Tài liệu Century Manufacturing P1 doc

Forward This textbook series is published at a very opportunity time when the discipline of industrial engineering is experiencing a phenomenal growth in China academia and with its increased interests in the utilization of the concepts, methods and tools of industrial engineering in the workplace. Effective utilization of these industrial engineering approaches in the workplace should result in increased productivity, quality of work, satisfaction and profitability to the cooperation. The books in this series should be most suitable to junior and senior undergraduate students and first year graduate students, and to those in industry who need to solve problems on the design, operation and management of industrial systems. Department ofIndustrial Engineering, Tslnghua University School ofIndustrial Engineering, Purdue University April, 2002 Contents MANIIMC7VRlIIIG:AlIT. RCHNOf.fHlY. ISCI._ _D __ NBS 1.1 Introduction: What Is "Manufacturing"? I 1.2 The Art of Manufacturing (from 20,000 n.c. to 1770 A.D.) 2 13 The Technology of Manufacturing: From the 1770s to the 1970s 5 1.4 A Science of Manufacturing: The 1980s to the Present 8 1.5 The Business of Manufacturing 13 1.6 Summary 15 1.7 References 17 1.8 Bibliography 18 1.9 Case Study: "The Next Bench Syndrome" 19 1.10 Review Material 19 2 _C7VRIIIIGJlNlU.YSIS: _. _ OU_ _ A STIIRJ'.III' __ 2' 2.1 Introduction:www.start-up.cem 21 2.2 Question 1: Who Is the Customer? 22 2.3 Question 2: How Much Will the Product Cost to Manufacture (C)? 26 2.4 Question 3: How Much Quality (Q)? 44 2.5 Question 4: How Fast Can the Product Be Delivered (D)? 57 2.6 Question 5: How Much flexibility (F)? 62 2.7 Management of Technology 65 2.8 References 67 2.9 Bibliography 70 2.10 Case Study 71 vII ,.,,_c. • • vIII Contents 2.11 Interactive Further Work 79 2.12 Review Material 80 3 PRODUCT " .6N,. COMI'fITRI AI"'" DamN (CADI. AND.OUD -.LING .1 3.1 Introduction 81 3.2 Is There a Definition of Design? 82 3.3 The Artistic, Creative, or Conceptual Phase of Design 82 3.4 The High-Level Engineering Phase of Design 83 3.5 The Analytical Phase of Design 86 3.6 The Detailed Phase of Design 90 3.7 Three Tutorials: An Overview 90 3.8 First Tutorial: Wire-Frame Construction 91 3.9 Solid Modeling Overview 98 3.10 Second Tutorial: Solid Modeling Using Constructive Solid Geometry (CSG) 104 3.11 Third Tutorial: Solid Modeling Using Destructive Solid Geometry (DSG) 109 3.12 Management of Technology 113 3.13 Glossary 117 3.14 References 119 3.15 Bibliography 121 3.16 URLs of Interest: Commercial CAD/CAM Systems and Design Advisers 122 3.17 Case Study 122 3.18 Question for Review 128 " .OUD ", •• PORM MBBlCAn_ (_I ANDRAI'I-.rtITOTIfPING 130 4.1 Solid Freeform Fabrication (SFF) Methods 130 4.2 Stereolithography: A General Overview 133 4.3 Comparisons Between Prototyping Processes 149 4.4 Casting Methods for Rapid Prototyping 154 4.5 Machining Methods for Rapid Prototyping 158 4.6 Management of Technology 161 4.7 Glossary 163 4.8 References 165 4.9 Bibliography 168 4.10 URLs of Interest 168 4.11 InteractiveFurtherWork 169 5 •••••ICfINDIICTOBMANUMCTUBING 171 5.1 Introduction 171 5.2 Semiconductors 171 Contents Ix 5.3 Market Adoption 172 5.4 The Microelectronics Revolution 174 5.5 Transistors 176 5.6 Design 182 5.7 Semiconductor Manufacturing I: Summary 184 5.8 Semiconductor Manufacturing II: NMOS 185 5.9 Layout Rules 189 5.10 More Details on Front-End Processing 192 5.11 Back-End Processing Methods 205 5.12 Cost of Chip Making 208 5.13 Management of Technology 213 5.14 Glossary 223 5.15 References 228 5.16 Bibliography 230 5.17 URLs of Interest 230 5.18 Appendix I: Worldwide Semiconductor Market Share 231 5.19 Appendix 2: Cost Model Variables in Year 2000--Example for a 64- MB Dram (Courtesy Dataquest) 231 5.20 Review Material 232 233 6.1 Introduction 233 6.2 Printed Circuit Board Manufacturing 235 6.3 Printed Circuit Board Assembly 239 6.4 Hard Drive Manufacturing 248 6.5 Management of Technology 255 6.6 Glossary 262 6.7 References 264 6.8 Case Study on Computer Manufacturing 267 277 7.1 Introduction 277 7.2 Basic Machining Operations 280 7.3 Controlling the Machining Process 289 7.4 The Economics of Machining 302 7.5 Sheet Metal Forming 306 7.6 Management of Technology 315 7.7 Glossary 318 7.8 References 322 7.9 Bibliography 324 7.10 URLsofInterest 324 7.11 Interactive Further Work I: The Shear Plane Angle 324 7.12 Interactive Further Work 2: "Fixnirenet" 325 7.13 Review Questions 327 8 COM"""'. _IIMtnlRfNG 7 M8TAI.