Chapter 8 Manufacturing Fundamentals Introduction SECTION 8.1 Manufacturing Systems SECTION 8.

2 Manufacturing Processes Chapter 8 Review and Assess

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ESSENTIAL QUESTION How do manufactured products impact your life every day? Manufacturing is the use of technology to make the things people want and need. Manufacturing creates tools that make tasks easier, and industrial materials that are stronger than natural materials. It also creates devices that enable us to send messages into outer space. With manufacturing, we extend our reach and improve our quality of life. If you build a bookcase from lumber, you are manufacturing a product. However, when most people think of manufacturing today, they think of the manufacturing industry. In factories, parts are made and then put together to create products. Today's manufacturing plants are very different from the factories of the past, and more changes in technology are coming rapidly. Computers are used in every aspect of manufacturing, from designing the product to storing and shipping it. New materials and methods are making entirely new products possible. One of the biggest changes on the horizon involves very small things: atoms and molecules. Nanotechnology involves building machines or materials on an atomic or molecular level to give them new properties. For example, nanotechnology has been used to make faster moving ski and snowboarding equipment.

Nanotechnology Application This snowboarder uses a special wax made with nanotechnology. The wax makes the snowboard ride smoother and go faster. What are some other ways that technology has helped you travel faster? Photo Credit: Richard Price/Taxi/Getty Images STANDARDS TECHNOLOGY AND SOCIETY ITEEA STL 4 Students will develop an understanding of the cultural, social, economic, and political effects of technology. ITEEA STL 7 Students will develop an understanding of the influence of technology on history. THE DESIGNED WORLD ITEEA STL 19 Students will develop an understanding of and be able to select and use manufacturing technologies. SCIENCE NSES G Students should develop understanding of science as a human endeavor, nature of scientific knowledge, historical perspectives. COMMON CORE STATE STANDARDS MATHEMATICS Statistics and Probability Making Inferences and Justifying Conclusions Make inferences and justify conclusions from sample surveys, experiments, and observational studies.

LANGUAGE ARTS Reading Range of Reading and Level of Text Complexity Read and comprehend complex literary and informational texts independently and proficiently.

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Reading Guide Before You Read What is the primary focus of manufacturing? What are some of the main challenges that face companies that manufacture products? Objectives

Explain the importance of manufacturing. Analyze the three basic types of production. Explain how companies compete in the global market. Investigate several manufacturing processes. Describe how manufacturing affects the environment.

Main Idea Main Idea In a manufacturing environment, companies develop ways to minimize the costs and time required for producing a product, while maximizing the quality of the product and the safety of the workers who produce it. Reading Strategy 1. Use the notebook feature in to write down the colored headings from Chapter 8. 2. As you read the text, visualize what you are reading. 3. Reflect on what you read by writing a few sentences under each heading to describe it. 4. Continue this process until you have finished the chapter. Reread your notes. Go online to for downloadable graphic organizers.

Vocabulary Content Vocabulary global market NAFTA profit productivity custom production intermittent production continuous production assembly line alloy composite raw material industrial material total quality management

Academic Vocabulary

capital company corporation subsidiary contract

Chapter 8 Manufacturing Fundamentals Introduction SECTION 8.1 Manufacturing Systems SECTION 8.2 Manufacturing Processes Chapter 8 Review and Assess

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SECTION 8.1 Manufacturing Systems What Is a System? As you know, a system is a group of parts that work together to achieve a goal. A system is needed to produce manufactured goods. To work efficiently, a manufacturing system needs to be well managed. Like other systems, a managed production system has inputs, processes, outputs, and feedback. (See Figure 8.1)

