Manufacturing

The revised and updated second edition of this book gives an in-depth presentation of the basic principles and operational procedures of general manufacturing processes. It aims at assisting the students in developing an understanding of the important and often complex interrelationship among various technical and economical factors involved in manufacturing. The book begins with a discussion on material properties while laying emphasis on the influence of materials and processing parameters in understanding manufacturing processes and operations. This is followed by a detailed description of various manufacturing processes commonly used in the industry. With several revisions and the addition of four new chapters, the new edition also includes a detailed discussion on mechanics of metal cutting, features and working of machine tools, design of molds and gating systems for proper filling and cooling of castings. Besides, the new edition provides the basics of solid-state welding processes, weldability, heat in welding, residual stresses and testing of weldments and also of non-conventional machining methods, automation and transfer machining, machining centres, robotics, manufacturing of gears, threads and jigs and fixtures. The book is intended for undergraduate students of mechanical engineering, production engineering and industrial engineering. The diploma students and those preparing for AMIE, Indian Engineering Services and other competitive examinations will also find the book highly useful. New to This Edition : Includes four new chapters Non-conventional Machining Methods; Automation: Transfer Machining, Machining Centres and Robotics; Manufacturing Gears and Threads; and Jigs and Fixtures to meet the course requirements. Offers a good number of worked-out examples to help the students in mastering the concepts of the various manufacturing processes. Provides objective-type questions drawn from various competitive examinations such as Indian Engineering Services and GATE.
Fabricated tells the story of 3D printers, humble manufacturing machines that are bursting out of the factory and into schools, kitchens, hospitals, even onto the fashion catwalk. Fabricated describes our emerging world of printable products, where people design and 3D print their own creations as easily as they edit an online document.

A 3D printer transforms digital information into a physical object by carrying out instructions from an electronic design file, or 'blueprint.' Guided by a design file, a 3D printer lays down layer after layer of a raw material to 'print' out an object. That's not the whole story, however. The magic happens when you plug a 3D printer into today’s mind-boggling digital technologies. Add to that the Internet, tiny, low cost electronic circuitry, radical advances in materials science and biotech and voila! The result is an explosion of technological and social innovation.

Fabricated takes the reader onto a rich and fulfilling journey that explores how 3D printing is poised to impact nearly every part of our lives.

Aimed at people who enjoy books on business strategy, popular science and novel technology, Fabricated will provide readers with practical and imaginative insights to the question 'how will this technology change my life?' Based on hundreds of hours of research and dozens of interviews with experts from a broad range of industries, Fabricated offers readers an informative, engaging and fast-paced introduction to 3D printing now and in the future.

Fundamentals of Manufacturing, Third Edition provides a structured review of the fundamentals of manufacturing for individuals planning to take SME'S Certified Manufacturing Technologist (CMfgT) or Certified Manufacturing Engineer (CMfgE) certification exams. This book has been updated according to the most recent Body of Knowledge published by the Certification Oversight and Appeals Committee of the Society of Manufacturing Engineers.

While the objective of this book is to prepare for the certification process, it is a primary source of information for individuals interested in learning fundamental manufacturing concepts and practices. This book is a valuable resource for anyone with limited manufacturing experience or training. 

Instructor slides and the Fundamentals of Manufacturing Workbook are available to complement course instruction and exam preparation.


