Essential Manufacturing

ISBN-13: 9781119061663 / Angielski / Miękka / 2019 / 424 str.

Gordon Mair

Opis

An introduction to the manufacturing industry Essential Manufacturing provides a comprehensive introduction to the wide breadth of the manufacturing industry. There is a need for all engineering and business students to understand the importance and context of the manufacturing industry. An engineer should have a well rounded appreciation of all aspects of the industry they work in, including manufacturing. This is evidenced by professional bodies expecting all accredited engineering courses to provide students with a background that allows them to see their own specific discipline in context. Similarly, business students will often find themselves dealing in some way with manufactured products or even be directly involved in manufacturing operations management. This book will cover the full spectrum of the manufacturing industry to provide a holistic appreciation of the topic but with enough detail to be of practical use. The book begins with an introduction to the manufacturing industry, its history, and some important manufacturing concepts.  The materials used in manufacturing and how they are produced are covered. This is followed by a more detailed description of the more common manufacturing processes, their application, and the types of automation used in the manufacturing industry. Consideration is then given to the important aspects of manufacturing operations management and production planning and control, work study, and manufacturing economics. How to maintain quality in the manufacturing process, including metrology, is examined and this is followed by human factors in manufacturing. Finally, a speculative look at the future of manufacturing is included. Key features:

• Takes a self–contained approach.
• Includes review questions.
• Suitable as an introduction for more advanced study.
• Satisfies the requirements of college and first and second year university engineering courses.

The book provides a comprehensive, concise introduction to the manufacturing industry for engineering and management students.

An introduction to the manufacturing industry Essential Manufacturing provides a comprehensive introduction to the wide breadth of the manufacturing industry. There is a need for all engineering and business students to understand the importance and context of the manufacturing industry.