Figure 8.1 Manufacturing System for a Car - The parts of a manufacturing system are inputs, processes, outputs, and feedback. When they work properly, the result is a finished product such as a new car. How might car companies use feedback comments from car owners when designing a new car? Input includes any of the seven resources put into the system. People in manufacturing may design products, purchase materials, run machines, assemble parts, inspect products, or sweep floors. Metals, plastics, wood, glass and other ceramics, textiles, and rubber are all materials commonly used in manufactured products. The tools and machines used in manufacturing may be hand tools, portable power tools, or large machines and equipment. Computer controlled machines provide power, heat, and light for manufacturing. The company's fixed capital is invested in buildings and equipment it owns. Its working capital is the money it uses to buy materials and supplies, pay workers, buy advertising, and pay taxes. Manufacturers also need information, such as the facts about the capabilities of the machines in the factory. Time is needed to order materials, produce parts, and assemble products. Processes include those in management and production. Managers make decisions in planning, organizing, and controlling. They make a plan of action so that things will work smoothly. Then, they gather and arrange everything needed to do the job. Finally, they keep track of things. Production processes include the steps taken to make the products.

Connection CONNECTION Multiply Decimals Suppose you just started your first job with a manufacturing company. You might be surprised at the amount on your first paycheck. There is quite a difference between your gross earningsthe amount you earn before taxes and other deductionsand your net earnings, or your actual takehome pay.

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One output of manufacturing is, of course, the manufactured product. This output is expected and desirable. Other outputs, such as waste and pollution, may not be expected, and sometimes they are not wanted. Manufacturers respond to feedback in ways that affect quality and how many products are produced. With the growing concern for the environment, for example, companies are spending money to address environmental issues before they occur. Check It Out! Recall the seven inputs of a manufacturing system. Who Does Manufacturing? Manufacturing is done by companies that specialize in making certain products. The companies that do the specialized manufacturing are located in many different countries. Companies and Corporations Companies and Corporations A company is an organization formed by a group of people for the purpose of doing business. A corporation is a company that is owned by people who have bought shares in it. You probably recognize many manufacturing companies and corporations by name, such as Apple, Disney, and Ford. (See Figure 8.2)

Figure 8.2 Product Names and Logos -You may recognize the manufacturer of this car by the logo on its grill. What are some ways that you are exposed to the names and logos of big companies? Photo Credit: Mercedes-Benz USA/AP Images Some very small companies have only a few workers. Much industrial manufacturing is performed by small, locally owned companies employing a few hundred workers. These companies usually make parts that go into other, larger products, such as seat covers and door panels for cars. The largest companies may manufacture many different products. The Proctor & Gamble company, for example, makes many different types of products, such as soaps, shampoos, cake mixes, and peanut butter. Sometimes large companies own smaller companies. The smaller companies are called subsidiaries. Sometimes the subsidiaries supply parts for the main product the company manufactures. For example, a company that makes telephones may also own a company that creates plastic molds, another company that makes computer telephone chips, and still another company that manufactures wire. Sometimes a parent company is diversified. That means the subsidiaries do not necessarily make the same kind of parts or products. For example, United Technologies, a parent company, has many subsidiaries: Otis makes elevators and escalators, Carrier makes air conditioners, Hamilton Sundstrand makes mechanical systems for aircraft, Pratt & Whitney makes jet engines, and Sikorsky makes helicopters. All of these companies, however, are owned by the parent corporation. (See Figure 8.3) All combined in one network, United Technologies is currently the 21st-largest manufacturer in the United States and the 66th-largest manufacturer in the world. Sixty-seven percent of its employees are based in countries outside the United States. Due to communication technologies, corporations can now use workers from all around the world.

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Figure 8.3 Diversified Companies -Sikorsky built this helicopter for a fire department. Sikorsky accounts for 12% of United Technologies' net sales. If one of United Technologies' subsidiaries experienced an economic downturn, how might that affect the parent company? Photo Credit: Erik Simonsen/Photographer's Choice/Getty Images Sometimes several corporations, often with different specialties and located in different areas, work together as though they were one company. This arrangement, called a virtual corporation, has no employees; they all work for one of the partner corporations. Another type of virtual corporation is one that does have employees, but it outsources all of its major functions. Suppose you and a friend come up with an idea for a new product and you establish a corporation. You hire an engineering firm to design your product. You contract, or make agreements with, other firms to make, advertise, and sell the product. You and your friend are the heads of a virtual corporation. The Global Market The Global Market Many companies have manufacturing plants in different parts of the world. Sometimes these locations are chosen to take advantage of lower labor costs and/or lower costs of materials. Other times, the locations are chosen so that products can be manufactured in the countries in which they are to be sold. This helps eliminate the high cost of shipping finished products. Companies from different countries may often enter into manufacturing agreements. In some cases, the factories are managed and operated in a cooperative manner.

