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Book Description

An introduction to the manufacturing industry

Essential Manufacturing provides a comprehensive introduction to the wide breadth of the manufacturing industry.

There is a need for all engineering and business students to understand the importance and context of the manufacturing industry. An engineer should have a well rounded appreciation of all aspects of the industry they work in, including manufacturing. This is evidenced by professional bodies expecting all accredited engineering courses to provide students with a background that allows them to see their own specific discipline in context. Similarly, business students will often find themselves dealing in some way with manufactured products or even be directly involved in manufacturing operations management. This book will cover the full spectrum of the manufacturing industry to provide a holistic appreciation of the topic but with enough detail to be of practical use.

The book begins with an introduction to the manufacturing industry, its history, and some important manufacturing concepts.  The materials used in manufacturing and how they are produced are covered. This is followed by a more detailed description of the more common manufacturing processes, their application, and the types of automation used in the manufacturing industry. Consideration is then given to the important aspects of manufacturing operations management and production planning and control, work study, and manufacturing economics. How to maintain quality in the manufacturing process, including metrology, is examined and this is followed by human factors in manufacturing. Finally, a speculative look at the future of manufacturing is included.

Key features:

  • Takes a self-contained approach.
  • Includes review questions.
  • Suitable as an introduction for more advanced study.
  • Satisfies the requirements of college and first and second year university engineering courses.

The book provides a comprehensive, concise introduction to the manufacturing industry for engineering and management students.