••••• ODfIC1'S -uMtnIR,NG Contents " •••••tnJI:-PIIIIfHIC MAlfUMcnnr,1IIG AND "'lUll. A••••• V 330 8.1 Introduction 330 8.2 Properties of Plastics 331 8.3 Processing of Plastics I: The Injection Molding Method 334 8.4 Processing of Plastics II: Polymer Extrusion 345 8.5 Processing of Plastics III: Blow Molding 346 8.6 Processing of Plastics IV; Thermoforming of Thin Sheets 346 8.7 The Computer as a Commodity: Design for Assembly and Manufacturing 348 8.8 Management of Technology 456 8.9 Glossary 358 8.10 References 361 8.11 Bibliography 362 8.12 URLs of Interest 362 8.13 Case Study on Assembly 362 8.14 Interactive Further work 364 8.15 Review Material 364 " BloncHNOI.OGY 3011 9.1 Introduction 366 9.2 Modern Practice of an Ancient Art 367 9.3 Capturing Interest 368 9.4 Milestones in Biotechnology History 369 9.5 A Bioscience Review 371 9.6 Bioprocesses 379 9.7 Genetic Engineering I: Overview 384 9.8 Genetic Engineering Il: Case Study on Gene Cloning of Hemoglobin 390 9.9 Bloprocess Engineering 395 9.10 Management of Technology 398 9.11 Glossary 402 9.12 References 404 9.13 Bibliography 405 - 10.1 Restatement of Goals and Context 406 10.2 Management of Technology 407 10.3 From the Past to the Present 408 10.4 From the Present to the Future 409 10.5 Principles of Organizational "Layering" 410 10.6 Layer I: The Learning Organization 411 10.7 Layer II: Compressing Time-to-Market 413 10.8 Layer III: Aesthetics in Design 414 10.9 Layer IV: Bridging Cultures to Create Leading Edge Products 415 '0 """"'" A$P8CJ'S Of' IIIIANfIMC7IIIIII11G Contents xl 10.10 Conclusions to the Layering Principle 420 10.11 References 420 10.12 Bibliography 421 _ A _"DOK" OF 'DDS FOR PIIO.IKTS. 'IVII_ AN".W'N'" PlANS 423 A.I Who Want" to Be an Entrepreneur? 423 A2 Projects on Prototyping and Business 424 A3 Project Steps and Making Progress 425 A.4 Outline of a Short Business Plan 427 AS Project Selection 428 A6 Project 1: Enhanced Mouse-Input Devices 429 A.7 Project 2: Blimp-Cams, Cart-Cams, and Telepresence Devices 430 A8 Project 3: Miniature Radios for Consumer Electronics 431 A.9 Project 4: GPS-Based Consumer Products 434 AID Consulting Projects 437 A.ll Overview of Possible Factory Tours 439 Al2 Rationale 439 A.13 Factory-Tour Case Study Write-Up 440 A.14 Suggested Format and Content for the Factory- Tour Case Studies 441 A.I5 References 443 A.16 Bibliography 444 A.17 URLs of Interest 444 A.18 Case Study- The "Palm Pilot" 444 'NIIIB '''17 CHAPTER MANUFACTURING: ART, TECHNOLOGY, SCIENCE, AND BusINESS 1.1 INTRODUCTION: WHAT IS "MANUFACTURING"? The word has Latin roots: manu, meaning by hand, joined to facere, meaning to make. The dictionary definition is "Making of articles by physical/abor or machinery, espe- cially on a large scale." Even this simple definition shows a significant historical trend. For hundreds of years. manufacturing was done by physical labor, in which a person with hand tools used craft skills to make objects. Since the industrial revolution 200 years ago, machinery has played an increasing role, as summarized in the second column of Figure 1.1. Also, the models for manufacturing processes have become better understood. And in more recent decades, computer aided design and manu- facturing (CAD/CAM) and new concepts in quality assurance (OA) have been intro- duced to improve efficiency in production. It is expected that the 21st century will bring even better process models, more exacting control, and increased integration. During the early part of the 20th century, the words largescale-used