Introduction of Production engineering

Introduction of Production engineering

Definition

Production engineering, also known as manufacturing engineering, is the design, development, implementation, operation, maintenance, and control of all processes in the manufacture of a product. Within this context a 'product' is defined as an item that has value added to it during the production process. Value is added by means of processes such as forming, machining, joining, and assembly.

Basic Processes

·         A product may be produced by:

·         Manipulating existing materials to produce another material.

·         Manipulating a produced material into a required form.

·         Cutting a produced material into a required form.

·         Assembling items and/or materials into a required product.

Producing the Raw Materials

Raw materials are obtained:

·         From within the earth, rocks, oil etc.

·         From on the earth, animal and plants.

Production Engineering the Raw Materials

While the oldest profession is rarely disputed, second place creates much discussion. I wish to place the production engineer in that slot. Who was it who made the first cutting tool? Who was it who organised the use of these first tools? It was the humans who made the first products.

Not much has changed fundamentally. A sharp edge is still used to cut. Fire is still used to form and remove material. Heat is generally an essential part of processing the raw materials from within the earth, while the sharp edge cuts the material growing on the earth.

From within the earth the raw materials are solid and liquid. Grown on the earth are plants and animals. These were the raw materials of the first production engineers, and it is still the same today. Proportions may have changed, but these are our raw materials.

Take the automobile. Materials from the earth include metals and oils. Materials from the soil include wood and animal skins. Prehistoric man might not recognise the car as a means of transport, but he would certainly recognise some of the basic materials it is made from.

Understanding Materials

Working with any material requires and understanding of that material. A production engineer needs to know how a material will behave when used as part of the manufacturing process. Because there are so many materials they are subdivided, and then subdivided again.

The following cover the majority of materials used in manufacturing. Often their properties will be described in the terms of the product made from that material. Note the properties and how they might help or hinder any processing on that material.

The main divisions and sub divisions are:

Metals

All metals

·         Metal

·         Alloys

Ferrous Metals- all based on iron

·         Steel

·         Iron

Non-Ferrous Metals- all other metals.

The following are the main metals used in manufacturing. Most metals are used in some form, often only as an alloying agent. Also most metals are used in alloy forms and some of these listed here refer to alloys.

·         Aluminium

·         Copper

·         Brass

·         Bronze

·         Zinc

·         Titanium

This will give you science of metals, but so far little in the way of application. As the Production Engineer is concerned with the metals in their applied form the performance of individual metals is dealt with under each process.

Non-Metals

Organic Materials

·         Wood and Fibres

Non-Organic Materials

The following is a list of the main non-organic, non-metallic materials . Consequently the materials will be dealt with individually under processes.

·         Plastic

·         Silicon

·         Carbon

·         Hydrocarbons

Understanding the Processes

An object may be manufactured in a number of ways. Obviously a finished product may have undergone a number of processes. For practical purposes the main processes are:

·         Forming: Casting, forging, moulding etc.

·         Cutting: Machining, blanking etc.

·         Joining: Assembly, welding, adhesives, fasteners etc.

 

 

 

 

Scope Of Study

Manufacturing is the backbone of any industrialized nation. Manufacturing and technical staff in industry must know the various manufacturing processes, materials being processed, tools and equipment’s for manufacturing different components or products with optimal process plan using proper precautions and specified safety rules to avoid accidents. Beside above, all kinds of the future engineers must know the basic requirements of workshop activities in term of man, machine, material, methods, money and other infrastructure facilities needed to be positioned properly for optimal shop layouts or plant layout and other support services effectively adjusted or located in the industry or plant within a well-planned manufacturing organization. The complete understanding of basic manufacturing processes and workshop technology is highly difficult for anyone to claim expertise over it. The study deals with several aspects of workshops practices also for imparting the basic working knowledge of the different engineering materials, tools, equipment’s, manufacturing processes, basic concepts of electromechanical controls of machine tools, production criteria’s, characteristics and uses of various testing instruments and measuring or inspecting devices for checking components or products manufactured in various manufacturing shops in an industrial environment. It also describes and demonstrates the use of different hand tools (measuring, marking, holding and supporting tools, cutting etc.), equipment’s, machinery and various methods of manufacturing that facilitate shaping or forming the different existing raw materials into suitable usable forms. It deals with the study of industrial environment which involves the practical knowledge in the area of ferrous and nonferrous materials, their properties and uses. It should provide the knowledge of basic workshop processes namely bench work and fitting, sheet metal, carpentry, pattern making, mould making, foundry, smithy, forging, metal working and heat treatment, welding, fastening, machine shop, surface finishing and coatings, assembling inspection and quality control. It emphasizes on basic knowledge regarding composition, properties and uses of different raw materials, various production processes, replacement of or improvement over a large number of old processes, new and compact designs, better accuracy in dimensions, quicker methods of production, better surface finishes, more alternatives to the existing materials and tooling systems, automatic and numerical control systems, higher mechanization and greater output.

Today’s competitive manufacturing era of high industrial development and research is being called the age of mechanization, automation and computer integrated manufacturing. Due to new researches in the manufacturing field, the advancement has come to this extent that every different aspect of this technology has become a full-fledged fundamental and advanced study in itself. This has led to introduction of optimized design and manufacturing of new products. New developments in manufacturing areas are deciding to transfer more skill to the machines for considerably reduction of manual labor. The scope of the subject of workshop technology and manufacturing practices is a extremely wide as it specifies the need of greater care for man, machine, material and other equipments involving higher initial investment by using proper safety rule and precautions. The through and deep knowledge in the course of study of this important subject is therefore becoming essential for all kinds of engineers to have sound foundation in their profession. Therefore the course of study of this subject provides a good theoretical background and a sound practical knowledge to the engineering students and workshop staff. One should also be aware of the following terms for better understanding of the scope of the study.