Intro. Lecture, EA&VH, 13 9 11

8/3/2019 Intro. Lecture, EA&VH, 13 9 11

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Manufacturing

Engineering II

MEEN 40030 Manufacturing Engineering II Semester I

UCD School of Mechanical and Materials Engineering

r. amonn earneDr. Vincent Hargaden

Semester I (2011-2012)


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Introduction to ManufacturingEngineering II

MEEN 4008 Manufacturing Engineering Lectures I and II


Eamonn Ahearne, Vincent Hargaden


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UCD AMS, 2011 Lecture Content

1. Module Coordination & Description

2. The Economic Importance of Manufacturing / High ValueManufacturing

3. Manufacturing Paradigms / The Productivity Revolution

4. Scope of Module

5. Supply Chain Management

6. Innovation, Research and Development

UCD School of Mechanical and Materials Engineering3

7. Product Design and Design for X8. The Engineer in Manufacturing and Manufacturing Engineering

9. Manufacturing Technologies Focus


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UCD AMS, 2011 Module Coordinators

Professor Gerry [email protected]

Manufacturing Engineering Processes & Technology

Dr. Eamonn [email protected]

Manufacturing Engineering Processes & Technology


[email protected]

Production Operations/Supply Chain Management


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UCD AMS, 2011

The Economic Importance of Manufacturing

Represents 20-30% of GDP in 1st World Economies:

Manufacturing and The Modern Economy

Definition of Manufacturing

Manufacturing is the process of converting raw materials into products [Kalpak.]

Manufacturing is the conversion of information into products by the controlled flow ofenergy [Van Brussel]


apan, ermany, ta y, rance, we en, re an ut ,

EU is a nett exporter of high value added manufactured products

Irish economic growth due to inward investment by manufacturing companies(Chemical-Pharmaceuticals, Computer-Electronics, Medical Devices)

Irish manufacturing sales revenues of 90 Billion in 2007

High value-added manufacturing: a basis for sustained economic growth ?


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UCD AMS, 2011

Medical Technologies Sector* Estimated Output 7 billion PA

ICT Manufacturing and Services Estimated Output 10 billion PA

Engineering Sector including aerospace, automotive and precision

engineering

Estimated Output 5 billion PA

High Value Manufacturing


Green Engineering Estimated Output 2.8 billion PA

Chemical & Pharmaceuticals Estimated Output 30.0 billion PA

Food Estimated Output 18.0 billion PA15 of Global Top 25 Companies

More than 160 Med. Tech. Companies

More than 24.000 employees

*Med. Tech. Sector Stats.

[Extracted from Forfas-National Competitiveness Council ReportDriving Export Growth, Dec 2009 & estimates from CSO trade statistics]


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UCD AMS, 2011

Sales

60Bn

40Bn

ModernManufacturing

59,000

86,000

Employment



20Bn

Traditional

Manufacturing

Internationally-tradedServices

1990 1995 2000 2007

Source: Forfs, 2008

158,000

15


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UCD AMS, 2011High Value Manufacturing

[Report of the High Level Group on Manufacturing, March 2008]



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UCD AMS, 2011

[Report of theHigh LevelGroup on

Manufacturing,March 2008]




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UCD AMS, 2011 Manufacturing Paradigms

Late 1800s Craft production, Karl Benz (1883)

Early 1900s Mass production, vertical integration, Henry

Ford, scientific management Mid 1900s Technical development, model variety

1970s Oil crisis, market saturation, global view

1980s Lean roduction To ota


1990s Outsourcing, consolidation

21st Century Mass customisation

21st Century Servitization Manufacturing + Services


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UCD AMS, 2011



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UCD AMS, 2011 Manufacturing Engineering Module Scope

Global Level:Design of Manufacturing

Supply Chains


Micro Level:Manufacturing Process

Technology


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UCD AMS, 2011

Second tiersupplier

First tiersupplier

First tiercustomer

Second tiercustomer

Endcustomer

Supply Chain Management


Demand sideSupply side

Informationflow

Physicalflow


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UCD AMS, 2011

Customer Customer Customer Customer

Distribution center

Distribution center

Manufacturer

Supply Chain


Supplier of materialsSupplier of services

Tier 1

Tier 3

Tier 2

Legend


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UCD AMS, 2011 Mercedes-Benz A Class

Johnson Controls +Johnson Controls +Johnson Controls +Johnson Controls +IntierIntierIntierIntier

Eybl: doorEybl: doorEybl: doorEybl: door

claddingscladdingscladdingscladdings Brose: doorBrose: doorBrose: doorBrose: doormodulesmodulesmodulesmodules

Supply Chain


Johnson Controls:Johnson Controls:Johnson Controls:Johnson Controls:seatsseatsseatsseats

Johnson Controls:Johnson Controls:Johnson Controls:Johnson Controls:dashboardsdashboardsdashboardsdashboards

