Chapter 1
A.Y
CHAPTER ONE:
INTRODUCTION TO MANUFACTURING
KNP2013 Manufacturing Technology
Assoc. Prof. Dr Abdullah Hj Yassin
1
Contents
2
Concepts of Manufacturing
Activities in manufacturing
Chapter 1
A.Y
Concept of Manufacturing
3
The word manufacturing from the Latin “manu factus”,
meaning made by hand.
 In modern sense, manufacturing involves making products
from raw materials by means of various processes, machinery,
and operations, through a well-organized plan for each activity
required.
 Manufacturing is a method/technique used to convert input in
any form with the use of certain processes into valuable
output, going through a series of transition/value-adding
processes.

Raw
material
Video
Manufacturing
Chapter 1
A.Y
End product
Concept of Manufacturing
4
Manufacturing is the backbone of any
industrialized nation
Manufacturing also involves activities in which
the manufactured product is itself used to make
other products
Manufactured item has undergone several
processes in which pieces of raw material have
been turned into a useful product, it has a value,
defined as monetary worth or marketable price
Product’s lifecycle
Source: Wikipedia
Product can be either in the form of physical
goods or even in the form of services.
Chapter 1
A.Y
Concept of Manufacturing
5
Manufacturing element
 Design
 Selecting material
 Manufacturing Process
In most countries, the income are mainly from
manufacturing industries. It is then important for a
nation to have a strong manufacturing industries.
Chapter 1
A.Y
Activities
6
Manufacturing is a complex activities. The activities involve:
 Product Design
 Machinery and Tooling
 Process Planning
 Materials
 Purchasing
 Manufacturing/Fabrication
 Production control
 Support Service
 Marketing
 Sales
 Shipping
 Customer Service
Chapter 1
A.Y
Activities
7
These activities however must follow several demands
and trend:
1)
2)
3)
4)
5)
6)
7)
To meet design requirements and product specification and
standards
Environmentally friendly and economical
Quality
Flexible to market demands
Developments in material, production methods and computer
integration
The system is view to be a large system
The manufacturing must constantly strive for high levels of
quality and productivity
Chapter 1
A.Y
Activities: Design Process
8
In order to design a product, one must understand
 Functions
 Performance
Market also plays an important part and must be
properly analysed
Chapter 1
A.Y
Activities: Design Process –
“Over-the-Wall Engineering”
9




Traditionally the design and
manufacturing are performed
sequentially
This means the design takes
place first and then
manufactured
In effect, the product flow from
one department to another
In many cases, this may cause
delays and increased of cost
Chapter 1
(a) Chart showing various steps
involved in traditional design and
A.Y
manufacture of a product.
10
Activities: Design Process –
Concurrent Engineering



Hence, nowadays, concurrent
engineering or simultaneous
engineering are usually used.
Concurrent engineering is a systematic
approach integrating the design and
manufacture of products
This approach also consider life cycle
- all aspects of product, such as
design, development, production,
distribution, use, disposal and
recycling are considered
Chapter 1
A.Y
(b) Chart showing
general product flow in
concurrent engineering,
from market analysis to
marketing the product.
11
Activities: Design Process – Role of
computers in Product Design
Certain companies model their product using software
such as Computer Aided Design (CAD), Computer Aided
Engineering (CAE), Computer Aided Manufacturing
These technology aid in designing the product so that
companies can reduce the manufacturing cost and avoid
over design
Video
Chapter 1
A.Y
Activities: Materials Selection
12
Any finished product, involved one or more than one type of material.
Material can be obtained in either their original form or artificial form.
Materials involved in engineering application; alloys, ceramics, metal and
polymers.
More materials is being developed to suit a specific application.
Engineer/Designer has no choice but to know how to choose/select the best
possible alternative for production to achieve their needs.
Chapter 1
A.Y
Activities: Materials Selection
13
every product must be able to function.
material selected will determine the characteristic,
function and also costing of the product.
costing involved includes the cost of material and also
the cost of processing the material involved.
Chapter 1
A.Y
Activities: Materials Selection
14
Factors that needed to be considered for material selection;
(a). Suitability of material - function of material in finished goods
and processing of the material to produce the product.
(b). Reliability of material - ability/repeatability in producing desired
dimension, surface texture, and tolerances.
(c). Manufacturability of the material - can be formed/casted/welded/
heat-treated/etc.
(d). Processing effect towards the final characteristics of the material
(quality, life, and performance of the products).
(e). Durability of the material - how long the product can last.
Chapter 1
A.Y
Activities: Materials Selection
15
(f). Availability of material - ease to obtain & reasonable cost.
(g). Manufacturing cost - reasonable & the best possible methods.
(h). Waste elimination – recycled & avoid illegal disposable.