Table of Contents
Chapter 1: Mathematics
Chapter 2: Units of Measure
Chapter 3: Light
Chapter 4: Sound
Chapter 5: Electricity/Electronics
Chapter 6: Statics
Chapter 7: Dynamics
Chapter 8: Strength of Materials
Chapter 9: Thermodynamics and Heat Transfer
Chapter 10: Fluid Power
Chapter 11: Chemistry
Chapter 12: Material Properties
Chapter 13: Metals
Chapter 14: Plastics
Chapter 15: Composites
Chapter 16: Ceramics
Chapter 17: Engineering Drawing
Chapter 18: Geometric Dimensioning and Tolerancing
Chapter 19: Computer-Aided Design/Engineering
Chapter 20: Product Development and Design
Chapter 21: Intelllectual Property
Chapter 22: Product Liability
Chapter 23: Cutting Tool Technology
Chapter 24: Machining
Chapter 25: Metal Forming
Chapter 26: Sheet Metalworking
Chapter 27: Powdered Metals
Chapter 28: Casting
Chapter 29: Joining and Fastening
Chapter 30: Finishing
Chapter 31: Plastics Processes
Chapter 32: Composite Processes
Chapter 33: Ceramic Processes
Chapter 34: Printed Circuit Board Fabrication and Assembly
Chapter 35: Traditional Production Planning and Control
Chapter 36: Lean Production
Chapter 37: Process Engineering
Chapter 38: Fixture and Jig Design
Chapter 39: Materials Management
Chapter 40: Industrial Safety, Health and Environmental Management
Chapter 41: Manufacturing Networks
Chapter 42: Computer Numerical Control Machining
Chapter 43: Programmable Logic Controllers
Chapter 44: Robotics
Chapter 45: Automated Material Handling and Identification
Chapter 46: Statistical Methods for Quality Control
Chapter 47: Continuous Improvement
Chapter 48: Quality Standards
Chapter 49: Dimensional Metrology
Chapter 50: Nondestructive Testing
Chapter 51: Management Introduction
Chapter 52: Leadership and Motivation
Chapter 53: Project Management
Chapter 54: Labor Relations
Chapter 55: Engineering Economics
Chapter 56: Sustainable Manufacturing
Chapter 57: Personal Effectiveness

Manufacturing and Design presents a fresh view on the world of industrial production: thinking in terms of both abstraction levels and trade-offs. The book invites its readers to distinguish between what is possible in principle for a certain process (as determined by physical law); what is possible in practice (the production method as determined by industrial state-of-the-art); and what is possible for a certain supplier (as determined by its production equipment). Specific processes considered here include metal forging, extrusion, and casting; plastic injection molding and thermoforming; additive manufacturing; joining; recycling; and more.

By tackling the field of manufacturing processes from this new angle, this book makes the most out of a reader's limited time. It gives the knowledge needed to not only create well-producible designs, but also to understand supplier needs in order to find the optimal compromise. Apart from improving design for production, this publication raises the standards of thinking about producibility.

  • Emphasizes the strong link between product design and choice of manufacturing process
  • Introduces the concept of a "production triangle" to highlight tradeoffs between function, cost, and quality for different manufacturing methods
  • Balanced sets of questions are included to stimulate the reader's thoughts
  • Each chapter ends information on the production methods commonly associated with the principle discussed, as well as pointers for further reading
  • Hints to chapter exercises and an appendix on long exercises with worked solutions available on the book's companion site: http://booksite.elsevier.com/9780080999227/
"Toyota Kata gets to the essence of how Toyota manages continuous improvement and human ingenuity, through its improvement kata and coaching kata. Mike Rother explains why typical companies fail to understand the core of lean and make limited progress—and what it takes to make it a real part of your culture."
—Jeffrey K. Liker, bestselling author of The Toyota Way

"[Toyota Kata is] one of the stepping stones that will usher in a new era of management thinking."
—The Systems Thinker

"How any organization in any industry can progress from old-fashioned management by results to a strikingly different and better way."
—James P. Womack, Chairman and Founder, Lean Enterprise Institute

"Practicing the improvement kata is perhaps the best way we've found so far for actualizing PDCA in an organization."
—John Shook, Chairman and CEO, Lean Enterprise Institute

This game-changing book puts you behind the curtain at Toyota, providing new insight into the legendary automaker's management practices and offering practical guidance for leading and developing people in a way that makes the best use of their brainpower.