above in the dictionary definition-were synonymous with the mass production of Henry Ford. Most people would agree that the present trends created by the Internet have now set the stage for an even larger scale or global approach to manufacturing. We can expect to see global networks of information and distributed manufacturing enterprises. The 20th century concept of a monolithic organization clinging to one centralized corporate ethos may fade. The new culture may well be smaller, more agile corporations that can spring up for specific purposes, exist while the market sus- tains the new product, and then gracefully disband as the market changes. The Internet iscertainly providing the infrastructure for these more flexible and informal ways of creating new enterprises that respond to people with a naturally entrepre- neurial spirit. In Chapter 1, the goals are to set the stage for these broad views of manufacturing and a new era of global change. Early 18th Century 20th Century Manufacturing: Art, Technology, Science, and Business Chap. 1 21st Century Manufacturing: Past,Present,and Future 19th Century A person with an anvil and hammer Poorly understood process Craftspeople Cottage industry Steam-powered machinery Improved understanding of processes Faclory conditions in cities Computer aided design,planning,and manufacturing Limited process models using closed loop control Increased factory automation Systemwide networks and information Robust processes and intelligent control Global enrerprtses and virtual . manufacturing corporations Figufe Ll Four centuries of manufacturing leading to 21st century manufacturing. 1.2 THE ART OF MANUFACTURING (FROM 20,000 B.C. TO 1770 A.D.I In the most general sense, manufacturing is central to existence and survival. Histo- rians connect the beginning of the last European Ice Age, approximately 20,000 years ago, to a period in which "technology took an extTa spurt" (Pfeiffer, 1986). Cro- Magnons retreated southward from the glacial ice that, more or less,reached what are now the northern London suburbs. They manufactured rough pelts for warmth, simple tools for hunting, and crude implements for cooking. This general period of prehistory around 20,000 B.G to 10,000 B.C. is referred to as the Stone Age. The availability of simple manufacturing tools and methods around the period of 10,000B.G also created the environment for community living, rather than an opportunistic, nomadic-tribe mentality. Such communities set the stage, at that time, for the agrarian revolution. Manufacturing must have then evolved from these arts and crafts roots with occasional similar spurts prompted by climate, famine, or war. For example, the acci- dental discovery that natural copper ore, mixed with natural tin are, would produce a weapon much more durable than stone replaced the Stone Age with the Bronze Age. Archaeologists believe that bronze weapons, drinking vessels, and other oma- ments were made in Thailand, Korea, and other Eastern civilizations as early as 5000 B.C.At a similar time, in the Western civilizations, the evidence suggests that tin was mined in the Cornwall area of England. The two contemporaneous societies of Egypt and Mesopotamia appeared on the historical scene around 3000 B.C.While the his- torical roots of these cultures appear hazy, they were blessed wilh sophisticated arti- sans (Thomsen and Thomsen, 1974). Their early arts and crafts skills were then passed on to the Greeks and Romans, thereby setting the stage for European man- ufacturing methods. These grew very slowly indeed until the Iron Age and, finally,the industrial revolution of the 17th and 18th centuries. One example of these early arts and crafts skills was the lost-wax casting process. It was discovered by both the Egyptians and the Koreans around the period 5000 B.C.to 3000 B.G In the process, an artist carves and creates a wax modeI-say 1.2 The Art of Manufacturing (from 20,000 B.C. to 1770 A.D.) of a small statue. Sand or clay is then packed around this wax