Product Design and Factory Development (The Handbook of Manufacturing Engineering, Second Edition) (Volume 1)

392 Pages·2005·19.47 MB·English

by  Richard Crowson

THE HANDBOOK OF
MANUFACTURING
ENGINEERING
Second Edition
Product Design
and Factory
Development
© 2006 by Taylor & Francis Group, LLC
THE HANDBOOK OF
MANUFACTURING
ENGINEERING
Second Edition
Product Design
and Factory
Development
EDITED BY
Richard Crowson
Boca Raton London New York
A CRC title, part of the Taylor & Francis imprint, a member of the
Taylor & Francis Group, the academic division of T&F Informa plc.
© 2006 by Taylor & Francis Group, LLC
DK192X_Discl.fm Page 1 Friday, November 11, 2005 5:42 PM
Published in 2006 by
CRC Press
Taylor & Francis Group
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© 2006 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group
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© 2006 by Taylor & Francis Group, LLC
Preface
Handbooks are generally considered to be concise references for specific subjects.
Today’s fast-paced manufacturing culture demands that such reference books provide
the reader with how-to information with no frills. Some use handbooks to impart
buzzwords on a particular technical subject that will allow the uninitiated to gain cred-
ibility when discussing a technical situation with more experienced practitioners.
The second edition of The Manufacturing Engineering Handbook was written to
equip executives, manufacturing professionals, and shop personnel with enough infor-
mation to function at a certain level on a variety of subjects. The level of professional
skill developed by reading this handbook is determined by the reader.
This series of books is written to serve as a textbook or supplemental material
for classes in engineering schools for students pursuing a manufacturing engineering
bachelor’s or graduate degree.
Manufacturing engineering professionals are taking the lead in a number of jobs
not traditionally thought to be covered in the discipline: decision-making executives
of manufacturing businesses; product design engineers; process design engineers;
and positions in tooling, facility planning, and production control are now filled by
engineers that first learned the trade of manufacturing engineering.
T he resurrection of an undesignated apprentice in our manufacturing culture has
become necessary as the technology continues to grow at a phenomenal rate. Compa-
nies can no longer afford to allow the manufacturing engineer to learn on the job. As
more universities graduate engineers with bachelors to doctorate degrees in manufac-
turing engineering, the challenges presented by the fiercely technical world we live
and work in are met by the manufacturing engineer. Therefore, the manufacturing
engineer must gain as much knowledge from as many credible sources as possible.
That is why this series of books was developed: to be an aid to successfully applying
manufacturing engineering skills in school or on the job.
Many manufacturing engineers choose to stay in the field of manufacturing engi-
neering due largely to the sense of accomplishment gained from creatively seeing
every step of the process by which raw material is turned into a finished product.
However, an increasingly large number of engineers who started as manufactur-
ing engineers are moving into positions of supervision in the design engineering,
research and development, and administrative areas. This is true because the manu-
facturing engineer brings the quality of knowledge that is hands-on, commonsense,
and practical.
T he advent of smaller and faster computer processors has made some of the sys-
tematic approaches to manufacturing affordable to the mid-sized to small manufac-
turer. Therefore the quality information presented by Geoffrey Boothroyd’s DFMA®
(Design for Manufacture and Assembly), which has historically been used by auto-
motive and aircraft manufacturers, is becoming available to the smaller, more flexible
manufacturer.
© 2006 by Taylor & Francis Group, LLC
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A s a manufacturing engineer uses this handbook to study history and apply
principles to an existing manufacturing firm, new ideas will be spawned that will
allow improvements in process flow and product flow. The successful efforts of many
years’ experience are captured in these chapters and can be used profitably by any
reader willing to think out of the box when facing challenges on a daily basis.
Human factors greatly influence productivity in the workplace, as does work-
place safety. The public awareness of hazardous practices requires the manufacturing
engineer to put the ergonomic and safety practices that are described in this hand-
book into practice.
T he historic data for anthropometry is based upon the U.S. military data and sta-
tistics compiled in the 1970s and 1980s. As the culture of manufacturing expands to
include the world, these data are no longer relevant. It is up to the new manufacturing
engineer to seek to add to these data and generate ethnicity-specific data to assist in
the design of ergonomically based products.
The cost of a product is directly impacted by injuries, product liability, and low
productivity. Thus, a manufacturing engineer must strive to become expert in the
mitigation of these areas.
T his second edition of T he Manufacturing Engineering Handbook is dedicated
to Jack M. Walker, who was unable to participate in the editing of this book but
who contributed greatly in the last few months of his life. Much written by Jack still
