00:00hi and welcome to our short course on the basics of modern manufacturing in this video we are
00:13going to learn in details about how we can define manufacturing manufacturing industries manufactured
00:22products production quantity production variety and manufacturing capability so let us start with
00:32what is manufacturing the word manufacturer is derived from two latent words which combined
00:39mean made by hand the English word manufacturer is several centuries old and made by hand accurately
00:50described the manual methods used when the word was first coined most modern manufacturing is
00:58accomplished by automated and computer-controlled machinery so how can we define manufacturing as a
01:07field of study in the modern context manufacturing can be defined in two ways one technological and
01:17the other economic technologically manufacturing is the application of physical and chemical
01:26processes to alter the geometry properties and appearance of a given starting material to make
01:35parts or products manufacturing also includes assembly of multiple parts to make the products the processes
01:43process to accomplish manufacturing involve a combination of machinery tools power and labor manufacturing is
01:52almost always carried out as a sequence of operations each operation brings the material closer to the
02:01desired final state economically manufacturing is the transformation of materials into items of greater value
02:10by meaning of one or more processing and assembly operations the key point is that manufacturing adds value to the material by changing its shape or properties or
02:23combining it with other materials that have been similarly altered when iron ore is converted into steel value is added when sand is transformed into glass value is added
02:37when petroleum is refined into plastic value is added and when plastic is molded into complex geometry of a
02:47patio chair it is made even more valuable the words manufacturing and production are often used interchangeably but the term production might have a broader meaning than manufacturing manufacturing
02:58manufacturing manufacturing is an important commercial activity performed by companies that sell products to customers the type of manufacturing done by company depends on the type of products it makes manufacturing industries
03:16industry consists of enterprises and organizations that produce or supply goods and service industries can be classified as primary secondary or tertiary
03:30primary industries cultivate and exploit natural resources such as agriculture and mining secondary industries take the outputs of primary industries and convert them into consumer
03:45consumer and capital goods manufacturing is the principal activity in these categories but construction and power utilities are also included
03:57tertiary industries constitute the service sector of the economy here is a list of specific industries in these categories when we discuss about manufacturing in our videos it means production of hardware which ranges from nuts and bolts to
04:15digital computers to digital computers and even military weapons plastic and ceramic products are included but apparel paper pharmaceuticals power utilities publishing and wood products are excluded in case of our discussion
04:33manufactured products final products made by the manufacturing industries can be divided into two major classes consumer goods and capital goods
04:43consumer goods are products purchased directly by customers such as cars personal computers tires tennis rackets etc but capital goods are those purchased by companies to produce goods and services for example aircraft computers communication equipment medical apparatus
05:04trucks trucks trucks and buses railroad locomotives machine tools and construction equipment
05:11most of these capital goods are purchased by service industries without the capital goods the service industries could not function in addition to final products other manufactured items include the materials components tools and supplies used by companies that make the final product for example sheet steel
05:33sheet steel bar stock metal stampings machine parts plastic moldings and extrusions cutting tools dies molds and lubricants thus manufacturing industries consist of a complex infrastructure with various categories and layers of intermediate suppliers with whom the final consumer never deals
05:55production quantity and variety the quantity of products made by factory has an important influence on the way its people facilities and procedures are organized
06:09annual production quantities can be classified into three ranges low production which includes quantities in the range of 1 to 100 units per year medium production which ranges from 100 to 10,000 units annually
06:24the boundaries between these three are somewhat arbitrary depending upon the kinds of products these boundaries might shift by an order of magnitude also production quantity refers to the number of units produced annually for a particular product type some plants produce a variety of different product types each type being small or medium in quantity
06:52other plants specialize in high production of only one product type it is instructive to identify product variety as a parameter distinct from production quantity product variety refers to different product designs or types that are produced in the plant different products
07:16different shapes and sizes and sizes and they perform different functions they are intended for different markets some have more components than others the number of different product types made each year can be counted when the number of product types made in the factory is high this indicates high product variety there is an inverse correlation between product variety and product quantity in terms of factory operations if a factory's product variety is high
