ÜRETİM NEDİR ANADOLU U N I V E R S I T Y ENM208 Industrial Eng. Dep. 2006 Saleh AMAITIK

factus = Yapmak,imal etmek Manufacturing Processes Üretimin Tanımı Latince kelimeler olan manu factus Ell imal etme manu = El factus = Yapmak,imal etmek Spring 2005

Manufacturing Processes Üretimin Tanımı Üretim, ürünleri ham malzemeden başlayarak pekçok prosesden,işlemden ve makinelerden geçiren, her aşamasının iyi planlandığı bir aktiviteler zinciridir. Üretimin tanımı Spring 2005

Manufacturing Processes Üretimin Tanımı Üretim İmalat İmalat Mühendisliği, tüm dünyada geniş kullanım alanına sahip ve endüstriyel aktiviteler alanını içeren bir tanımdır. Üretim Mühendisliği ise Amerika dışındaki tüm ülkelerde kullanılan İmalat Mühendisliğine eşdeğer bir tanımdır. Derslerimizde Üretim Mühendisliği olarak kullanılacaktır. Spring 2005

Üretim Sistemi, üretim proseslerini tasarlamak veya düzenlemektir. Manufacturing Processes Üretim Sistemleri Üretim Sistemi, istenilen ürünleri elde etmek için kullanılan üretim proseslerinin tamamına ve organizasyonuna verilen isimdir. Üretim Sistemi, üretim proseslerini tasarlamak veya düzenlemektir. Üretim Sisteminin kontrolu demek, tüm proseslerin veya teçhizatın kontrol altında bulunması demektir. Tüm üretim sistemi, bir program veya plana göre, üretimin kontrolü, stok seviyesi ve ürünün kalite seviyesi gibi kavramları kontrol altında tutmak zorundadır. Spring 2005

Manufacturing Processes Üretim Sistemleri Üretim sistemi, Ürettiği ürünlerin girdilerini dış müşterilerinin isteklerinden alır. Spring 2005

Tekli ürünler Sürekli ürünler Manufacturing Processes Üretim Sistemleri Bir üretim sistemi aşağıdaki ürün tiplerini üretebilir: Tekli ürünler Ayrık-tek parça halindeki ürünler (çivi,vida,dişliler,motor bloğu vb.) Sürekli ürünler Tek parça halinden kesilerk ve böylece tekli ürün halina getirilenler(Kablo teli,sac veya plastik plaklar,borular,profiller vbg.) Spring 2005

Manufacturing Processes Production Systems Bir üretim sistemi veya teşebbüs, tüm işletmeyi ve üretim sistemini kapsayan bir sorumluluk alanına sahip olacaktır. Üretim sistemi, Üretim birimine ek olarak tesisin, işletmenin tüm diğer fonksiyonları ile birlikte, iletişim ,tasarım,analiz ve kontrolunden sorumlu olacaktır. Bu alt sistemler, üretilen tüm ürünler için çeşitli anlamlar ifade edeceklerdir. Spring 2005

Manufacturing Processes Production Systems Manufacturing System (where value is added) Spring 2005

Production Types Production Systems Manufacturing Processes Production Systems Production Types Low-quantity production (1 ~ 100 units/yr) Job shop, prototyping. Medium-quantity production (100 ~ 10,000 units/yr) Batch production & cellular manufacturing. High-quantity production (> 10,000 units/yr) Mass production. Spring 2005

Machine tools linked together to make a manufacturing system cell Manufacturing Processes Machine A specific piece of equipment designed to accomplish specific processes, often called a Machine Tool Examples: Milling machine, punch press, …. Machine tools linked together to make a manufacturing system cell Spring 2005

Manufacturing Processes Job (Station) A collection of operations done on machines or a collection of tasks performed by one worker at one location on the assembly line. Examples: Machining, inspection, final assembly, …… Spring 2005

Manufacturing Processes Operation (Process) A specific action or treatment, often done on a machine, the collection of which makes up the job of a worker. Examples: Drilling, Forming, Welding, assembly, …… Spring 2005

Manufacturing Processes Tool Refers to the implements used to hold, cut, shape, or deform the work materials. Examples: Cutting tools in machining. Jigs and fixtures in work holding. Punches and dies in metal forming. Spring 2005

Design and Manufacturing process Manufacturing Processes Design and Manufacturing process Spring 2005

Concurrent Engineering Manufacturing Processes Concurrent Engineering Concurrent engineering is a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support. Spring 2005

Design for Manufacturing (DFM) Manufacturing Processes Design for Manufacturing (DFM) It is a comprehensive approach to production of products, ant it integrates the design process with materials, manufacturing methods, process planning, assembly, and quality assurance. Implements design for manufacture requires that designers have a fundamental understanding of the characteristics, capabilities, and limitations of materials, manufacturing processes and related operations, machinery and equipment. Spring 2005