Rapid transportation and communications via satellite have helped products become popular throughout the world rather than in just one nation. Many products, such as automobiles, clothes, appliances, and medicines, are in demand around the world. This has created a global market. (See Figure 8.4)

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Figure 8.4 Global Markets - Nanjing Road in Shanghai, China, is a large pedestrian mall. Stores there carry name-brand merchandise from all over the world. Why is it important for companies to advertise and sell products in other countries besides the United States? Photo Credit: Glen Allison/The Image Bank/Getty Images This growing need for products is being helped by a gradual and steady reduction of trade barriers. The European Union permits member nations to sell goods among themselves without import taxes or restrictions. A similar trade agreement, NAFTA, also permits free trade among Canada, the United States, and Mexico. This decrease in trade barriers helps manufacturers find larger, worldwide markets for their products. However, this move to find cheaper manufacturing has also resulted in the loss of local manufacturing jobs. International Competition International Competition One definite effect of the development of the global economy is the increase in competition for a share of the world marketplace. Often, the major differences between products produced by different manufacturers are the safety, reliability, and potential life of the product. However, to stay in business, a manufacturer must also make a profit. Profit is the money a business makes after all expenses have been paid. Because the selling price of a product must be competitive with similar products, the amount of profit may be small. One method for staying competitive is to increase productivity. Productivity is the comparison of the amount of goods produced (output) to the amount of resources (input) that produced them. If you increase your output without increasing your input, you increase your productivity. High productivity helps keep costs down, and thus can lead to greater profits.

Check It Out! Describe companies and corporations. How do they differ?

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Types of Production The demand for products determines what will be manufactured. If fewer consumers need or want CD players, fewer will be manufactured. If fewer people take bus transportation, the demand for buses will decrease and fewer buses will be manufactured. On the other hand, if more consumers want DVD players or vehicles powered by fuel cells, more will be manufactured to meet the demand. Consumer products that are widely used, such as candy bars and DVDs, are produced for stock. The company makes large amounts of the product and keeps them on hand. When orders come in, the products are shipped to customers. When a product is not widely used, the manufacturer may not start producing it until customers have placed orders. In this case, the product is produced on demand. For example, aircraft manufacturing companies make aircraft only when they have a firm order. The order may be for a single plane or for 100 planes, but the company does not start production until the order is placed. A manufacturer generally chooses from three basic types of modern production systems to meet the demand for products. These are custom, intermittent, and continuous production. Each has its own advantages. Custom Production Custom Production In custom production, products are made one at a time according to the customer's needs and requirements. Each one is different. This type of production is usually the most expensive per number of products made. Custom-made products may be large and complex, such as a cruise ship, or small and simple, such as a piece of jewelry. (See Figure 8.5.)

Figure 8.5 Custom-Made Products -Custom-made products, such as this guitar, are often expensive and usually one of a kind. What financial benefits might companies have when they create products using the custom production process? Photo Credit: Dorling Kindersley/Getty Images At one time, manufacturers believed that making products individually by hand would become a thing of the past. Instead, handcrafted industries have survived and grown. There are many small businesses producing specialized and/or custom-made, handcrafted products. While furniture manufacturing, for example, is becoming more automated, the most valued pieces of furniture are handcrafted. Intermittent Production Intermittent Production In intermittent production, a limited quantity of a product is made. Then, any necessary retooling or changeovers are made so a different part or product can begin to be produced. Many seasonal items, such as lawn mowers and snowblowers, are manufactured this way. Per part, this type of production, also called job lot production, is less expensive than custom production. Continuous Production Continuous Production Continuous production is the system used for mass-producing products. It is also called line production or mass production. This means thousands, or even millions, of the same product are made in one steady process using an assembly line. In an assembly line, the product moves from one workstation to the next while parts are being added. (See Figure 8.6)