07:44then its production quantity is high then its production quantity is likely to be low but if the production quantity is high then product variety will be low manufacturing plants tend to specialize in a combination of production quantity and product variety that lies somewhere inside the diagonal band
08:06although product variety has been identified as a quantitative parameter the number of different product varieties made by the plant or company this parameter is less exact than the production quantity because details on how much designs differ are not captured simply by the number of different designs
08:30differences differences between an automobile and an air conditioner are far greater than between the air conditioner and a heat pump
08:38within each product type there are differences among specific models the extent of the product differences may be small or great as illustrated in the automotive industry
08:51each automotive company produces cars with two or three different name plates in the same assembly plant
08:58although the body styles and the other design features are virtually same in different plants the company builds heavy trucks the terms hard and soft might be used to describe these differences in product variety
09:14soft product variety occurs when there are only small differences among products such as the differences among car models on the same inline in the assembled product
09:27soft variety soft variety is categorized by a high proportion of common parts among the models
09:34hard product variety occurs when the products differ substantially and there are few common parts if any
09:44the differences between a car and a truck exemplifies hard variety
09:50so we can see that a manufacturing plant consists of a set of processes and systems and people designed to transform a certain limited range of materials into products of increased value
10:07these three building blocks materials processes and systems constitute the subject of modern manufacturing there is a strong interdependence among these factors
10:20Now, a company engaged in manufacturing cannot do everything it must only do certain things and it must do these things well
10:32Manufacturing capability refers to the scope of technical and physical capabilities and limitations of a manufacturing company and each of its plants
10:44manufacturing capabilities has three dimensions
10:481. technological process and capability 2. physical size and weight of the product
10:563. production capacity
10:59The technological processing capability of a plant or company is its available set of manufacturing processes
11:07Certain plants perform machining operations
11:11Others roll steel billets into sheet stock
11:14And others build automobiles
11:17A machine shop cannot roll steel
11:20A rolling mill cannot build cars
11:22The underlying feature that distinguishes these plants is the processes they can perform
11:29Technological processing capability is closely related to material type
11:35Certain manufacturing processes are suited to certain materials
11:37Certain manufacturing processes are suited to certain materials
11:39Whereas other processes are suited to other materials
11:43By specializing in a certain process or group of processes
11:47The plant is simultaneously specializing in a certain material
11:53Technological processing capability includes not only the physical processes
11:59But also the expertise processed by plant personnel in these processing technologies
12:07Companies must concentrate on the design and manufacture of products
12:13That are compatible with their technological processing capability
12:18Physical product limitations
12:20A second aspect of manufacturing capability is imposed by the physical product
12:27A plant where the given set of processes is limited in terms of size and weight of the products
12:33That can be accommodated, large heavy products are difficult to move
12:39To move these products, the plant must be equipped with grains of required load capacity
12:45Smaller parts and products made in large quantities can be moved by conveyors or other means
12:55The limitation of product size and weight extends to the physical capacity of the manufacturing equipment as well as production
13:05Machines come in different sizes
13:09Larger machines must be used to process larger parts
13:13The production and material handling equipment must be planned for products that lie within a certain size and weight range
13:21Production capacity
13:23A third limitation on the plant's manufacturing capability is the production quantity that can be produced in a given time period
13:33Say a month or a year
13:35This quantity limitation is commonly called plant capacity or production capacity
13:41Defined as the maximum rate of production that a plant can achieve under assumed operating conditions
13:49The operating conditions refer to the number of shifts per week, hours per shift, direct labor, manning levels in the plant and so on
14:01These factors represent inputs to the manufacturing plant
14:05Given these inputs, how much output can the factory produce?
14:09Plant capacity is usually measured in terms of output units such as annual tons of steels produced by a steel mill
14:19Or number of cars produced by a final assembly plant
14:23In these cases, the outputs are homogeneous
14:27In cases in which the output units are not homogeneous
14:31Other factors may be more appropriate
14:35Measures such as
14:37Available labor hours of productive capability
14:41In a machine shop that uses variety of parts, materials, processes or systems
14:47Are basic building blocks of manufacturing
14:51And three broad subject areas of our discussion in manufacturing processes
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