Spis treści

Preface xvPart I Introduction 11 Introduction 31.1 Wealth and Prosperity 41.2 Manufacturing Industry 51.3 Manufacturing as a Stimulant 71.4 The Supply Chain 81.5 Conclusion 9Review Questions 102 Manufacturing History 112.1 Toolmaking Humans 112.2 The New Stone Age 122.3 The Bronze Age 132.4 The Iron Age 142.5 The Industrial Revolution 162.6 The Twentieth Century 212.7 The Twenty-First Century 24Review Questions 253 Typical Manufacturing Industries 273.1 Introduction 273.2 Aerospace Industry 293.3 Automotive Industry 303.4 Shipbuilding and Marine Engineering 313.5 Electronics and Electronic Products 323.6 Household Appliances 323.7 Pharmaceutical Industry 333.8 Food Processing 333.9 Beverage Industry 343.10 Clothing Industry 343.11 Producer Goods 353.12 Materials and Chemicals Production 35Review Questions 364 Designing for Manufacture 374.1 Introduction 374.2 Computer Aided Design, Virtual Reality and Augmented Reality 374.3 Design for X 384.4 The Product Life Cycle 394.5 The Design Process 404.6 Identifying the Market Need 414.7 The Product Design Specification 414.8 Concept Design 434.9 Detail Design 434.10 Prototyping 444.11 Production 444.12 Contributors to the Design 444.13 Some Principles of Product Design 454.14 Standardisation and Modularisation 464.15 A Design for Manufacture Example 474.16 Conclusion 50Review Questions 505 Manufacturing Concepts 535.1 The Manufacturing System 535.2 Lean Manufacturing and Added Value 555.3 Integrating the Effort 565.4 The Formal Organisation 605.5 Types of Manufacture 635.6 Types of Manufacturing Equipment 66Review Questions 67Part II Manufacturing Materials 696 Materials for Manufacture 716.1 Introduction 716.2 The Structure of Metals 726.3 Plastics 796.4 Ceramics 826.5 Composites 836.6 Properties and Testing of Materials 836.7 Conclusion 88Review Questions 887 Materials Production 917.1 Introduction 917.2 Ferrous Metals Production 917.3 Non-Ferrous Metals Production 957.4 Forms of Material Supply 977.5 The Primary Production of Plastics 98Review Questions 100Part III Manufacturing Processes 1018 Casting 1038.1 Introduction 1038.2 Ingot Casting 1038.3 Continuous Casting 1048.4 Sand Casting 1058.5 Centrifugal Casting 1078.6 Shell Moulding 1078.7 Full Mould Process 1088.8 Investment Casting 1098.9 Die Casting 1108.10 Defects in Castings 1128.11 Cleaning of Castings 1128.12 When to Use Casting 113Review Questions 1139 Cutting Processes 1159.1 Introduction 1159.2 Sawing and Filing 1159.3 Basic Principles of Machining 1169.4 Machine Tools 1219.5 Other Cutting Processes 129Review Questions 13010 Deformation Processes 13310.1 Introduction 13310.2 Rolling 13410.3 Forging 13610.4 Extrusion 138Review Questions 13911 Press working 141Review Questions 14512 Plastics Processing 14712.1 Introduction 14712.2 Extrusion 14712.3 Blow Moulding 14812.4 Calendering 14912.5 Vacuum Forming 14912.6 The Blown Film Process 15012.7 Injection Moulding 151Review Questions 15713 Additive Manufacturing Processes 15913.1 Introduction 15913.2 Advantages of Additive Manufacturing 15913.3 Disadvantages of Additive Manufacturing 16013.4 General Types 160Review Questions 17014 Miscellaneous Metal working Processes 17114.1 Electro discharge Machining 17114.2 Electrochemical Machining 17214.3 Chemical Machining 17214.4 Ultrasonic Machining 17314.5 High Energy Rate Forming 17314.6 Powdered Metal Processes 17414.7 Pipe and Tube Manufacture 17514.8 Metal Finishing Processes 176Review Questions 17815 Manufacturing Processes in the Electronics Industry 18115.1 Introduction 18115.2 Semiconductor Component Manufacture 18215.3 Clean Rooms 18615.4 Printed Circuit Board Manufacture 18715.5 Conclusion 193Review Questions 19316 Assembly and Joining 19516.1 Introduction 19516.2 Mechanical Fastening 19516.3 Soldering 19716.4 Brazing 19816.5 Welding 19916.6 Adhesive Bonding 208Review Questions 21017 Material and Process Selection 211Part IV Manufacturing Automation 21518 Manufacturing Automation - Introduction 21718.1 Types of Automation 21718.2 The Advantages of Automation 21818.3 Typical Examples of Manufacturing Automation 220Review Questions 22219 The Building Blocks of Automated Systems 22319.1 Cams 22319.2 Geneva Mechanism 22319.3 Transfer Systems 22419.4 Conveyors 22519.5 Limit Switches 22519.6 Fluid Power Components 22619.7 Electric Motors for Actuation 22719.8 Feedback Devices 22919.9 The Vibratory Bowl Feeder 23119.10 Programmable Logic Controllers (PLCs) 23219.11 Control of Automated Machines 233Review Questions 23420 Reprogrammable Automation 23520.1 Industrial Robots 23520.2 Reprogrammable Equipment Precision 24220.3 Computer Numerical Controlled (CNC) Machine Tools 24320.4 Automated Guided Vehicles (AGVs) 24320.5 Reprogrammable Automation and Industrial Robot Safety 247Review Questions 25021 Machine Vision 25321.1 Areas of Application of Artificial Vision 25321.2 Vision System Components 25421.3 Lighting 25921.4 Some Further Application Examples 26121.5 Conclusion 262Review Questions 262Part V Manufacturing Operations Management 26322 Production Planning 26522.1 Introduction 26522.2 Plant Location 26522.3 Plant Layout 26722.4 Project Planning 27022.5 Process Planning 275Review Questions 27823 Production Control 28123.1 Introduction 28123.2 Elements of Production Control 28223.3 Material Requirements Planning 28523.4 Manufacturing Resource Planning 28823.5 Enterprise Resource Planning 28923.6 Recognising Constraints 29023.7 Just in Time Manufacture 291Review Questions 29524 Work Study 29724.1 Introduction 29724.2 Method Study 29924.3 Work Measurement 30624.4 Work Study As a Service to Management 309Review Questions 31125 Manufacturing Economics 31325.1 Introduction 31325.2 Costs for Decision Making 31525.3 Investment Appraisal 32025.4 Cost Analysis and Control 32325.5 Conclusion 325Review Questions 325Part VI Maintaining Manufacturing Quality 32726 Quality Defined - Quality Management and Assurance 32926.1 Defining Quality 32926.2 Quality Management 32926.3 Organisation for Quality 33126.4 The Cost of Quality 33526.5 Conclusion 338Review Questions 33927 Metrology and Statistical Quality Control 34127.1 Introduction 34127.2 Metrology 34227.3 Factory and Workshop Metrology 34527.4 Surface Texture and Measurement 34727.5 Statistical Quality Control (SQC) 349Review Questions 352Part VII Human Factors in Manufacturing 35528 Human Factors in Manufacturing 35728.1 Introduction 35728.2 Job Satisfaction 35728.3 Health and Safety 35828.4 Ergonomics 36428.5 Conclusion 374Review Questions 375Part VIII Conclusion 37729 Introduction 37929.1 Additive Manufacturing 37929.2 Augmented Reality (AR) and Virtual Reality (VR) 38029.3 Immersive Telepresence 38129.4 Communications Technologies and the IoT 38129.5 Cloud Computing 38229.6 Big Data Analytics 38329.7 Conclusion 383Appendix A: SI prefixes and multiplication factors 385Index 387

O autorze

GORDON MAIR has carried out teaching, research, and consulting in the Department of Design, Manufacture, and Engineering Management at the University of Strathclyde for almost four decades. He is also a Chartered Engineer, Fellow of the Institution of Engineering and Technology, and Fellow of the Higher Education Academy. His teaching has covered the broad spectrum of manufacturing including its technology, management, and implications for product design. His research interests and publications are in the areas of manufacturing automation and robotics, telepresence, multisensory and multimodal displays, and all aspects of the interaction between humans, products and the environment. He has been a consultant to industry for production engineering, advanced manufacturing technology and operations management projects. He has also served as an expert to the European Commission for various multinational project assessments and reviews.