Table of Contents

  1. Cover
  2. Preface
  3. Part I: Introduction
    1. 1 Introduction
      1. 1.1 Wealth and Prosperity
      2. 1.2 Manufacturing Industry
      3. 1.3 Manufacturing as a Stimulant
      4. 1.4 The Supply Chain
      5. 1.5 Conclusion
    2. 2 Manufacturing History
      1. 2.1 Toolmaking Humans
      2. 2.2 The New Stone Age
      3. 2.3 The Bronze Age
      4. 2.4 The Iron Age
      5. 2.5 The Industrial Revolution
      6. 2.6 The Twentieth Century
      7. 2.7 The Twenty‐First Century
    3. 3 Typical Manufacturing Industries
      1. 3.1 Introduction
      2. 3.2 Aerospace Industry
      3. 3.3 Automotive Industry
      4. 3.4 Shipbuilding and Marine Engineering
      5. 3.5 Electronics and Electronic Products
      6. 3.6 Household Appliances
      7. 3.7 Pharmaceutical Industry
      8. 3.8 Food Processing
      9. 3.9 Beverage Industry
      10. 3.10 Clothing Industry
      11. 3.11 Producer Goods
      12. 3.12 Materials and Chemicals Production
    4. 4 Designing for Manufacture
      1. 4.1 Introduction
      2. 4.2 Computer Aided Design, Virtual Reality and Augmented Reality
      3. 4.3 Design for X
      4. 4.4 The Product Life Cycle
      5. 4.5 The Design Process
      6. 4.6 Identifying the Market Need
      7. 4.7 The Product Design Specification
      8. 4.8 Concept Design
      9. 4.9 Detail Design
      10. 4.10 Prototyping
      11. 4.11 Production
      12. 4.12 Contributors to the Design
      13. 4.13 Some Principles of Product Design
      14. 4.14 Standardisation and Modularisation
      15. 4.15 A Design for Manufacture Example
      16. 4.16 Conclusion
    5. 5 Manufacturing Concepts
      1. 5.1 The Manufacturing System
      2. 5.2 Lean Manufacturing and Added Value
      3. 5.3 Integrating the Effort
      4. 5.4 The Formal Organisation
      5. 5.5 Types of Manufacture
      6. 5.6 Types of Manufacturing Equipment
  4. Part II: Manufacturing Materials
    1. 6 Materials for Manufacture
      1. 6.1 Introduction
      2. 6.2 The Structure of Metals
      3. 6.3 Plastics
      4. 6.4 Ceramics
      5. 6.5 Composites
      6. 6.6 Properties and Testing of Materials
      7. 6.7 Conclusion
    2. 7 Materials Production
      1. 7.1 Introduction
      2. 7.2 Ferrous Metals Production
      3. 7.3 Non‐Ferrous Metals Production
      4. 7.4 Forms of Material Supply
      5. 7.5 The Primary Production of Plastics
  5. Part III: Manufacturing Processes
    1. 8 Casting
      1. 8.1 Introduction
      2. 8.2 Ingot Casting
      3. 8.3 Continuous Casting
      4. 8.4 Sand Casting
      5. 8.5 Centrifugal Casting
      6. 8.6 Shell Moulding
      7. 8.7 Full Mould Process
      8. 8.8 Investment Casting
      9. 8.9 Die Casting
      10. 8.10 Defects in Castings
      11. 8.11 Cleaning of Castings
      12. 8.12 When to Use Casting
    2. 9 Cutting Processes
      1. 9.1 Introduction
      2. 9.2 Sawing and Filing
      3. 9.3 Basic Principles of Machining
      4. 9.4 Machine Tools
      5. 9.5 Other Cutting Processes
    3. 10 Deformation Processes
      1. 10.1 Introduction
      2. 10.2 Rolling
      3. 10.3 Forging
      4. 10.4 Extrusion
    4. 11 Pressworking
      1. Review Questions
    5. 12 Plastics Processing
      1. 12.1 Introduction
      2. 12.2 Extrusion
      3. 12.3 Blow Moulding
      4. 12.4 Calendering
      5. 12.5 Vacuum Forming
      6. 12.6 The Blown Film Process
      7. 12.7 Injection Moulding
    6. 13 Additive Manufacturing Processes
      1. 13.1 Introduction
      2. 13.2 Advantages of Additive Manufacturing
      3. 13.3 Disadvantages of Additive Manufacturing
      4. 13.4 General Types
    7. 14 Miscellaneous Metalworking Processes
      1. 14.1 Electrodischarge Machining
      2. 14.2 Electrochemical Machining
      3. 14.3 Chemical Machining
      4. 14.4 Ultrasonic Machining
      5. 14.5 High Energy Rate Forming
      6. 14.6 Powdered Metal Processes
      7. 14.7 Pipe and Tube Manufacture
      8. 14.8 Metal Finishing Processes
    8. 15 Manufacturing Processes in the Electronics Industry
      1. 15.1 Introduction
      2. 15.2 Semiconductor Component Manufacture
      3. 15.3 Clean Rooms
      4. 15.4 Printed Circuit Board Manufacture
      5. 15.5 Conclusion
    9. 16 Assembly and Joining
      1. 16.1 Introduction
      2. 16.2 Mechanical Fastening
      3. 16.3 Soldering
      4. 16.4 Brazing
      5. 16.5 Welding
      6. 16.6 Adhesive Bonding
    10. 17 Material and Process Selection
  6. Part IV: Manufacturing Automation
    1. 18 Manufacturing Automation – Introduction
      1. 18.1 Types of Automation
      2. 18.2 The Advantages of Automation
      3. 18.3 Typical Examples of Manufacturing Automation
    2. 19 The Building Blocks of Automated Systems
      1. 19.1 Cams
      2. 19.2 Geneva Mechanism
      3. 19.3 Transfer Systems
      4. 19.4 Conveyors
      5. 19.5 Limit Switches
      6. 19.6 Fluid Power Components
      7. 19.7 Electric Motors for Actuation
      8. 19.8 Feedback Devices
      9. 19.9 The Vibratory Bowl Feeder
      10. 19.10 Programmable Logic Controllers (PLCs)
      11. 19.11 Control of Automated Machines
    3. 20 Reprogrammable Automation
      1. 20.1 Industrial Robots
      2. 20.2 Reprogrammable Equipment Precision
      3. 20.3 Computer Numerical Controlled (CNC) Machine Tools
      4. 20.4 Automated Guided Vehicles (AGVs)
      5. 20.5 Reprogrammable Automation and Industrial Robot Safety
    4. 21 Machine Vision
      1. 21.1 Areas of Application of Artificial Vision
      2. 21.2 Vision System Components
      3. 21.3 Lighting
      4. 21.4 Some Further Application Examples
      5. 21.5 Conclusion
  7. Part V: Manufacturing Operations Management
    1. 22 Production Planning
      1. 22.1 Introduction
      2. 22.2 Plant Location
      3. 22.3 Plant Layout
      4. 22.4 Project Planning
      5. 22.5 Process Planning
    2. 23 Production Control
      1. 23.1 Introduction
      2. 23.2 Elements of Production Control
      3. 23.3 Material Requirements Planning
      4. 23.4 Manufacturing Resource Planning
      5. 23.5 Enterprise Resource Planning
      6. 23.6 Recognising Constraints
      7. 23.7 Just in Time Manufacture
    3. 24 Work Study
      1. 24.1 Introduction
      2. 24.2 Method Study
      3. 24.3 Work Measurement
      4. 24.4 Work Study As a Service to Management
    4. 25 Manufacturing Economics
      1. 25.1 Introduction
      2. 25.2 Costs for Decision Making
      3. 25.3 Investment Appraisal
      4. 25.4 Cost Analysis and Control
      5. 25.5 Conclusion
  8. Part VI: Maintaining Manufacturing Quality
    1. 26 Quality Defined – Quality Management and Assurance
      1. 26.1 Defining Quality
      2. 26.2 Quality Management
      3. 26.3 Organisation for Quality
      4. 26.4 The Cost of Quality
      5. 26.5 Conclusion
    2. 27 Metrology and Statistical Quality Control
      1. 27.1 Introduction
      2. 27.2 Metrology
      3. 27.3 Factory and Workshop Metrology
      4. 27.4 Surface Texture and Measurement
      5. 27.5 Statistical Quality Control (SQC)
  9. Part VII: Human Factors in Manufacturing
    1. 28 Human Factors in Manufacturing
      1. 28.1 Introduction
      2. 28.2 Job Satisfaction
      3. 28.3 Health and Safety
      4. 28.4 Ergonomics
      5. 28.5 Conclusion
  10. Part VIII: Conclusion
    1. 29 Introduction
      1. 29.1 Additive Manufacturing
      2. 29.2 Augmented Reality (AR) and Virtual Reality (VR)
      3. 29.3 Immersive Telepresence
      4. 29.4 Communications Technologies and the IoT
      5. 29.5 Cloud Computing
      6. 29.6 Big Data Analytics
      7. 29.7 Conclusion
  11. Appendix A:
  12. Index
  13. End User License Agreement
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