model. Next, the wax model is melted out through a small hole in the bottom to leave a hollow core. The small hole is plugged, and then liquid metal is poured into a wider hole at the top of the hollow cavity. After the metal freezes and sets, the casting is broken out of the sand. Some hand finishing, deburring, and polishing render the desired art object. Later chapters in the book will describe modern rapid-prototyping shops, connected to the Internet, producing small batches of trial-run computer casings for AT&T, Sil- icon Graphics, and IBM. These are high-tech operations by anyone's standards. Iron- ically,however, this lost-wax process remains one of the basic processes that is widely used in prototyping. If the roots of forging and casting are with the Egyptian and Korean artisans, what about slightly more complex processes such as turning and milling? Bronze drinking vessels extracted by archaeologists from the tombs in Thebes, Egypt, show the characteristic turned rings on their bases as if made on a crude lathe. (As described later, a lathe is a turning machine tool, predominantly used today to change the diameter of a bar of stee1.) The manufacturing date is estimated to be before 26 B.C.,because Thebes was sacked in that year (Armarego and Brown, 1969). In the British Museum and the Natural History Museum in New York, many art objects show these characteristic turned circles from early machining operations. Even the word lathe has romantic roots. It derives from the word lath, related to the description for a flexible stick or slender tree branch used to spin the bar as described below. Early lathes were operated by two people: one holding the tool, the other turning the bar being machined. Sooner or later someone figured out (prob- ably one of the exhausted turning guys) that one could rig up a crude system some- thing like an old-fashioned sewing machine treadle. A rope was wrapped and looped around the free end of the bar being machined. One end was.tied to the turner's foot, rather like a stirrup; the other end was tied to the end of a springy stick or tree branch (the lath) that was nailed up into the roof rafters. As the turner raised his foot up and down, the motion rotated the bar back and forth, and the lath functioned as a return spring for the rope. Obviously this was a relatively crude process from a modern day view of achievable precision! But from the word lath comes today's word lathe. And in Britain, the word "turner" is frequently used instead of the American word "machinist" for the lathe operator. This introduction to manufacturing from an artistic point of view brings up the first thoughts on design for manufacturability (DFM) (see Bralla, 1998). It must be clear from the above descriptions of open-die forging, casting, and machining that there is always a trade-off between the complexity of the original design and how easily it is made. It was certainly clear to the original artisans. In any natural history museum showing European art, one can see many functional items such as cooking pots, ordinary tools, eating implements that are rather dull looking: no fancy f1eurs-de-lis or insets, no beautifully rounded corners. By contrast, exotic jewelry and necklaces do contain these fanciful additions. The most decorative items are the handles and scabbards of swords. These were obviously the most important objects to even an average soldier's heart, and they were willing to pay relatively large sums of money to the artisan to create beauty as well as functionality. Asian cultures had different ways of demonstrating wealth or societal position, where simplicity was synonymous [...]