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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 ,.,,_c. • _DMANIIMC7VRlIIIG:__ NBS AlIT. RCHNOf.fHlY. ISCI._ • 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 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 8 COM"""'. _IIMtnlRfNG 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 7 M8TAI.•••••ODfIC1'S ..-uMtnIR,NG 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 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 '0 """"'" A$P8CJ'S Of' IIIIANfIMC7IIIIII11G 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 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 is certainly 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. Manufacturing: Art, Technology, Science, and Business Chap. 1 Manufacturing: Past,Present,and Future Early 18th Century 19th Century 20th Century 21st Century A person with an Steam-powered Computer aided Systemwide networks anvil and hammer machinery design,planning,and and information Poorly understood Improved manufacturing Robust processes and process understanding of Limited process intelligent control Craftspeople processes models using closed Global enrerprtses loop control Cottage industry Faclory conditions in and virtual .

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