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Figure 8.6 Assembly Line Process -The process that makes these ice cream bars is an example of continuous production. The ice cream bars are made by using an assembly line. What are the benefits of using an assembly line? Photo Credit: Juan Silva/ the Image Bank/Getty Images Because changing a production line setup is expensive, continuous production is the most economical type of manufacturing system. Cars and electronic products, such as radios and computers, are made this way. Many manufacturers today are combining the ideas of continuous and intermittent production. They are making large quantities of the same product with slight variations. Automobiles are an example. Two models may seem the same at first glance, but on close inspection, they may have many differences. The engine, seats or other interior features, and trim may vary. However, by producing many basic models at the same time, production is more efficient. Very close coordination of parts and assembly procedures is required to make this happen.

8.1 Check Your Understanding Perform the following tasks. 1. Explain how the inputs, processes, outputs, and feedback of a manufacturing system work together to achieve the goal of a finished product. 2. Evaluate the three different production processes. Which process do you think is most important to the economy of the United States? Give reasons to support your answer. 3. Analyze the effect of competition in the international marketplace on the profitability of manufactured products. Extend Develop Communication Skills Writing Summarize how you would set up an assembly line for making peanut butter and jelly sandwiches for your entire class. Chapter 8 Manufacturing Fundamentals Introduction SECTION 8.1 Manufacturing Systems SECTION 8.2 Manufacturing Processes Chapter 8 Review and Assess

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SECTION 8.2 Manufacturing Processes Manufacturing Materials Manufacturing often requires special materials. Several basic processes are used to turn those materials into products. Materials may be natural, synthetic (human made), or a combination of both. Most raw materials need some refining or processing to convert them to industrial materials. Industrial materials are in a form that can be used to make into products. For example, metal ore must be heated to a very high temperature to remove its impurities before it can be used to make a product. Industrial materials are usually turned into standard stock. This means that the material is formed or packaged in a widely used (standard) size, shape, or amount that is easy to ship and to use. Standard stock includes sheets of plywood, steel, and aluminum. Bolts of cloth and barrels of liquid chemicals are also standard stock.

Scientists continue to develop new materials capable of providing specific properties not available in conventional materials. An alloy is made by combining two or more metals or a metal and a nonmetal. The new material has improved properties. A composite is a material made by combining two or more materials. A composite is usually much stronger and more durable than the individual materials from which it was made. One widely used composite material is fiberglass. Another example is graphite-reinforced plastic, sometimes called carbon fiber. Similar to fiberglass, it is a cloth-like woven mesh of carbon fibers instead of glass fibers, which are then coated with plastic. The result is a molded or shaped part that is smooth, stiff, and strong. These products are the result of chemical technologies that allow us to alter or modify materials. Materials The materials used in manufacturing processes are carefully tested and evaluated. Each type of manufacturing industry uses its own test for quality.

Photo Credit: Comstock Images/Jupiterimages Connection Green reSource Waste Reduction Successful businesses recognize that efficiency is the key to remaining competitive in the marketplace. The ultimate goal in efficiency is to achieve zero waste, also known as a zerocarbon footprint.

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Ceramics are materials made from nonmetallic minerals that have been heated to very high temperatures. Ceramic materials are strong, hard, and resistant to corrosion and heat. Check It Out! Describe how a composite is made. Why do manufacturers use composites? Production Processes All the processes used to actually produce the product are production processes. These processes can be classified as preprocessing, materials processing, and postprocessing.