WOCO: pedalWOCO: pedalWOCO: pedalWOCO: pedalmodulesmodulesmodulesmodules

Decoma: frontDecoma: frontDecoma: frontDecoma: frontmodulesmodulesmodulesmodules

Faurecia: exhaustFaurecia: exhaustFaurecia: exhaustFaurecia: exhaustsystemsystemsystemsystem

Radsystem:Radsystem:Radsystem:Radsystem:completecompletecompletecomplete

wheelwheelwheelwheel

Leoni: cableLeoni: cableLeoni: cableLeoni: cableharnessesharnessesharnessesharnesses

IntierIntierIntierIntier NherNherNherNher: carpeting: carpeting: carpeting: carpeting


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UCD AMS, 2011 Supply Chain - V Class Minivan Seat

ABS Resin

Bayer AG

Molding

Simoldes Plasticos, PortugalProduct Development

Daimler-Benz


Seat ManufactureGrupo Antolin Irausa, Spain Assembly Plant

Daimler-Benz

50% lighter

Reduced parts count Integrated seat belts

20% cost saving


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UCD AMS, 2011

Market Led / Technology Led

Continuous / Disruptive

Product Development Drivers

Market (Performance, Functionalityand Price)

Environment Cost or Profit

o Reduced Quality Costs

Innovation / Research and Development

19921989 1995 1998 2001

3

6

3,8 kg

2,5 kg2,6 kg

1,8 kg

Weight

0

6,2 kgkg

[Bosch]


o Reduced Material Costso Reduced Number of Componentso Reduced Manufacturing Costs

Legislation

Lab-on-Chip [HSG-IMIT]


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UCD AMS, 2011

Ceramic Valves Improved Valve Dynamics Higher Valve Acceleration

Reduction of Mechanical

Losses

Reduction of Valve SpringLosses

Increase in Efficiency

Innovation / Research and Development


[AWK]

Estimated Reduction of Fuel

Consumption with the use of

Ceramic Valves in Germany250 Million Litres per Annum

Weight Comparison

0 25 50 10075

Ceramic

Metal


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UCD AMS, 2011Innovation / Research and Development / The Design Process


[Kalpakian]


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UCD AMS, 2011

Role of Engineer in Manufacturing Management / Strategic

Research and Development Product Design / Development Manufacturing System Design / Process Development Manufacturing Management / Team Leaders (Quality, Maintenance, Facilities etc.) Systems Design and Development (Quality, Maintenance, Facilities etc.) Technical Support (Specialists)

The Engineer in Manufacturing

Managing Director


Manufacturing

Engineering

Manufacturing Accounts Personnel

Maintenance Purchasing

Marketing

& Sales

R&D /ProductDesign

Quality


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UCD AMS, 2011 Manufacturing Engineering / Definition [1]

Is an engineering activity / science which is concerned with all relevant

functions within a manufacturing system. It involves:

design for production

the design, operation and control of production processes and

production methods the planning scheduling and control of production (stock control)

quality assurance


Further, it links with and uses such disciplines as mechanical, electrical,chemical, materials and systems engineering as well as management.

Manufacturing engineering embraces all the technical aspects ofmanagement, i.e. the operation and control of production. It also

involves human, legal and social aspects of work and working inmanufacturing industry.

[1] Dictionary of Production Engineering 3 (CIRP), ISBN 3-540-20555-1, Springer-Verlag


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UCD AMS, 2011

Shorter Product Life-Cycles

Higher Product Variety / Lower Volumes Reconfiguarable Production Systems

Quality of Design

Quality of Conformance

Process Capability (Accuracy and Precision)

Process Stability and Reliability

Traceability & Certification

Reduced Cost

Manufacturing System Change Drivers

92 93 94 95 96 97 98 99 00 01 02

WSPW

Year

1.0 m 0.b8 m

0.6 m

0.35 m

0.25 m

0.18 m

0.13 m


Labour

Quality

Materials etc

Human Resource Availability

Environmental Legislation

Design for Recycling

Design for Disassembly

Waste Management


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UCD AMS, 2011

ManufacturingProcesses

Materials

Components

Tooling

Staff

Instructions Schedules

Products

Waste

Scrap

DataAnalysis

Production

Output

Time

Key Performance Indicators

Click to enlarge

The Engineer in Manufacturing: System Control


Machines Test Equipment

Yield

Time

Costper unit

Time


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UCD AMS, 2011

Manufacturing Processes

Materials

Components

Tooling

Instructions Schedules

Products

Waste

Scrap

MakeParts

Make sub-assembly Assembly

The Engineer in Manufacturing: System Control


Staff

Machines Test equipment

Data

Test

KPIs


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UCD AMS, 2011 Manufacturing Technologies Focus



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THE END


Thanks !

Documents

Intro. Lecture, EA&VH, 13 9 11