Chapter 1: INTRODUCTION TO
MANUFACTURING TECHNOLOGY
1. WHAT IS MANUFACTURING?
2. MANUFACTURING PROCESSES
3. PRODUCTION SYSTEMS
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1 What is Manufacturing?
The word manufacture is derived from two Latin
words manus (hand) and factus (make); the
combination means “made by hand”
 “Made by hand” accurately 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
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1 What is Manufacturing?
1.1.1 Manufacturing Defined
In Serope Kalpakjian & Steven R. Schmid:
“Manufacturing is the process of converting raw
materials into products. It includes,
 The design of products.
 The selection of raw materials.
 The sequence of processes through which the
product will be manufactured.”
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1 What is Manufacturing?
1.1.1 Manufacturing Defined:
In Mikell P Groover:
“Technologically, manufacturing is the application
of physical and chemical processes to alter the
geometry, properties, and/or appearance of a
starting material to make parts or products
 Manufacturing also includes assembly
 Almost always carried out as a sequence of
operations”
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1 What is Manufacturing?
1.1.1 Manufacturing Defined:
In Mikell P Groover:
“Economically, manufacturing is transformation of
materials into items of greater value by means of
one or more processing and/or assembly
operations
 Manufacturing adds value to the material by
changing its shape or properties, or by
combining it with other materials”
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1 What is Manufacturing?
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1.2 Manufacturing Industries
1.1.2.1 Manufacturing Industries
 Industry consists of enterprises and
organizations that produce or supply goods
and services

Industries can be classified as:
1. Primary industries
2. Secondary industries
3. Tertiary industries
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1.2 Manufacturing Industries
Primary Industries
 cultivate and exploit natural resources, such as
agriculture and mining.
Secondary Industries
 convert the outputs of the primary industries into
consumer and capital goods.
Tertiary Industries
 constitute the service sector of a country.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Table 1.1: Specific Industries in the Primary, Secondary, and Tertiary
Categories
Primary
Secondary
Tertiary (service)
Agriculture
Aerospace
Food processing
Banking
Insurance
Forestry
Apparel
Glass, ceramics
Communications
Legal
Fishing
Automotive
Heavy machinery
Education
Real estate
Livestock
Basic metals
Paper
Entertainment
Repair and
maintenance
Quarries
Beverages
Petroleum refining
Financial
services
Restaurant
Mining
Building materials
Pharmaceuticals
Government
Retail trade
Petroleum
Chemicals
Plastics (shaping)
Health and
medical
Tourism
Computers
Power utilities
Hotel
Transportation
Construction
Publishing
Information
Wholesale trade
Consumer appliances
Textiles
Electronics
Tire and rubber
Equipment
Wood and furniture
Fabricated metals
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.1.2 Manufacturing Industries
1.1.2.2 Manufactured Products
Final products made by the industries can be divided into:i. Consumer Goods
 products purchased directly by consumers, such as
cars, personal computers, TV’s, tennis rackets, etc.
ii. Capital Goods
 purchased by other companies to produce goods and
supply services, such as aircraft, mainframe
computers, railroad equipment, machine tools, and
construction equipment.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.2 Manufacturing Processes
Can be divided into two basic types:
i. Processing Operation
ii. Assembly Operation
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.2.1 Processing Operation
 transform a work material from one state of
completion to a more advanced state that is
closer to the final desired product.
 it adds value by changing the geometry,
properties, or appearance of the starting
material.
 performed on discrete workparts and applicable
to assembled items.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.2.2 Assembly Operation
 joins two or more components in order to
create a new entity called an assembly,
subassembly, or some other term that refers to
the joining process.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Figure 1.2 Classification of manufacturing processes
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Shaping Processes – Four Categories
1.
2.
3.
4.
Solidification processes - starting material
is a heated liquid or semifluid
Particulate processing - starting material
consists of powders
Deformation processes - starting material
is a ductile solid (commonly metal)
Material removal processes - starting
material is a ductile or brittle solid
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Solidification Processes
Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
 Examples: metal casting, plastic molding
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Particulate Processing
Starting materials are powders of metals or
ceramics
 Usually involves pressing and sintering, in
which powders are first compressed and then
heated to bond the individual particles
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Deformation Processes
Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
 Examples: (a) forging, (b) extrusion
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Material Removal Processes
Excess material removed from the starting piece
so what remains is the desired geometry
 Examples: machining such as turning, drilling,
and milling; also grinding and nontraditional
processes
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Property-Enhancing Processes
Performed to improve mechanical or physical
properties of work material
 Part shape is not altered
 Examples:
 Heat treatment of metals and glasses
 Sintering of powdered metals and ceramics
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Surface Processing Operations



