Transcript

Welcome back, till now we saw very brief about design thinking, different stages about design thinking, now we will go to next important step in this design thinking process is Manufacturing. I have a wonderful idea, I wanted to convert this wonderful idea into a product or a prototype idea. So this prototype making comes part of manufacturing. So in this lecture we will try to see what are all the different steps in manufacturing and what are all the important things in manufacturing and how do you manufacture one product which we our self went through keeping an agricultural application.

So when we talk about design for manufacturing, so manufacturing involves first is Material, then we have to Process this Material to get an Output or, I can say the processed material is the output. So you start with a material, again here materials there are several materials available today you have metals, polymer and ceramics. Of course, today you have several hybrid materials like composix which are into existence, but the basic materials are metals, polymer and ceramics. To a large extent today polymer materials are very much used. So polymer again they are classified into three – one is Thermoset Polymer (TP), Thermoplast Polymer (TP) and Elastomer. So, these are the three classifications. Today, we are looking at thermoplastics for making even prototypes and final products in thermoplastics because it is recyclable and then second thing it is light. Earlier, we used to have steel pipes today we get all these PVC pipes and today we have flexible pipes. So if you see all across the agricultural fields we see thermoplastic cubes which are flexible in nature. So, these are all some of the advancements happening in materials and these materials by choosing a proper process it will try to generate the required output. So, there are three important things one is Materials, next one is Processing and then you try to get the output. In Manufacturing again two things are there – single part can be a product, single part, product and then it can be several parts or several parts as products. So here you need to have assembly, here it is one shot. Whatever you try to produce a part it becomes a final product. So let us understand little bit of manufacturing. Manufacturing is derived from a Latin word called as manufactus, where manus means hand and factus means made. I repeat, Manufacturing is derived from the Latin word manufactus, where manus means hand and factus means made. So, earlier whatever is made by hand was called as Manufacturing. Of course today the same terminology is used. Technology has come into existence. Today machines are also falling under this category. The practical definition of manufacturing is – a process of converting or processing raw materials into usable product where productivity is maintained. So a process of converting or processing raw material into a usable product. So you can use the raw material and that raw material if you convert it into a usable product and we would try to optimize the usage that’s why I have written this “where productivity is maintained”. So productivity means using lesser input to get maximum output. Items used in manufacturing can be raw materials or processed part components of a large product. The manufacturing usually happens on a large scale production line with machinery and skilled labours.

If you look at Manufacturing Cycle – starts research and analysis first stage so, you do a market survey or you do understand what are all the process available from looking into the literature available, state of the art then visiting some factories. You do research and then analysis from that you try to develop Design and Development this is stage 2 from the design so here when I talk about design, design here we talk about is Engineering Design. Engineering Design – means where in which we talk about dimensions, tolerance and then we also look for Materials. So, that’s why do design and development here and then comes production. So from the design and development now what we do is we get into a Production phase where in which here we try to talk more in manufacturing, but the entire process Manufacturing Cycle consists of Research, Design and Development , Production and from there we do Marketing, marketing to Distribution, distribution again the cycle keeps repeating. So marketing and distribution. So the Manufacturing Cycle will have 5 stages – Research Analysis, Design Development, Manufacturing or Production, Marketing and then Distribution. These are all part of manufacturing today. Please don’t think manufacturing is only producing. Gone those days you are only trying to produce and keep it in your stock. Today, after producing it, how do you sell it and how do you distribute it. All these things come into existence. And when you are talking about sustainable manufacturing today from the distribution how do you collect the recycle and then how do you process once again into your cycle. So Research and Analysis – research and analyze your product need as well as other products that are already in the market. So that’s what I said state of the art, looking into literature available, looking into other companies what are they that is research analysis.

The next step is design and development: making different models or prototypes that will satisfy the function and developing the model/prototype the future. Production: The process for making the product on a large scale or atleast economically feasible scale. Marketing: Marketing strategy and product marketing techniques for selling is marketing and Distribution: is includes delivery methods from production to market. So, there are different types of manufacturing – Make-to-Stock (MTS): means factory produces goods to stock, stores and showrooms. For example all screws, nuts, or fasteners soap and then other fast moving consumable goods (FMCG). They all fall under the category of Make-to-stock. Why is this important because looking into which type of manufacturing you fall you try to decide what is your capital investment you have to do. By predicting the market for their goods, the manufacturer will plan production activities in advance. Hoping that there will be a customer you try to buy and stock and keep that is what is make to stock. If your product falls in this category you have to be careful you have to produce it in advance and keep it. So, if they produce too much they may need to sell surplus at loss and in producing too little they might miss the market and not sell enough to cover costs. So there has to be a trade of between producing more and producing less. You will have to find out an optimum and then start producing whatever you want. So, the category under this is called as Make to stock.