Selecting materials for manufacturing Manufacturing Processes Selecting materials for manufacturing Variety of materials is now available, each having its own properties, applications, advantages, and limitations. Spring 2005

Selecting materials for manufacturing Manufacturing Processes Selecting materials for manufacturing When selecting materials for products, we consider Mechanical properties of materials (Strength, toughness, ductility, hardness, elasticity, fatigues, creep, ……( Physical properties of materials (density, specific heat, thermal expansion and conductivity, melting point, and electrical and magnetic properties, ……) Chemical properties of materials (corrosion, toxicity, flammability, ……) Spring 2005

Selecting materials for manufacturing Manufacturing Processes Selecting materials for manufacturing The material properties specified for a product should be appropriate to the conditions under which the product is expected to function. The manufacturing properties of materials determine whether they can be cast, formed, machined, welded, and heated-treated with relative ease. Spring 2005

Selection of manufacturing processes Many processes are used to produce parts and shapes and there is usually more than one method of manufacturing a part from a given material Classification of manufacturing processes Machining (turning, drilling, milling, grinding, ……. Forming and shaping (rolling, forging, sheet forming,….. Casting (expendable mold, permanent mold, ……) Joining (welding, brazing, soldering, ….) Finishing (honing, polishing, coating, heat treatment, … Spring 2005

Characterizing a manufacturing process Manufacturing Processes Characterizing a manufacturing process Spring 2005

Machine or equipment avalibility Cost Manufacturing Processes Factors affecting the selection of manufacturing processes There are many factors which affect the selection of a suitable manufacturing process for a part. These factors are: Geometry Quality Quantity Material Machine or equipment avalibility Cost Spring 2005

Manufacturing Processes Factors affecting the selection of manufacturing processes Geometry Cylindrical, conical, and screw threads are mostly easily produced on a Lathe. Plane surface, block shapes and slots are generally produced by shaping, planning or milling. More complex parts may need to be cast, forged or shaped before machining. The shape of a part will decide the process which must be used to produce that part. Spring 2005

Dimensional accuracy (tolerances). Manufacturing Processes Factors affecting the selection of manufacturing processes Quality Dimensional accuracy (tolerances). Geometrical accuracy. Surface finish. An appropriate manufacturing process should provide suitable dimensional accuracy, geometrical accuracy, and surface finish. Spring 2005

Manufacturing Processes Factors affecting the selection of manufacturing processes Quantity The quantity (batch size) determines the economics of manufacturing process selection. The cost falls as the batch size increases and more productive techniques can be employed. Spring 2005

The material from which the part is going to be made Manufacturing Processes Factors affecting the selection of manufacturing processes Material The material from which the part is going to be made The material specified by the designer influences the method of manufacturing. Spring 2005

Machine or equipment availability Manufacturing Processes Factors affecting the selection of manufacturing processes Machine or equipment availability Availability of machines and equipment and of operating experience with the manufacturing facility Cost Operational and manufacturing cost. Spring 2005

Improper selection of material. Manufacturing Processes Consequences of improper selection of materials and processes Numerous examples of product failure can be traced to Improper selection of material. Improper selection of manufacturing processes. Improper control of process variables. A part is generally considered to have failed when It stops functioning (e.g. broken shaft, gear, ….) It does not functioning properly or perform within required specification limits (e.g. worn bearing, …) It becomes unreliable or unsafe for further use (e.g. crack in a shaft, ..) Spring 2005

Manufacturing Processes Net-shape Manufacturing Since not all manufacturing operations produce finished parts, additional operations may be necessary. Net-shape or near-net-shape manufacturing. The part is made, in the first operation, as close to the final desired dimensions, tolerances, surface finish, and specifications as possible. Spring 2005

Manufacturing Processes Manufacturing Automation The major goals of automation in manufacturing facilities are to integrate various operations so as to improve productivity, to increase product quality, to minimize cycle times, and to reduce labor costs Computers are now used in a very broad range of applications including: Control and optimization of manufacturing processes. Material handling Automated assembly Automated inspection and testing of products Spring 2005

Spring 2005

Üretim Prosesleri Bilgisayarla Bütünleşik İmalat - CIM

Manufacturing Processes Üretimde Bilgisayar Uygulamaları Üretimde bilgisayar kullanım alanları aşağıdaki şekilde özetlenebilir. Bilgisayar Destekli Üretim - BDÜ (CNC) Bilgisayar Destekli Üretim Planlama - BDÜP (CAPP) Otomasyon ve Robotik Montaj Sistemleri. Esnek Üretim Sistemleri - EÜS (FMS) Otomatik Malzeme İletimi. Yapay Zeka. Spring 2005