remains unchanged in this edition because of its value in the workplace and manu-
facturing environment today. Jack was a wonderful and inventive man who loved to
look for ways to do things that had not been thought of before.
I will always remember with joy the hours he and I spent together while he
gave example after example of inventions and designs that he had authored. Most of
these were incredibly simple and ingenious. Jack delighted in swimming upstream
by solving problems too quickly for others. He would recount examples of being
made to prove over and over again the idea he had come up with quickly. This did not
discourage him, and he delighted in the fact that the proving of his ideas took many
times longer than the invention of that idea. His favorite saying was that waiting for
others to catch up with him was “better than a sharp stick in the eye.”
His smile and the gleam in his eye let you know he had experienced a full life and
had a deep understanding of the human interaction in the manufacturing engineering
process. We will miss Jack, but we will all enjoy his spirit of joy at the discovery of
new ways to manufacture.
RICHARD D. CROWSON
SET, CMfgT, CMfgE
© 2006 by Taylor & Francis Group, LLC
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Editor
Richard D. Crowson
R ichard Crowson is currently a mechanical engineer at Controlled Semiconductor,
Inc., in Orlando, Florida. He has worked in the field of engineering, especially in the
area of lasers and in the development of semiconductor manufacturing equipment, for
over 25 years. He has experience leading multidisciplinary engineering product devel-
opment groups for several Fortune 500 companies as well as small and start-up com-
panies specializing in laser integration and semiconductor equipment manufacture.
Crowson’s formal engineering training includes academic undergraduate and
graduate studies at major universities including the University of Alabama at Bir-
mingham, University of Alabama in Huntsville, and Florida Institute of Technology.
He presented and published technical papers at Display Works and SemiCon in San
Jose, California.
He has served on numerous SEMI task forces and committees as a voting mem-
ber. His past achievements include participating in writing the SEMI S2 specifica-
tion, consulting for the 9th Circuit Court as an expert in laser welding, and sitting on
the ANSI Z136 main committee that regulates laser safety in the United States.
© 2006 by Taylor & Francis Group, LLC
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Contributors
Geoffrey Boothroyd Paul Riedel
Boothroyd Dewhurst, Inc. Certified Industrial Hygienist
Wakefield, Rhode Island Rockledge, Florida
Richard D. Crowson Jeffery W. Vincoli
Consultant CSP, REP
Melbourne, Florida Titusville, Florida
Vijay S. Sheth Jack M. Walker
McDonnell Douglas Corporation Consultant
Titusville, Florida Merritt Island, Florida
Timothy L. Murphy William L. Walker
McDonnell Douglas Corporation National High Magnetic Field Laboratory
Titusville, Florida Florida State University
Tallahassee, Florida
Allen E. Plogstedt
McDonnell Douglas Aerospace East
Titusville, Florida
Marc Plogstedt
ITEC
Orlando, Florida
© 2006 by Taylor & Francis Group, LLC
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Contents
Chapter 1 Product Development 1
Jack M. Walker and Richard D. Crowson, with
Geoffrey Boothroyd
1.0 Introduction to Product Development 1
1.1 Concurrent Engineering 9
1.2 Quality Function Deployment 15
1.3 Design for Assembly 30
Geoffrey Boothroyd and Jack M. Walker
1.4 Rapid Prototyping 43
Chapter 2 Product Design 57
Jack M. Walker and Richard D. Crowson
2.0 Introduction to Product Design 57
2.1 Design for Machining 58
2.2 Design for Casting and Forging 78
2.3 Design for Sheet Metal 115
2.4 Process Selection 146
Chapter 3 The Deductive Machine Troubleshooting Process 149
Richard D. Crowson
3.0 Systematic Design Engineering 149
3.1 Machine Debug Process 154
3.2 Error Budgeting 155
3.3 Engineering Case Studies Used in the Debug Process 158
3.4 Debugging Machines through Burn-In Analysis 161
3.5 References 162
Chapter 4 Factory Requirements 165
Vijay S. Sheth and Richard D. Crowson
4.0 Introduction to Facilities Requirements 165
4.1 General Factory Requirements 168
4.2 Requirements of the Manufacturing Process 169
4.3 Requirements for the Flow of Materials 194
4.4 Analysis of Factory Equipment Needs 204
4.5 Implementation Plan for Factory and Equipment 212
© 2006 by Taylor & Francis Group, LLC
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Chapter 5 Factory Design 217
William L. Walker
5.0 Introduction to Factory Design and Construction 217
5.1 The Twenty-First-Century Manufacturing Facility 218
5.2 Site Selection 226
5.3 The Building Program 234
5.4 Project Design 246
5.5 Construction 264
5.6 References 275
Chapter 6 Human Elements in the Factory 277
Jack M. Walker with Timothy L. Murphy,
Jeffery W. Vincoli, and Paul R. Riedel
6.0 Introduction to Human Elements in the Factory 277
6.1 Ergonomics 281
6.2 Worker’s Compensation Timothy L. Murphy 319
6.3 Industrial Safety Jeffery W. Vincoli 324
6.4 Industrial Hygiene Paul R. Riedel 336
Chapter 7 Computers and Controllers 349
Allen E. Plogstedt with Marc Plogstedt
7.0 Introduction to Computers and Controllers 349
7.1 Mainframe Systems 352
7.2 Minicomputers 354
7.3 Personal Computers 354
7.4 Networks 361
7.5 Computer-Integrated Enterprise Architecture 368
7.6 Process Controllers Marc Plogstedt 369
7.7 Human Interface to the Computer-Integrated Enterprise 376
7.8 CAD/CAM 380
7.9 Extended Enterprise 382
© 2006 by Taylor & Francis Group, LLC
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