Preprocessing Preprocessing - Pre- means before. Preprocessing happens before any work is done on the material. When the raw material or standard stock is received at the factory, it must be unloaded, stored, and protected until used. These activities are examples of preprocessing. Note that preprocessing activities do not actually change the material. Materials Processing Materials Processing Materials processing means changing the size or shape of a material in order to increase its usability or value. Industrial materials are turned into components or parts. Materials can be changed using several basic processes: forming, separating, conditioning, combining, assembling, and finishing. (See Figure 8.7) Postprocessing Postprocessing - Post- means after. Postprocessing activities include things done to the product after the materials have been changed in form or shape. Installing, maintaining, repairing, altering, handling, protecting, and storing are all examples of postprocessing. Postprocessing may also include recycling activities. Collecting glass or plastic bottles, sorting them, and grinding them into chips is an example of recycling. The chips can then be used as raw material or standard stock for manufacturing other products. Postprocessing may also include servicing a product to keep it in good operating condition during a warranty period. Automobiles are an example. Automobiles have regular servicing routines, such as oil changes and tire rotation, that can keep them in good working condition. Total Quality Management Total Quality Management Total quality management means that employees are expected to meet a performance standard for their jobs. Their job descriptions describe how they will be measured to see if they are doing a good job. Empowerment means allowing employees to make decisions without asking the boss every time.

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Figure 8.7 Materials Processing SystemIndustrial materials are converted into manufactured products through materials processing. How might the rising cost of industrial materials affect the profitability of a materials processing system?

Manufacturing Engineer How many different products result from the application of basic manufacturing engineering principles? The possibilities are endless. One of the manufactured products is carpeting. At some companies, manufacturing engineers have helped make the production of carpeting safer for the environment.

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Designers and engineers must think about how people will interact with the product during manufacturing and must also shape the product accordingly. They must plan the manufacturing processes so that workers can perform in safety and comfort. Poka-yoke was first implemented by Shigeo Shingo, a Japanese engineer. (Poka-yoke in Japanese translates to mistakeproofing.) It is a method for minimizing and/or eliminating assembly errors. For example, using color-coded parts makes it easier for workers to remember that the red wire plugs go into the red socket. Instead of having separate left-hand and right-hand parts, only one part that can be flipped over so it fits either way is used. When parts are designed to clip or snap together instead of requiring screws and bolts, workers are less likely to make mistakes attaching them. Check It Out! Explain how the combining and finishing processes are different. Impacts and Effects of Manufacturing Technology Manufacturing is important to our society and our economy. Many people work in manufacturing to help produce products. They also buy products with the money they earn. The more products people buy, the more products are manufactured. This enables more people to work. Also, materials are worth more after they have been changed into useful products. That is value added. Their value is increased by the manufacturing process. Cars, for example, are an output of a manufacturing system. They are so numerous and widely used that they have an impact on nearly every part of our lives. Cars affect our:

Economy Many people's jobs depend on the automobile industry. Cars enable people to work far from their homes and to travel more for pleasure. Politics Who should pay for road building? Should the government protect the American car industry from foreign competition? Should the speed limit be raised or lowered? All these political issues result from our use of automobiles. Environment To build and drive cars, we use nonrenewable resources, such as metals and oil. Car exhaust pollutes the air. Auto junkyards are an eyesore, and they can pollute the land and the water. Society People sometimes see cars as a symbol of status, wealth, or even personality. (See Figure 8.8.) Cars can be a way to express who we are or who we would like to be.

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Figure 8.8 Impacts of Manufacturing -This car attracts a lot of attention. What characteristics does this car have that might convey a symbol of status? Photo Credit: Dave M. Benett/Getty Images Entertainment/Getty Images Sometimes, manufacturing can play a part in overcoming negative impacts. For example, one way to prevent environmental damage is to design products that can be demanufactured (taken apart) and recycled. Another approach is to focus on reducing waste materials left over from the manufacturing process. Still other companies have found that garbage can be a valuable industrial material. Some park benches and picnic tables are manufactured from recycled plastic. 8.2 Check Your Understanding Perform the following tasks. 1. Describe the six different types of materials processing. Choose one and describe its importance to the manufacture of a product. 2. Evaluate the types of materials that are used to manufacture products. Name some advantages and disadvantages for each. 3. Analyze the ways that manufacturing technology has affected people's lives. Choose one and explain how it is affected by manufactured products. Extend Develop Communication Skills Listening Have a classmate describe three ways that the manufacture of products has affected his or her daily life. Classify the effects as positive or negative.

