Manufacturing Systems and Processes

As a core discipline within industrial engineering, Manufacturing Systems and Processes is concerned with the design, analysis, and optimization of the integrated systems of people, materials, information, and equipment used to produce goods. This field examines both the individual physical and chemical processes that shape, form, or assemble materials—such as machining, casting, welding, and 3D printing—and the overarching system-level strategies for factory layout, production planning, quality control, and automation. The ultimate goal is to create efficient, cost-effective, and high-quality production operations that can transform raw materials into finished products that meet market demands.

1. Introduction to Manufacturing
   1. Definition and Scope of Manufacturing
      1. Definition of Manufacturing
      2. Objectives of Manufacturing
      3. Role of Manufacturing in Society
      4. Relationship to Other Economic Sectors
         1. Service Sector Integration
         2. Agricultural Sector Connections
   2. Historical Evolution of Manufacturing
      1. Pre-Industrial Craft Production
         1. Guild Systems
         2. Artisan Methods
         3. Hand Tool Manufacturing
      2. The Industrial Revolution
         1. Mechanization and Steam Power
         2. Factory System Emergence
         3. Division of Labor
      3. Mass Production Era
         1. Assembly Line Development
         2. Standardization of Parts
         3. Interchangeable Components
      4. Post-War Manufacturing Developments
         1. Toyota Production System
         2. Just-In-Time Manufacturing
         3. Quality Revolution
      5. Digital Age Manufacturing
         1. Automation and Computerization
         2. Cyber-Physical Systems
         3. Smart Manufacturing
   3. Classification of Production Systems
      1. Job Shop Production
         1. Characteristics
         2. Advantages
         3. Limitations
      2. Batch Production
         1. Characteristics
         2. Advantages
         3. Limitations
      3. Mass Production
         1. Characteristics
         2. Advantages
         3. Limitations
      4. Continuous Production
         1. Characteristics
         2. Advantages
         3. Limitations
   4. Manufacturing Performance Metrics
      1. Production Rate Metrics
         1. Throughput
         2. Cycle Time
         3. Takt Time
      2. Time-Based Metrics
         1. Manufacturing Lead Time
         2. Order-to-Delivery Time
         3. Setup Time
      3. Work-In-Process Metrics
         1. WIP Inventory Levels
         2. Flow Time
      4. Utilization Metrics
         1. Machine Utilization
         2. Labor Utilization
         3. Equipment Availability
      5. Quality Metrics
         1. Yield
         2. Defect Rate
         3. Scrap Rate
         4. First Pass Yield
      6. Overall Equipment Effectiveness
         1. Availability Component
         2. Performance Component
         3. Quality Component
   5. Manufacturing Materials
      1. Metallic Materials
         1. Ferrous Metals
            1. Carbon Steel
            2. Alloy Steel
            3. Cast Iron
            4. Stainless Steel
         2. Non-Ferrous Metals
            1. Aluminum Alloys
            2. Copper Alloys
            3. Titanium Alloys
            4. Magnesium Alloys
            5. Nickel Alloys
      2. Polymeric Materials
         1. Thermoplastics
            1. Polyethylene
            2. Polypropylene
            3. Polyvinyl Chloride
            4. Polystyrene
            5. ABS
         2. Thermosets
            1. Epoxy Resins
            2. Phenolic Resins
            3. Polyurethanes
         3. Elastomers
            1. Natural Rubber
            2. Synthetic Rubber
      3. Ceramic Materials
         1. Traditional Ceramics
            1. Clay-Based Ceramics
            2. Refractories
         2. Advanced Ceramics
            1. Technical Ceramics
            2. Structural Ceramics
      4. Composite Materials
         1. Fiber-Reinforced Composites
            1. Glass Fiber Composites
            2. Carbon Fiber Composites
         2. Particle-Reinforced Composites
         3. Laminar Composites