The above factors should be studied carefully before the best
alternative for manufacturing is selected.
It’s not necessarily wise to always go for the cheapest mode,
because it might cost you even more in the end.
Chapter 1
A.Y
Activities: Materials Selection
16
Chapter 1
A.Y
Activities: Materials Selection
17

U.S Pennies
1793-1837
100% copper
1837-1857
95% copper, 5% tin & zinc
1857-1863
88% copper, 12% nickel
1864-1962
95% copper, 5% tin & zinc
1943
Steel, plated zinc
1962-1982
95% copper, 5% tin
1982- present
97.5% zinc, plated with copper
Chapter 1
A.Y
Activities: Selection of
Manufacturing Processes
18

What are the
manufacturing
processes:
 Casting
https://youtu.be/Um_g8sQ_p3Y
Chapter 1
A.Y
Activities: Selection of
Manufacturing Processes
19

What are the
manufacturing processes:
 Forming and Shaping –
rolling, forging, drawing,
sheet forming, molding
Chapter 1
A.Y
Activities: Selection of
Manufacturing Processes
20

What are the
manufacturing processes:
 Forming and Shaping –
drawing, sheet forming
Chapter 1
A.Y
Activities: Selection of
Manufacturing Processes
21
What are the
manufacturing
processes:
- Forming and Shaping
–molding

Chapter 1
A.Y
Activities: Selection of
Manufacturing Processes
22
What are the
manufacturing
processes:
- Joining – welding,
brazing, soldering,
bonding

Chapter 1
A.Y
Activities: Selection of
Manufacturing Processes
23
What are the
manufacturing
processes:
- Machining – turning,
milling, boring,
shaping, grinding
- Finishing – polishing,
surface treatment,
coating, plating

Chapter 1
A.Y
Activities: Selection of Manufacturing
Processes
24

The selection of a particular manufacturing process
depends on:
 Geometric features – dimensional tolerances, surface
texture required
 Flat part & thin cross section – not suitable for casting
 Complex part – not suitable for forging
 Dimensional tolerances – not suitable for hot-working environment
(distortion, warping, oxidation – elevated temperature)
 Workpiece material & its manufacturing properties:
 Brittle & hard materials
 Cannot be shaped/formed unless at high temperature
 Easily machined or cast
Chapter 1
A.Y
Quiz #1
25

Manufacturing does not involved activities in which the manufactured
product is itself used to make other products.
Ans:

Manufacturing consists of two elements: Design & Manufacturing
processes.
Ans: False

In term of time & cost, “Over-the-Wall” approach is better than Concurrent
Engineering.
Ans: False

Selection of materials depend on (1) Geometric (2) characteristics of
material.
Ans: True
Chapter 1
A.Y
Quiz #1
26
1. Which of the following best exemplifies the transformation aspect of
manufacturing?
a) Selling the product at market value
b) The assembly of a product
c) Designing the initial product blueprint
d) Converting raw materials into a valuable output through various processes
2. In the context of sustainability, why is it important for manufacturing
processes to be environmentally friendly and economical?
a) To ensure that products are affordable for all consumers
b) To comply with international trade laws
c) To minimize the environmental impact and ensure long‐term viability
d) To increase the speed of production
Chapter 1
A.Y
Quiz #1
27
3. Which manufacturing approach integrates design and production
considerations simultaneously to improve efficiency?
a) Sequential Engineering
b) Over-the-Wall Engineering
c) Concurrent Engineering
d) Traditional Engineering
4. What is the primary benefit of using Computer-Aided Design (CAD)
in manufacturing?
a) It eliminates the need for a manufacturing process.
b) It allows for precise control over material selection.
c) It helps in reducing manufacturing costs and preventing overdesign.
d) It automates the marketing process.
Chapter 1
A.Y
Quiz #1
28
5. Considering the selection of materials, which material characteristic
is crucial for products that must endure mechanical stress without
deformation?
a) Aesthetic appeal
b) Electrical conductivity
c) Thermal resistance
d) Durability
6. In materials selection, what does the ease of obtaining a material
and its cost signify?
a) The material's complexity
b) The material's availability
c) The efficiency of the manufacturing process
d) The quality of the finished product
Chapter 1
A.Y
Quiz #1
29
7. How does the concept of 'castability' affect the choice of material for a flat
part with a thin cross-section?
a) It suggests that a flat, thin part is ideal for casting.
b) It indicates that such a part is not suitable for casting due to the risk of
defects.
c) It determines the color of the finished product.
d) It has no impact on the manufacturing process.
8. What does the historical change in the composition of U.S. pennies suggest
about manufacturing materials?
a) The intrinsic value of pennies has increased over time.
b) Material selection remains constant throughout history.
c) Economic and resource availability factors influence material selection in
manufacturing.
d) Pennies have become less durable over time.
Chapter 1
A.Y
Quiz #1
30
9. The trend towards concurrent engineering in manufacturing is
primarily due to:
a) A need to reduce the skills required for manufacturing.
b) The desire to streamline the product development lifecycle.
c) A shift away from technology in design processes.
d) Increased customer demand for traditionally made products.
10. Which factor would likely be considered when selecting a material
that must undergo significant deformation during manufacturing?
a) Electromagnetic properties
b) Color and texture
c) Workpiece material's ability to be shaped at high temperatures
d) The sound it produces when struck
Chapter 1
A.Y
31
End of Chapter One
Chapter 1
A.Y