Drawing on six years of research into Toyota's employee-management routines, Toyota Kata examines and elucidates, for the first time, the company's organizational routines--called kata--that power its success with continuous improvement and adaptation. The book also reaches beyond Toyota to explain issues of human behavior in organizations and provide specific answers to questions such as:

  • How can we make improvement and adaptation part of everyday work throughout the organization?
  • How can we develop and utilize the capability of everyone in the organization to repeatedly work toward and achieve new levels of performance?
  • How can we give an organization the power to handle dynamic, unpredictable situations and keep satisfying customers?

Mike Rother explains how to improve our prevailing management approach through the use of two kata: Improvement Kata--a repeating routine of establishing challenging target conditions, working step-by-step through obstacles, and always learning from the problems we encounter; and Coaching Kata: a pattern of teaching the improvement kata to employees at every level to ensure it motivates their ways of thinking and acting.

With clear detail, an abundance of practical examples, and a cohesive explanation from start to finish, Toyota Kata gives executives and managers at any level actionable routines of thought and behavior that produce superior results and sustained competitive advantage.

The concrete tools manufacturing enterprises need to thrive in today's global environment

For a manufacturing enterprise to succeed in this current volatile economic environment, a revolution is needed in restructuring its three main components: product design, manufacturing, and business model. The Global Manufacturing Revolution is the first book to focus on these issues. Based on the author's long-standing course work at the University of Michigan, this unique volume proposes new technologies and new business strategies that can increase an enterprise's speed of responsiveness to volatile markets, as well as enhance the integration of its own engineering and business.

Introduced here are innovations to the entire manufacturing culture:

  • An original approach to the analysis of manufacturing paradigms

  • Suggested methods for developing creativity in product design

  • A quantitative analysis of manufacturing system configurations

  • A new manufacturing "reconfigurable" paradigm, in which the speed of responsiveness is the prime business goal

  • An original approach to using information technology for workforce empowerment

The book also offers analysis and original models of previous manufacturing paradigms' technical and business dimensions—including mass production and mass customization—in order to fully explain the current revolution in global manufacturing enterprises. In addition, 200 original illustrations and pictures help to clarify the topics.

Globalization is creating both opportunities and challenges for companies that manufacture durable goods. The tools, theories, and case studies in this volume will be invaluable to engineers pursuing leadership careers in the manufacturing industry, as well as to leaders of global enterprises and business students who are motivated to lead manufacturing enterprises and ensure their growth.

The new edition of this professional resource reveals how to optimize all aspects of the global manufacturing process to build the highest quality goods at the lowest price in the shortest possible time.

How can one apply technical and business knowledge to develop a strategic plan that delivers increased productivity, quality, sustainability, reliability, agility, resilience, and best practices with rapid time to production and value? The answers are found in the fully updated new edition of Manufacturing Engineering Handbook.

The goal of this second edition is to provide the essential knowledge needed to build products with the highest quality at the lowest cost in the least amount of time by optimizing all aspects of the manufacturing process—design, development, tools, processes, quality, speed, output, safety, and sustainability. You will gain access to information on conventional and modern technologies, manufacturing processes, and operations management that will assist you in achieving these goals.

The book is written by a team of more than 100 internationally renowned manufacturing engineering experts, and pared down from its original 1200 pages. The new and vastly improved second edition is specifically designed to concisely and succinctly cover traditional manufacturing processes and advanced technologies as well as newer manufacturing software and systems to integrate them into the modern, global manufacturing world.

  • Brand-new chapters on: eco-design and sustainability; nano materials and nano manufacturing; facilities planning; operations research
  • New sections on plastics, composites, and moldmaking; global manufacturing and supply chain management
  • Increased coverage of Design for Six Sigma and adaptive manufacturing
  • Affiliated web site with color illustrations, graphs, charts, discussions on future trends, additional technical papers, and suggestions for further reading
Improve Your Ability to Read and Interpret All Types of Construction Drawings

Blueprint Reading is a step-by-step guide to reading and interpreting all types of construction drawings. Filled with hundreds of illustrations and study questions, this easy-to-use resource offers a complete overview of construction drawing basics for every aspect of the construction process- from site work, foundations, and structural systems to interior work and finishes.

