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Manufacturing Technology: Selection of Manufacturing Processes
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Process Selection Aim: To select a suitable process for the manufacture of the products listed below, and provide reasons as to why the particular process would be employed. ƒ° Machine Tool Beds ¡V small batch quantities. ƒ° Fuse Wire ¡V large production requirements. ƒ° Tungsten Carbide drawing dies ¡V low numbers. ƒ° Aluminium Foil ¡V large production requirements. ƒ° Artificial Body Joints ¡V small/medium batch quantities. ƒ° Metallic Filters ¡V medium batch quantities. ƒ° Carburettor Bodies ¡V mass production. ƒ° Diesel Engine Crankshafts ¡V medium/high batch quantities. ƒ° High-Tensile Bolts ¡V medium/high batch quantities. ƒ° Aluminium Gear Housing ¡V medium batch quantities. Process Selection..........Explained Deciding on a suitable manufacturing technique, in terms of feasibility, quality, performance and cost becomes an important decision making task. Therefore in order to do this correctly; there are many aspects to consider. Factors affecting Process Selection In most circumstances there will be a range of processes available that could be used for the manufacture of a component. The final selection should be made after analysis of the following factors: ƒ° Production Quantity ¡V the amount of the component to be manufactured, also known as the batch size. ƒ° Material ¡V First of all which material would be most appropriate, the properties the component specifications state the material must carry. Once you have a specified material, there is the following to consider: „X Cost and availability „X Process compatibility „X Functional/property requirements ƒ° Component Form and Dimensions ¡V to choose a suitable manufacturing process¡¦s the dimensions of the component are vital, as this will affect the processes available. „X Size „X Shape ƒ° Component Quality Requirements ¡V The required state the component it to be when completely manufactured. „X Tolerance „X Surface Finish „X Surface Treatment ƒ° Manufacturing Costs ¡V When choosing a process the cost has to be taken into consideration, as there are budgets and limits to stick to. Cost can cover many areas, not just the process itself. „X Equipment „X Tooling „X Labour „X Overheads „X Time ƒ° Processing Times ¡V This being the production time, from material to component, again budgets and limits with time can apply too. ƒ° Labour Requirements- The amount of people/engineers needed to carryout the process. ƒ° Process waste ¡V Nearly every manufacturing process around forms some sort of waste during/after the process. Yet a lot of waste causes the component to be uneconomical and wastes vital costs. ƒ° Material/Component Recycling ¡V For example, if waste is produced can it be recycled to use again, or can the component itself be recycling when it¡¦s working life is over. All of which helps with costing and quality. With the wide range of materials in use, the manufacturing processes available, process selection to produce a certain component can be very difficult, especially when taking into account the previous factors. Therefore it is recommended to follow a Process Selection Strategy. Each Manufacturer would probably have their own Strategy written up, in order to follow their guidelines, and that will be specific to their component. Another tool to help the manufacturer chose the appropriate process, is a Process selection matrix. This is a general guide, to which processes may be suitable for a particular component, relating quantity and material. A copy of the Matrix can be seen on the following pages. Below is a strategy plan I will follow to select the best process for my product: Process Selection Strategy: ƒü Obtain an estimate of the following: „B Budget „U Production Quantity ƒ¦ Production Time Scale ƒý Research and select a material to satisfy the product specification. ƒþ Research and select the appropriate and best processes for the production of the product. „@ Once selected, you need to consider each process against the engineering and economic requirements. ƒ¶ Understand the process and its variations ƒ¶ Consider the material capability ƒ¶ Compare waste/time scales and budget variations and capability requirements. „A Review the processes against the requirements and choose the most appropriate and compatible one. Another tool available to help with selection is that of a classification List, this is simply a table of all the processes available to use in the production of components, this can too be seen on the following pages. Through research I also found a document on selecting a manufacturing process, stating the various factors that affect the selection, including dimensional/surface finish requirements, operational and manufacturing costs and consequences of improperly selection materials. This document can be seen in the research section on pages 1 & 2. Along with a table of the various processes, with the disadvantages and advantages, on pages 3, 4 & 5. Machine Tool Beds ƒü Estimates of the following: ƒ¦ A stated time is not given, yet a reasonable time scale will be kept to, as no company wants a process that is very time consuming, as it makes way for other companies to win the customers. „B A stated budget is not given, yet a reasonable cost limit will be followed, as no production company wants a very expensive process that will bring in no profit.
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