Cleaning - chemical and mechanical
processes to remove dirt, oil, and other
contaminants from the surface
Surface treatments - mechanical working
such as sand blasting, and physical
processes like diffusion
Coating and thin film deposition - coating
exterior surface of the workpart
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Assembly Operations
Two or more separate parts are joined to form a
new entity

Types of assembly operations:
1. Joining processes – create a permanent
joint

Welding, brazing, soldering, and
adhesive bonding
2. Mechanical assembly – fastening by
mechanical methods

Threaded fasteners (screws, bolts and
nuts); press fitting, expansion fits
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.3 Production Systems


Production systems consists of people,
equipment, and procedures used for the
combination of materials and processes that
constitute a firm's manufacturing operations
A manufacturing firm must have systems and
procedures to efficiently accomplish its type
of production
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.3 Production Systems
 Two categories of production systems:
 Production facilities
 Manufacturing support systems
 Both categories include people (people make
the systems work)
 In general, direct labor people are responsible
for operating the manufacturing equipment,
and professional staff people are responsible
for manufacturing support.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.3.1 Production Facilities
 The factory, production equipment, and
material handling systems
 Refers to the physical equipment and the
arrangement of equipment in the factory.
 Equipment usually organized into logical
groupings, called manufacturing systems
 Examples:
 Automated production line
 Machine cell consisting of an industrial
robot and two machine tools
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Manufacturing Support Systems
A company must organize itself to design the
processes and equipment, plan and
control production, and satisfy product
quality requirements
 Accomplished by manufacturing support
systems - people and procedures by which a
company manages its production operations
 Typical departments:
1. Manufacturing engineering
2. Production planning and control
3. Quality control
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.3.2 Manufacturing Support Systems
 To design the processes and equipment, plan
and control the production orders, and satisfy
product quality requirements.
 Most of these support systems do not directly
contact the product, but they plan and control
its progress through the factory.
 Manufacturing support functions are often
carried out in the firm by people organized into
departments such as :
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.3.2 Manufacturing Support Systems
1.3.2.1 Manufacturing Engineering
 responsible for planning the manufacturing
processes – deciding which processes should
be used to make the parts and assemble the
products.
 this department is also involved in designing
and ordering the machine tools and other
equipment used by the operating
departments to accomplish processing and
assembly.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.3.2 Manufacturing Support Systems
1.3.2.2 Production Planning and Control
 responsible for solving the logistics problems
in manufacturing - ordering materials and
purchased parts, scheduling production,
and making sure that the operating
departments have the necessary capacity to
meet the production schedules.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
1.3.2 Manufacturing Support Systems
1.3.2.3. Quality Control



producing high-quality products should be a
top priority of any manufacturing firm in
today’s competitive environment.
it means designing and building products that
conform to specifications and satisfy customer
expectations.
much of this effort is the responsibility of the
QC department.
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Manufacturing and Production System
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
A spectacular scene in steelmaking is charging of a basic oxygen
furnace, in which molten pig iron produced in a blast furnace is
poured into the BOF. Temperatures are around 1650°C (3000 ° F).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
A machining cell consisting of two horizontal machining centers
supplied by an in-line pallet shuttle (photo courtesy of Cincinnati
Milacron).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
A robotic arm performs
unloading and loading
operation in a turning
center using a dual gripper
(photo courtesy of
Cincinnati Milacron).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Metal chips fly in a high
speed turning operation
performed on a computer
numerical control turning
center (photo courtesy of
Cincinnati Milacron).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Photomicrograph of the cross section of multiple coatings of
titanium nitride and aluminum oxide on a cemented carbide
substrate (photo courtesy of Kennametal Inc.).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
A batch of silicon wafers enters a furnace heated to 1000°C
(1800°F) during fabrication of integrated circuits under clean room
conditions (photo courtesy of Intel Corporation).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Two welders perform arc
welding on a large steel
pipe section (photo
courtesy of Lincoln
Electric Company).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Automated dispensing of
adhesive onto component
parts prior to assembly
(photo courtesy of EFD,
Inc.).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Assembly workers on an
engine assembly line
(photo courtesy of Ford
Motor Company).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Assembly operations
on the Boeing 777
(photo courtesy of
Boeing Commercial
Airplane Co.).
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e