The next one is called as Make-To-Order (MTO). The producer/factory waits for order before manufacturing stock. So moment you receive the order, you have every design in place, you will start now manufacturing after you get an order. In the previous case no, it was not like that. You produce it and keep it people will use it. Inventory is easier to control and owner does not need to rely as much on market demand. Customer waiting time is longer and the manufacturing need and constant stream of orders to keep the factory in production. So these are some of the difficulties which you will face but you have to be clear. If you take your product and if it falls under Make-To-Order category so, you will try to keep all the design ready wait for the customer order to come or purchase order to be released.

Make-To-Assembly – The factory produces component parts in anticipating of orders for assembly. By doing this, the manufacturer is ready to fulfill customer orders but if order does not materialize, the producer will have a stock of unwanted parts. For example when you go to the food chain industry they almost follow Make-To-Assembly. They will have all the raw materials which is ready for the final product in the ready state so soon as there is a customer order they will try to do all the processing and try to get the required output.

So examples in manufacturing: We will now take a live example what we worked on. This is an example of manufacturing an Amla pricking machine which we saw a deseeding machine now we will saw a pricking machine which was developed in IIT Kanpur. The key points of this machine are – it is low cost, easy to operate, long life and increasing per person productivity. Productivity means as I told you minimum input maximum output. So that does not mean that you will try to produce with zero input produce 100. Whatever you are taking raw material for making 100 you will try to use it very optimally without loss or reducing the utilization of man, machine and material but still producing the output. So that is called as productivity. Today, if you talk in any industry they always talk in terms of Productivity. Following are the images of manufacturing involved in making this machine. So the concept of Amla pricking, amla is I told you last time itself so, it has a hard seed and it is almost spherical fruit where in which this portion is the flesh and this portion is the nut. So last time we were discussing about how do we deseed the nut. Nut of the seed, how do we deseed was discussed last time now what we are trying to do is we are trying to do a piercing operation. That is called as pricking. Piercing operation in this so that you can have diffusion of solutions. This is pricking why for diffusing solutions inside amla. For that we are trying to develop a machine. Again here if you do it by hand it is going to take lot of time so last time itself we thought if we could use leg it is going to be more efficient. So here then pricking one at a time is going to be a time costly so if we could do multiple things together then it becomes easy. So, following are the images of the manufacturing involved in making a machine. So, we started working on developing prototypes. So in this prototype first what we saw is here you can see people are working around the machine so this is the frame of the machine. So, frame is nothing but the skeleton of the machine. So, here people have put all the other parts inside the machine and they are trying to do assembly, for assembly we were trying to do wielding technique. We were first joining it  then we were grinding it wherever there were unnecessary projections we were trying to grind it and remove it. So here we were trying use in square tube tresses we were trying to make and now after this you see that this is a skeleton and now the amla whatever hop from the hopper feed impressions we are trying to make and here in which you can see lot of needles are been assembled in a dice. So what we did was we manufactured two dice were in these dice you will have needles, these needles will move back and forth. And in between you will try to feed it with amla. So, now whatever they did it with hand now, you can do it with leg and this up and down movement is attached to your pedal and then that reciprocates and now the amla can be pushed. At given point of time this is flat, here it is 2D, so you can see it is 3D so several of these amlas can be fed in at any given point of time. So, through this what we have done is we have used all the manufacturing processes for developing a prototype. So then we finally develop the product you can see whatever I was talking about the needle is here. So we just painted it and then converted it into a working model for amla pricking. So, in this lecture what we were more focused is towards manufacturing. When we talk about manufacturing there are two stages, one is primary manufacturing and secondary manufacturing. In primary manufacturing you will have costing processes, metal farming processes. In secondary manufacturing predominantly it will be subtract two processes and assembly processes. So subtract two process is to give a shape to it and the finally we assemble several of this small parts together to form a large part there we do assembly. So this is the basic technique, so using this technique you can make a final product or you can make prototypes where in which the fabricated prototypes can be given for market testing and validation, comeback, realitrate and then develop a final product.

So here in which we at every stage we have used this Design Thinking Approach – what should be the ergonomics, how should we place the pedal, where should at what angle should be the needle inclined, what will be the rolling velocity of amla and how what is the shape of it, how do you feed one at a time. So all these things were design thinking approach was done and finally we came out with a brilliant solution which is today used in several of the food processing industries.

Thank You!