This document provides an overview of fundamental manufacturing concepts. It begins with a history of manufacturing, noting that the word derives from "made by hand" but now mostly refers to mechanized processes. Key definitions of manufacturing are presented from both technological and economic perspectives. The main types of manufacturing are described based on quantity produced: project, job shop, batch, and mass. Additional concepts covered include lean manufacturing, group technology, just-in-time systems, Kanban cards, and common manufacturing layouts and processing categories.

1. MALVIYA NATIONAL INSTITUTE OF
TECHNOLOGY,JAIPUR

A PRESENTATION ON
FUNDAMENTAL OF MANUFACTURING
SUBMITTED BY :
NAME – NIKUNJ PATEL
ID NO.- 2017PMT5480
DEPT.- METALLURGY AND MATERIAL
ENGINEERING

2. INDEX POINTS:-
• HISTORY OF MANUFACTURING
• INTRODUCTION
• DEFINATIONS
• TYPES OF MANUFACTURING(ON QUANTITY BASIS)
• LEAN & AGILE MANUFACTURING
• GROUP TECHNOLOGY
• JIT
• KANBAN SYSTEM
• MANUFACTURING LAYOUTS
• BASIC CLASSIFICATION OF MANUFACTURING PROCESSES

3. HISTORY OF MANUFACTURING WORD
 The word manufacture is derived from two Latin words manus
(hand) and factus (make); the combination means “made by hand”
“Made by hand” described the fabrication methods that were
used when the English word “manufacture” was first coined
around 1567 A.D.
Most modern manufacturing operations are accomplished by
mechanized and automated equipment that is supervised by
human workers

4. INTRODUCTION
1What is “MANUFACTURING”?“the process of converting raw materials into
products”or“processing or making a product from raw materials, especially as a
large scale Operation using machinery” – (by Collin English Dictionary, 1998).
“economic term for making goods and services available to satisfy customer” .
“the making of products from raw materials using various processes, equipments,
operations and manpower according to a detailed plan”
Manufacturing can be defined two ways:
1) Technology
2) Economic .

5. 1. TECHNOLOGICAL DEFINATION
manufacturing is the application of physical and chemicalprocesses to alter the
geometry, properties, and/or appearance of a givenstarting material to make parts or
products.Manufacturing also includes the assembly of multiple parts to make
products. The processes to accomplish manufacturing involve a combination of
machinery, tools, power, and manual labor.

6. 2. ECONOMICAL DEFINATION
 manufacturing is the transformation of materials into items of greater value by
means one or more processing involve. Therefore, manufacturing is “added
value” to the material. - “Added value” – by changing the material’s shape or
properties or by combining it with other materials that have been similarly altered.

7. TYPES OF MANUFACTURING(ON QUANTITY
BASIS)
1) Project – 1 to 10 units. [Low production]
2) Job shop – 10 to 100 units. . [Low production]
3) Batch – 100 to 10,000 units. [Medium production]
4) Mass – Above 10,000 units. [High production].
Production quantity: number of unit produced annually of a particular product type.
Product variety: different product designs or types that are produced in the plant.

10. 1. PROJECT BASED:
 Product position – remains stationary during the
manufacturing process – size,weight, location of the product.-
Materials, people, machinery are brought to the product or
product site.
- Based on customer specifications.
 Example: aircraft, ships, locomotive.rockets,jets.

11. 2. JOB SHOP BASED:
 Low volume and production quantities called lot sizes with high product variety.
 Satisfies a market for nonstandard or unique product.
 - Layout – different machines with similar functional or processing capabilitiesare
grouped together as department.
 - Require high skill levels labor – to operate a variety of equipments.- A short
duration activities to provide custom goods.
 - Example: space vehicles, reactor vessels, turbines, aircraft components.

12. 3. BATCH TYPE
 Batch production produce or process any product in groups which is
called“batches”.
 - Can produce a variety of products
 – opposed to a continuous production process, or a one time production.-
Useful for industries that makes seasonal items/products for which it isdifficult to
forecast the demand.
 Example: Similar standard items made periodically in batches: bakery,
paint,hand tools.- Same facilities used to manufacture all the different items.