... control in basic manufacturing will always be mandatory 1.6 SUMMARY By reviewing the art, technology, science, and business aspects of manufacturing, it can be concluded that the activity of manufacturing is much more than machining metals or etching wafers: manufacturing is an extended social enterprise In the last 250 years, people have been dramatically changed by the advances in manufacturing Society... questions 2' 22 Manufacturing Analysis: Some Basic Questions for a Start-Up Company Chap 2 \START»~ Technical invention Next product Who is the customer? Potential new synergie! Market analysis Conceptual design System assembly phase Detailed design phase Plastic-products manufacturing Rapid protolyping and design changes Metal-products manufacturing Computer , manufacturing Semiconductor manufacturing. .. ofTQM, JIT, eE, and lean manufacturing, combined with the engineering sciences of CIM, all began to create an important improvement in U.S manufacturing (Schonberger, 1998; Macher et al., 1998) And this set the stage for the economic growth of the 1990s,as described in the next section 1.5 THE BUSINESS OF MANUFACTURING Ayres and Miller (1983) provide the succinct definition of manufacturing as the "confluence... "design artist" or "manufacturing artist" no matter how mathematically sophisticated and high-tech these fields eventually become As this book moves on to the technology and business of manufacturing, it is suggested that new students in the field keep this concept of aesthetic experience in mind 1.3 The Technology of Manufacturing: From the 1770s to the 1970s 1.3 THE TECHNOLOGY OF MANUFACTURING: FROM... New York: Harper and Bros , Manufacturing: Art, Technology, Science, and Business Chap 1 Thomsen.B G., and H H Thomsen 1974 Early wire drawing through dies Transactions of the ASME, Journal of Engineering for Industry 96, Series B, no 4: 1216-1224 Abo see Thomsen, E G Tracing the roots of manufacturing technology: A monogram of early manufacturing techniques Journal of Manufacturing Processes Dearborn,... Hall Groover, M P 1996 Fundamentals tice-Hall of modern manufacturing Jaeger, R C.1988 Introduction to microelectronic Modular Series on Solid State Devices Kalpakjian, S 1997, Manufacturing CA: Addison Wesley Longman fabrication processes for engineering and processes in manufacturing, Upper Saddle River, NJ: PrenReading, MA:Addison Koenig, D T 1987 Manufacturing engineering: Principles for optimization... robotics and unattended flexible manufacturing systems (FMS) in order to reduce factory floor labor costs Taken together, robotics and unattended flexible manufacturing systems can be defined as computer integrated manufacturing (Cllvl) By the mid-1980s, this investment in CIM did begin to show considerable promise Nevertheless, as emphasized in the preface, to compete in manufacturing, no amount of fabulous... heterogeneous software products Collaborative design '0 Manufacturing: Art, Technology,Science, and Business elM Chap 1 FlgureU Engineering science aspects of Computer Integrated Manufacturing ;:f1llUfa~~I::::~~ syste~ (elM) (organization, scheduling) Process control Th, -, process ~hYSICS!J EngineerIDg Sdenft as machining, welding, or semiconductor manufacturing) , control issues (such as servo-control... across several manufacturing steps Second, in the next circle, there is now a well-established body of knowledge in control theory that prescribes stability, settling time, and accuracy in machines used for manufacturing Combined with the standard kinematic analyses for linkages, cams and drive mechanisms, and friction, another body of scientific knowledge has been established for this part of manufacturing, ... the Toyota Production System, which reduced work in progress by pulling products through a flexible manufacturing system (FMS) rather than pushing unnecessary amounts of subcomponents into an already log-jammed system Just in time (JIT) manufacturing is often used to describe this method of operation Lean manufacturing is another associated phrase emphasizing a focus on reduced work-in-progress (WIP) . of manufacturing and a new era of global change. Early 18th Century 20th Century Manufacturing: Art, Technology, Science, and Business Chap. 1 21st Century. and virtual . manufacturing corporations Figufe Ll Four centuries of manufacturing leading to 21st century manufacturing. 1.2 THE ART OF MANUFACTURING