory Enrollment Lecture (ME 383)
  Laboratory (ME 283)

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Enrollment

• Shelton State Community College (ME 283)

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Class Structure and Policies

• Mandatory Attendance
• Assignments Regular HW and in-class quizzes
  HW due as specified
• 50 off for late HW
• Exams 1 midterm, 1 final
• ME 283 Lab _at_SS Mr. Marlon Boshell
• Tel [phone] mboshell_at_sheltonstate.edu BAMA
  Vise Project
• ME283 Lab Reports assigned by instructors

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Class Structure and Policies

• Fishbone Chart

HWs, Exams, and Quizzes
Lectures
Manufacturing
Lab Reports
Labs
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Class Structure and Policies

• Grading
• ME 383 Homework Quiz 40
• Midterm 30
• Final 30
• ME 283 100
• (at the discretion of the instructors)

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Class Structure and Policies

• Grading A 90-100
  B 80-89.9 C 70-79.9
  D 60-69.9 F lt 60
  and - upper and lower 25 in each
  range

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Introduction To Manufacturing

• Scope
• Manufacturing processes
• Equipments/control
• Manufacturing systems
• Design for manufacturing
• Cost, quality, efficiency, environment

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Introduction To Manufacturing

• Mission
• How to satisfy human needs and create wealth
• Product to meet the customers requirements
• Quality, flexibility
• Cost, rate/productivity
• Recyclability !
• Objectives
• Exposure to key manufacturing processes
• Understand the measure of success or failure of
  processes, machines or systems
• Apply physics to control the measure
• cost, rate, quality, flexibility

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Introduction To Manufacturing

• Objectives (cont)
• Understanding of constraint and variation of the
  manufacturing processes and systems
• Control of processes and systems with the
  presence of variation
• SONY TV
• Mercedez, BMW
• Six sigma 3.4 defects per million

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Introduction To Manufacturing

• Manufacturing
• Made by hand manus (hand), factus (make)
• Single part (nail, bolt, tire, )
• Assembled system (Car 15,000 Boeing 747-400 6
  M)
• 5 Trillion business
• Definition The process of converting raw
  materials into products

Product Design
Materials Selection
Manufacturing
Marketing
(Value added)
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Manufactured Products

• Discrete Products individual parts, such as
  nails, gears, bearing balls, cans, engine blocks,
  
• Low production 1 to 100/yr
• Medium production 100 to 10,000/yr
• High/mass production over 10,000 units/yr
• Continuous Products items produced by continuous
  processes, such as sheet metal coil (almost), oil
  refinery,

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Manufacturing A System View
Market
(Design)
Market
Specification
Manufacturing processes
Concept Design
Manufacturing system
Detail Design
(Manufacturing)
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Materials Selection

• Material properties
• Cost and availability
• Recycling
• Engineering materials
• metals, polymers, composites, ceramics, glasses,
  

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Manufacturing Processes
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Manufacturing Processes Examples- Casting
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Manufacturing Processes Examples- Forming
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Manufacturing Processes Examples- Machining
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Manufacturing Processes Examples - Joining
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Manufacturing Processes Examples - Selection

• Quality
• Quantity
• Cost
• Environment

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Manufacturing System Lean Manufacturing

• Lean Manufacturing
• A methodology to minimize waste at all levels
  through assessment of each activities of a
  company
• Agile Manufacturing
• Implementation of lean principles on a broad
  scale
• Flexibility (quick response to market)

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Global Competitiveness

• Outsourcing
• Labor issue China, India, Mexico,
  (globalization)
• Political issue
• Environmental issue
• General trends
• New materials and processes
• Manufacturing sys. (IT-driven)
• Organization Top-down vs. broad
• National vs. international