Process: It is simply a method which products can be manufactured from raw materials. It could also be described as a method for shaping raw materials into usable product forms. In this course, the term process, applies to the shaping of metal, plastic or rubber in the raw material states. The course does not concern about those industries which produce food stuffs, textiles, chemicals or medicines. This course is also not intended for use in relation to the industry which makes raw materials.
General Manufacturing Processes:
- Casting and Moulding
- Machining or Cutting
- Forming or Deforming
- Assembly
In addition to the process for shaping raw materials, finishing operations are used to obtain the
final quality desired. These processes include: Cleaning, Painting, Buffing, Plating, Polishing,
Deburring, Heat treatment etc. Nearly all products manufactured require at least two or more of the five general processes. Therefore process engineering deals with all five general processes
Product Engineering:
The product to be manufactured is first conceived by the engineer. This engineer determines the need for
a product. It may be an entirely new product or new model of the old product. Experimental designs are
made ,and scale models are made and tested. Finally a production design is created after all faults have been
corrected. Part prints are drawn to illustrate the product graphically. All dimensions and specifications required are included on the print. The material to be used in the product is specified, and product name and number is included. Functions of a product engineering department can be itemized as follows:
A. Design Product for Function
1. Build model for testing
2. Provide part prints
a. Physical dimensions
b. Material
c. Special process required such as painting plating, heat
treatment, testing etc.
3. Provide tool design and construction aids
a. Master layouts
b. Templates
c. Master models.
4. Provide specifications or standards manual
a. Material specification
b. Specification for testing and inspection
c. Procedures for testing and inspection
d. Specification for threads, gears, keys, splines etc.
e. Procedures and specifications for joining process
B. Design the Product for Customer
Satisfaction
1. Sales appeal
a. Appearance
b. Improvements
c. Design to meet the needs of the customer
2. Durability and life expectancy
C. Design the Product for Cost
1. Cost should be low enough to compete in market
2. Cost should be high enough to provide profit
3. Cost should be in correct relationship with
durability and life expectancy
D. Design the Product for ease of Maintenance
and Assembly
1. Ease of repair
2. Ease of assembly and disassembly
3. Provide drawing for maintenance and assembly
The product engineer must transmit the Information to the process engineer so that work May continue. Paper work passing from product to Process engineer includes
A. Paper prints
B. Engineering releases
i. Production rate per year
ii. Sub-assembly and assembly numbers
iii. Release date-date on which processing, tooling and all
planning may start.
iv. Part name, number and material.
C. Change in part prints when revision are made
D. Change in engineering releases
