Manufacturing

Brian Russell

Manufacturing

Turning raw materials into goods which we need or want and are able to sell to others.

Manufacturing

Requires:• Special buildings or places of work• Organisation of people• Organisation of tools & equipment• Communication systems• Efficient working methods• Health and safety considerations

Manufacturing Terms

• Primary Processing

• Secondary Processing

Primary Processing

Turning raw materials into useful stock sizes

Materials come from:

Out of the ground

Animals

Trees & plants

Oil

Making Paper

Trees cut & shredded

Water added

Boiled up to make wood pulp

Chemicals and dyes added

Pulp poured over fine mesh and squeezed between rollers

Secondary Processing

• Casting & moulding

• Forming

• Wastage (or separation)

• Conditioning

• Assembling

• Finishing

Casting & Moulding

Injection Moulding

Die Casting

Food Moulding

Forming

Drop Forging

Pressing Line Bending

Wastage

+X

-X

-Z

+Z

Sawing

Turning

Milling

Finishing

Painting

Printing

Manufacturing Costs

Finance

Labour Costs

(or Automation)Transportation

EnergyPlant

Raw Materials

Scales of Production

• One-off or Jobbing Production

• Batch Production

• Mass or Flow Production

• Continuous Production

Just in Time

• Shared information systems

• Reduced lead times

• Less finance tied up in stock

Flexible Manufacturing

• Benefits of one-off production at mass production prices

• Only possible with ICT

Computer Integrated Manufacture

All the computer functions are integrated together in a fully automated system.

This would include moving materials/assemblies between machining operations.

Quality Issues

• Consistency

• Right first time every time

• Working to tolerances

• Materials in as well as products out

Quality Assurance

• Procedures to manage all functions which affect quality

• QA checks the systems

• Monitors processes

• Applies standards

Part of the Total Quality Management (TQM) of the company

Quality control

• One part of QA

• A series of checks – size, strength, weight, taste etc.

Tolerances

• Acceptable range of difference from standard

• Sometimes measured in plus/minus

No product manufactured in quantity can be considered to be perfect in every detail

Certification

• Manufacturers who work to recognised standards are awarded certification

BS EN ISO 9000:2000

One of the most important series of standards, these provide companies with a framework for developing a set of processes that ensure a common sense approach to the management of the organisation.