13. 4. MASS TYPE
 Also known as flow production, repetitive flow production, series production.
 Producing goods in large quantities at low cost per unit and produce in a shortperiod
of time.
 Machinery (eg: robots, machine press) that is needed to set up the massproduction
line is so expensive.
 Involved fewer labor cost and a faster rate of production.- Plant and equipments are
arranged in a flow line layout.
 Operation is done base on specific product and thus make the productioncontrol
easily.
 Work piece is transfer automatically from one machine to another.
 Example: light bulbs, refrigerator, tv.

14. Lean Production and Agile Manufacturing
A systematic approach to identifying and eliminating waste in
manufacturingprocess through continuous improvement by following the
product at thedemand of the customer.- Related to a word “less”: less
time, inventory space, people, developing theproduct, – minimize the
cost.- It is all about “speed” and getting it right at the first time.
Agile manufacturing: The implementation of the principles of lean production
on a broad scale.it is a term applied to an organization that has created
theprocesses, tools, and training to enable it to response quickly to
customer needs andmarket changes while still controlling costs and
quality.

15. GROUP TECHNOLOGY
 Also known as “families of parts”.- Parts can be grouped and then produced by
classifying them into families.- This can be done according to similarities in: i)
design. ii) manufacturing process to produce the part.- Parts will pass through a
similar sequence of manufacturing operations and will beprocessed on the same
machine tools.-
 Example of GT: Cylindrical parts – they may look almost the same, but it has
differencein the materials, tolerances, and surface finishes and thus causing them
to be madeon different machine tools. - The set-up of an automated machine only
requires small changes between the individual batches and some of the individual
set-up times will be drastically reduced.- Having different machine in one section,
so that each parts is completed in thatparticular section.

16. JUST IN TIME(JIT)
 Raw materials, parts & components are delivered to the
manufacturer just in time to be used, parts & components are
produced JIT to be made into subassemblies & assemblies,
and products are finished JIT to be delivered to the
customer.-
 JIT is also known as “pull system”.- It tends to simplify and
break the whole system into small, autonomous units.

17. KANBAN SYSTEM
 KANBAN SYSTEM- Integrated with the implementation of JIT concept.- Kanban – means
“visible record”.-
 Originally consisted of two types of cards:
 i) Production card: authorizes the production of one container or cart of identical,
specified parts at a workstation.
 ii) Conveyance/move card: authorizes the transfer of one container or cart of parts from
that particular w/station to the w/station where the parts will be used.
 The cards contain information on: i) Type of parts. ii) Location where issued. iii) Part
number. iv) Number of items in container.

19.  FIXED POSITION LAYOUT- Involved with huge parts; eg: construction of
aeroplane, bridge, buildings.- All resources such as manpower, raw
materials, tools, machinery and etc will bebrought to the product.- Involve
with longer lead time.
 FUNCTIONAL (PROCESS) LAYOUT- Plant grouped according to type of
process.- Specialization of skills.- Higher machine utilization.- Queues of
work.- Longer lead times.- Flexibility of operation.- Low volume and high
variety of manufacturing.

21. 4.FLOW LINE PRODUCT LAYOUT
 Plant arrangement to facilitate material processing in the same order.-
Machines and equipment are positioned along a flow line.- Product
passes from workstation to another workstation along the flow line.-
Suitable for mass production system.- Several flow lines may come
together to feed the final assembly line.- Need to categorize operations
to ensure equal processing time at all work stations(line balancing).-
High level of machine and manpower utilization.

22. CLASSIFICATION OF
MANUFACTURING PROCESS
 Based on the nature of work involved these processes may be divided into
following seven categories:
 Processes for changing physical properties of the materials – Hardening,
Tempering, Annealing, Surface Hardening.
 Casting Processes – Sand Casting, Permanent mold casting, die casting,
Centrifugal casting
 Primary metal working processes – Rolling, forging, extrusion, wire drawing
 Shearing and Forming processes – Punching, blanking, drawing, bending,
forming
 Joining processes – Welding, brazing, soldering, joining
 Machining Processes – Turning, drilling, milling, grinding
 Surface finishing processes – Lapping, honing, superfinishing

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