Covering all the latest technological advances, noted architect Sam Kubba offers detailed information on:

  • Blueprint standards-ANSI, ISO, AWS, and ASME
  • Computer-aided design (CAD) and computer-aided design and drafting (CADD)
  • Lines, views, elevations, and dimensions
  • Layouts of all construction drawing types-architectural, structural, mechanical, and electrical
  • Specifications-MasterFormat and UniFormat
  • Symbols-materials, electrical, plumbing, HVAC, and others
  • How to avoid costly pitfalls on construction projects

You'll also find a glossary of terms for quick reference, convenient tables and charts for identifying symbols and abbreviations, and much more.

Inside This Skills-Building Guide to Construction Drawing Basics

• Blueprint Standards • Blueprints and Construction Drawings: A Universal Language • Understanding Lines • Types of Views • Understanding Dimensions • Layout of Construction Drawings • Understanding Industrial Blueprints • The Meaning of Symbols • Understanding Schedules • Specifications • ISO Issues, Codes, and Building Regulations • Construction Business Environment
Learn how Lean IT can help companies deliver better customer service and value

Lean Enterprise Systems effectively demonstrates how the techniques derived from Lean Manufacturing, combined with the thoughtful application of information technology, can help all enterprises improve business performance and add significant value for their customers. The author also demonstrates how the basic concepts of Lean Manufacturing can be applied to create agile and responsive Lean IT.

The book is divided into three parts that collectively explore how people, processes, and technology combine forces to facilitate continuous improvement:
* Part One: Building Blocks of the Lean Enterprise sets forth the essentials of Lean. Readers discover where, when, and how Lean IT adds substantial value to the Lean Enterprise through integrated processes of planning, scheduling, execution, control, and decision making across the full spectrum of operations.
* Part Two: Building Blocks of Information Systems explores the primary components of an enterprise information system and how these components may be integrated to improve the flow of information supporting value streams. Readers learn how information systems help organize and deliver knowledge when and where it's needed.
* Part Three: Managing Change with IT demonstrates how the skillful combination of process and information technology improvements empowers people to continuously improve the Lean Enterprise. Readers develop the skills to exploit emerging information technology tools and change management methods, crafting a Lean IT framework-reducing waste, complexity, and lead time-while adding measurable value.

Executives, managers, and improvement teams across a broad range of industries, as well as IT professionals, can apply the techniques described in this publication to improve performance, add value, and create competitive advantage. The book's clear style and practical focus also makes it an excellent textbook for upper-level undergraduate and graduate courses in business, operations management, and business information systems.
A veteran New York Times economics correspondent reports from factories nationwide to illustrate the continuing importance of industry for our country.
 
In the 1950s, manufacturing generated nearly 30 percent of US income. But over the decades, that share has gradually declined to less than 12 percent, at the same time that real estate, finance, and Wall Street trading have grown. While manufacturing’s share of the US economy shrinks, it expands in countries such as China and Germany that have a strong industrial policy. Meanwhile Americans are only vaguely aware of the many consequences—including a decline in their self-image as inventive, practical, and effective people—of the loss of that industrial base.
 
Reporting from places where things were and sometimes still are “Made in the USA”—New York, New York; Boston; Detroit; Fort Wayne and Indianapolis, Indiana; Los Angeles; Midland, Michigan; Milwaukee; Philadelphia; St. Louis; and Washington, DC—Louis Uchitelle argues that the government has a crucial role to play in making domestic manufacturing possible. If the Department of Defense subsidizes the manufacture of weapons and war materiel, why shouldn’t the government support the industrial base that powers our economy?
 
Combining brilliant reportage with an incisive economic and political argument, Making It tells the overlooked story of manufacturing’s still-vital role in the United States and how it might expand.
 
