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Introduction to
Manufacturing
- Part 1Darrell Wallace
Youngstown State University
Department of Mechanical and
Industrial Engineering
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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)
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Evolution of Manufacturing
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Just as today, the historical evolution of
manufacturing occurred as an exchange
between material technology and
processing capability
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Prehistoric Periods
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Stone Ages (~10,000,000 – 2,000 BC)
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Time period varied geographically
Three periods:
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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)
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Manufacturing as Craft and Art
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Prior to about 1800, nearly all
manufacturing was “craftsmanship.”
All products made as “one-offs”
No standardization or mass-production
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Industrial Revolutions
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Major periods of Industrial growth
beginning around 1800 and continuing
through modern day
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Transfer of expertise from person to process
Improvements in processes
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Automation
Machine Tools
Power Sources
Materials Processing
Improvements in Infrastructure
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Some Key Components of the
Industrial Revolutions
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Consumerism
Military
Development and Transfer of Technology
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Manufacturing Tools and Processes
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Power sources
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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
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Transportation
Communication
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Year: 2004
Manufacturing
Finance, insurance,
real estate, rental, and
leasing
Government
Professional and
business services
Educational services,
health care, and social
assistance
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500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Contribution to U.S. GDP ($Billions)
Source: U.S. Bureau of Economic Analysis
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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
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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
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Source: BLS
Recent Shifts in U.S. Manufacturing
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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.
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Engineering Skills Valued in Modern
Manufacturing Environment
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Process Expertise
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Design Expertise
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Improve process efficiencies
Bridge gap be between design technology and production
technology
Adapt designs to make them more manufacturable
Logistics and Process Flow
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Maximize efficiency throughout the manufacturing process
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Course Objectives
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Show the relationship of manufacturing to other
engineering pursuits
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Familiarize you with the most common manufacturing
processes and some fundamental analyses
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Encourage you to consider the many processes by
which each product you encounter is manufactured
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Provide fundamental background for future work and
education in manufacturing and related fields
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