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CH01General introduction (What is manufacturing (Significance (societies…
CH01
General introduction
What is manufacturing
Significance
a nation creates material wealth
the higher the level of manufacturing activity in a country, the higher is the living standard of its people.
(This may not be true in the 21st century due to
high globalization of economics
.)
經濟全球化→製造外移，低成本
the backbone of any industrialized nations
Manufacturing accounts for approximately 20-30% of GNP
higher than 30% in Taiwan
societies better making things are more successful
American civil war:
the North (industry-based) won the war over the South (agriculture-based) because of its capacity of manufacturing.
World War II: the US out-produced Japan and Germany.
Components
four essential components
Machines
Systems
Processes
(Human)
Materials
interdisciplinary field（跨領域）
Mechanical engineering
focused on more
macroscopic material responses
, mfg process design, operation control, machine design, and automation
Industrial engineering
studies manufacturing in a
system manner
including process design, operation sequences, logistics（物流管理), production facility layout（設施規劃）, quality control, and inventory control
Material science
to characterize
material responses/behaviors
subject to external physical/chemical forces in a
microscopic view
.
systems engineering
Management
Business
emphasize on accounting, cost control and enterprise integration.
Definition
Technologically
change the geometry, properties, appearance of a given stock material
to make parts or products
:warning:scraps（廢料） or waste produced in any manufacturing process
involves application of energy
(in a physical, chemical, electrical, optical, or mixed form)
Economically
create values through manufacturing process
iron→steel
petroleun（原油）→oil
cube→complex shape
Capability
Examples
Boeing 767 is made of 4-million parts
one of the largest manufactured product; how to assembly such a huge product efficiently is an extremely difficult task.
Pentium 4 micro-processor is 25 mm x 25 mm containing million transistors
it is one of the most complex manufactured products consisting of thousand process operations.
Criteria
the niche（利基） (core competence) of a manufacturing company
Part size
how big or how small a part can be made?
Part hardness or strength
the harder the material is, the more difficult its manufacturing process would be
e.g. Ti>Al>Copper>Wood.
Precision（精密度） / Tolerance
how precise a manufactured part can be made?
Production rate / cost
how fast/cheap a manufactured part can be made?
Sustainabilty（永續性）
how environment-benign a manufacturing process can be performed? (Sustainable product/manufacturing)
Manufacturing
Made by hand
making products from raw materials (stock, stock materials)
Latin word first appears in 1567
by a variety of physical principles, equipment, and operations
Manufacturing in a Product Life Cycle
70% to 80% of the cost of product development and manufacture is determined by the
decisions made in the initial design stages
.
Traditionally design and manufacturing activities take place sequentially
rather than concurrently or simultaneously
Life cycle, a product from creation to end of use
marketing, planning, design, development, production（量產）, distribution（物流）, use, disposal, and recycling
All disciplines are involved in the early design stages
design for manufacture (DFM), design for assembly (DFA), design for recyclability, and design for safety
only one aspect in a product life cycle (PLC)（產品生命週期）
Classification of Manufacturing Processes
Process operation
Property-enhancing operations
add value
to the material
by improving its properties
without changing its shape
Surface processing operations
:check: performed to clean[減法], coat(鍍) or deposit(沉積)[加法] material onto the exterior surface of a part.
:check:They usually do
not induce a bulk（整體） effect
:check:have been widely adopted to fabricate semi-conductor materials
Shaping operations
change the
geometry
of the work material.
Application of
heat
or
mechanical forces
.
transforms a work material from one state to a more advanced state that is
closer to the final product
Assembly operation
joins two or more components to create a new entity
Welding（焊接）
the most commonly joining process.
Soldering（點焊） and adhesive（黏著劑） bonding are used in Printed Circuit Board assembly