“Compelling . . . demonstrates the intimate connection between good work and national well-being . . . economics with a heart.” —Mike Rose, author of The Mind at Work
The definitive practical guide to choosing the optimum manufacturing process, written for students and engineers. Process Selection provides engineers with the essential technological and economic data to guide the selection of manufacturing processes. This fully revised second edition covers a wide range of important manufacturing processes and will ensure design decisions are made to achieve optimal cost and quality objectives.

Expanded and updated to include contemporary manufacturing, fabrication and assembly technologies, the book puts process selection and costing into the context of modern product development and manufacturing, based on parameters such as materials requirements, design considerations, quality and economic factors. Key features of the book include: manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes and their variants in a standard format; process capability charts detailing the processing tolerance ranges for key material types; strategies to facilitate process selection; detailed methods for estimating costs, both at the component and assemby level.

The approach enables an engineer to understand the consequences of design decisions on the technological and economic aspects of component manufacturing, fabrication and assembly. This comprehensive book provides both a definitive guide to the subject for students and an invaluable source of reference for practising engineers.

  • Manufacturing process information maps (PRIMAs) provide detailed information on the characteristics and capabilities of 65 processes in a standard format
  • Process capability charts detail the processing tolerance ranges for key material types
  • Detailed methods for estimating costs, both at the component and assembly level
Lasers play a major part in the processing of the disparate materials used in engineering and manufacturing. The range of procedures in which they are involved is ever increasing. The informal style of Laser Material Processing (4th Edition) will guide you smoothly from the basics of laser physics to the detailed treatment of all the major materials processing techniques for which lasers are now essential.

• Helps you to understand how the laser works and to decide which laser is best for your purposes.

• New chapters on laser physics, drilling, micro- and nanomanufacturing and biomedical laser processing reflect the changes in the field since the last edition, updating and completing the range of practical knowledge about the processes possible with lasers already familiar to established users of this well-known text.

• Provides a firm grounding in the safety aspects of laser use.

• Now with end-of-chapter exercises to help students assimilate information as they learn.

• The authors’ lively presentation is supported by a number of original cartoons by Patrick Wright and Noel Ford which will bring a smile to your face and ease the learning process.

Laser Material Processing (4th Edition) will be of use as university or industrial course material for senior undergraduate, graduate and non-degree technical training in optoelectronics, laser processing and advanced manufacturing. Practising engineers and technicians in these areas will also find the book an authoritative source of information on the ever- expanding use of industrial lasers in material processing.

The methods and concepts presented in the bestselling first edition revolutionized the approach to the management and control of Lean companies. Enhanced with extensive end-of-chapter exercises and downloadable resources with Lean accounting tools, the second edition of this preeminent practitioner’s guide is now suitable for classroom use.

Practical Lean Accounting: A Proven System for Measuring and Managing the Lean Enterprise, Second Edition explains exactly what it takes to transform a traditional accounting system to one that supports and enhances a company’s Lean efforts. Defining the fundamental principles of Lean accounting, it demonstrates how to use them to identify and eliminate wasteful transactions. The book includes coverage of cell performance measurement, use of the box score, operational and financial planning, cost targeting, Lean accounting diagnostics, and value stream mapping. Retaining the easy-to-use format that made the first edition a bestseller, this updated edition includes:

  • A new section on the use of value stream performance measurements in continuous improvement
  • A re-written Target Costing chapter that emphasizes a value-based approach to the management of the Lean value system
  • A Lean Accounting Diagnostic tool to help you assess progress and develop a plan for implementing changes
  • Cutting-edge examples that illustrate implementation in accounting departments
  • Downloadable resources with data from the ECI Value Stream Cost Analysis case study included in the text, Excel templates, and end-of-chapter questions with solutions

The book contains a wealth of tools that makes it ideal for company training sessions and advanced undergraduate and graduate-level courses. For each major example provided, two similar problems are included—one for instructors to guide students through and a second for students to work through on their own. An additional set of problems and questions for testing purposes are also available to instructors on the authors’ website.

Unfortunately, during the publishing process mistakes can be made that are not caught before the book is printed. Productivity Press takes great care to catch any errors prior to the printing stage.

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