Section 8.2 Review

Chapter 8 Manufacturing Fundamentals Introduction SECTION 8.1 Manufacturing Systems SECTION 8.2 Manufacturing Processes Chapter 8 Review and Assess

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CHAPTER 8 Think Like an Engineer Engineering Design Process: Create and Test Composite Materials Design Brief Composite materials, or composites, are commonly used as materials in many products, such as the hull of a fishing boat or the body of a car. A composite material consists of a matrix (woven mesh) that is reinforced with a liquid (often a plastic resin) that hardens and turns the matrix into a thin sheet. 1. Identify a Problem or Opportunity 1. Identify a Problem or Opportunity You are working at a manufacturing firm. You are given a task to make three samples of composite materials and test their strength, flexibility, and breaking point. You will need to keep a daily log of your work and document and chart your test results carefully so that your firm may be able to use the composite materials to manufacture products in the future. 2. Define the Project Constraints 2. Define the Project Constraints Using your three samples, you must design three different tests to determine the materials' strength, flexibility, and breaking point. Materials for the project may include gauze, cotton cloth, and paper towels. Your samples must not exceed four square inches in size. You must also keep a daily log with all the information that can be recorded during the project.

3. Research and Brainstorming 1. Research existing composite materials and matrix properties available to you. The materials you use to make the composite material should be easy to find. Ask: What types of composite materials already exist? What properties do the materials have? 2. Brainstorm ways of testing the properties of composite materials. For example, what do you think determines a material's flexibility? Come up with at least three ways to test each property. 3. Narrow down the number of different tests to one for each property by a preliminary evaluation of the given constraints. 4. Development and Prototyping 1. Choose the best composite material designs that will solve your problem. For example, you may be able to determine before testing that some matrices will not produce a strong product. 2. After choosing the best materials for your first composite material, you can build your first prototype. Gather any tools or materials you will need. When making the prototype, be sure to wear plastic gloves. 5. Testing, Analysis, and Optimization 1. After each of your samples has hardened, analyze the properties of each one. Ask: Which was the strongest composite? Which was the most flexible? What was the breaking point of each composite material? What changes to future products may result from this data? 2. Refine the design of the composites based on your evaluation of the properties of the composite materials. 3. Choose a final design for your composite materials and test them again. Be sure to document your results. 6. Evaluation and Presentation 6. Evaluation and Presentation Present your finished composites and test results to your manufacturing firm. Be prepared to answer questions. Turn in the final report of your findings, which should include the name of your activity, your definition of the problem, a description of how you solved the problem, your log sheets, and test results.

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Connect Activity Center Go to the Activity Center to review chapter vocabulary. Main Ideas

The purpose of manufacturing is to make things that people want and need. Like other systems, manufacturing has inputs, processes, outputs, and feedback. Manufacturers generally choose from three types of production systems to meet the demand for products. Manufacturing impacts our economy, our society, our politics, and our environment.

Understanding Concepts 1. 2. 3. 4. Why is manufacturing so important to our daily lives? What are the three basic types of production? Describe how companies compete in a global market. Name the six production processes.

Thinking Critically 1. Explain How has an improvement in leisure time and education occurred since the beginning of modern manufacturing processes? 2. Analyze Do you think that the modern manufacturing processes have occurred in all countries around the world at about the same time? Why or why not? 3. Explain Manufacturing the product in the photo results in producing harmful by-products such as starch or dye. Why would a manufacturer allow this negative output when producing the jeans? Why would a manufacturer allow negative outputs when producing a product? 4. Evaluate Why is communication essential in a global market?

Photo Credit: C Squared Studios/Photodisc/Getty Images Problem Solving 1. Analyze Evaluate the quality of a manufactured product. Assess the quality of the product and the process used to make it. How could this product have been manufactured differently to have less negative impacts? 2. Evaluate Impacts Discuss the economic effects of producing a practical, pollution-free car. How would this car affect your personal life, your local area, and the oil industry? Ch 8 Review