MANUFACTURING PROCESS:

Manufacturing process is basically a complex activity, concerned with people who have a
broad number of disciplines and expertise and a wide range of machinery, tools, and
equipment with numerous levels of automation, such as computers, robots, and other
equipment. Manufacturing pursuits must be receptive to several needs and developments.
Besides above, all the future technicians must understand the basic needs of workshop
routines in terms of man, material, methods, revenue and other infrastructure conveniences
needed to be placed properly for maximum shop or plant layouts and other support solutions
effectively regulated or positioned in the field or industry within a properly planned
manufacturing firm.

MEANING:
The complete knowledge of fundamental workshop technology and manufacturing processes
is highly troublesome for anybody to claim competence over it. It deals with numerous
aspects of workshops procedures also for providing the basic working awareness of the
various engineering materials, tools, accessories, manufacturing processes, basic concepts of
machine instruments, production criteria’s, traits and uses of numerous testing instruments
and calibrating or inspecting units for checking materials or products designed in various
production shops in a commercial environment. It also explains and illustrates the use of
several hand tools (calibrating, marking, forming and supporting gear etc.), tools, machinery
and diverse methods of production that facilitate forming or shaping the existing raw
materials into appropriate usable forms. Below are some of the manufacturing processes that
are worth reading.

TYPES OF MANUFACTURING PROCESS:

Following are the 4 types of manufacturing processes:

1. MACHINING:
Tools used for machining are immobile power-driven units used to form or shape solid
materials, specifically metals. The forming is done by removing extra materials from a work-
piece. Machine tools make up the foundation of advanced industry and are utilized either
indirectly or directly in the manufacturing of tool parts.
They are categorized under three main categories:
1. Traditional Chip-making tools.
2. Presses.
3. Modern machine tools.
Traditional chip-making tools form the work-piece by trimming away the unwanted part
accessible as chips. Presses implement a several shaping processes, which includes shearing,
pressing, or elongating. Non-traditional machine tools implement light, electric powered,
chemical, and sonic power; superheated gas; and high-energy compound beams to form the
exotic supplies and materials that have been created to meet the requirements of modern
technology.

2. JOINING:
Every joining approach has particular design needs, while certain joint needs may propose a
particular joining approach. Design for assembly, and fastener selection apply their own
specifications.
Bolting is a standard fastening method, for instance, but welding may cut down the weight of
assemblies. Naturally, joints intended for the two approaches would differ tremendously
However, all joint patterns must consider features such as load factors, assembly
effectiveness, operating surroundings, overhaul and upkeep, and the materials chosen.
Welding is generally a cost-effective approach to fabricate. It doesn't require overlapping
materials, and so it removes excess weight brought on by other fastening methods. Fasteners
don't have to be purchased and stored in stock. Welding also can minimize costs related to
extra parts, for example angles mounted between parts.

3. FORMING:
Metal forming is the approach of creating the metallic components by deforming the metal
but not by removing, cutting, shredding or breaking any part. Bending, spinning, drawing,
and stretching are a few important metal forming process in manufacturing. The metal press
such as die and punching tools are implemented for this manufacturing process.

Advantages: – Same equipment can be utilized for manufacturing various components by

simply changing the dies.
Disadvantages: – High apparatus and tooling expenses. – Heat treatment must be applied
afterwards.

4. CASTING:
Casting is a manufacturing process in which a solid is dissolved into a liquid, heated to
appropriate temperature (sometimes processed to change its chemical formula), and is then
added into a mould or cavity. Thus, in just one step, complex or simple shapes can be crafted
from any kind of metal that has the capability to be melted. The end product can have
practically any arrangement the designer wants.
Furthermore, the reluctance to working challenges can be improved, directional attributes can
be managed, and a pleasing look can be developed.
 CHALLENGES & ISSUES FACED BY DIFFERENT
MANUFACTURING COMPANIES:

1. SUPPLY CHAIN COLLABORATION:

In supply chain management, supply chain collaboration is defined as two or
more autonomous firms working jointly to plan and execute supply chain operations. It can
deliver substantial benefits and advantages to collaborators. It is known as a cooperative
strategy when one or more companies or business units work together to create mutual
benefits. There are two main types of supply chain collaboration: vertical collaboration and
horizontal collaboration. Vertical collaboration is the collaboration when two or more
organizations from different levels or stages in supply chain share their responsibilities,
resources, and performance information to serve relatively similar end customers; while
horizontal collaboration is an inter-organizational system relationship between two or more
companies at the same level or stage in the supply chain in order to allow greater ease of
work and cooperation towards achieving a common objective.

IMPORTANCE OF SUPPLY CHAIN MANAGEMENT:

It is well known that supply chain management is an integral part of most businesses and is
essential to company success and customer satisfaction. The main importance of Supply
Chain Management is: -
REDUCE OPERATING COSTS:
• Decreases Purchasing Cost – Organizations generally prefer quick distributions of
costly products and raw materials to avoid expensive inventory
• Decrease Production Cost – A reliable supply chain delivers materials to assembly
plants and avoid any costs that may occur due to delays.
IMPROVE CUSTOMER SERVICES:
• Right quantity and quality – Customer expect delivery of right quantity and quality
of products.
• On-time delivery – Customers expect to receive the correct product mix and quantity
to be delivered on time. A reliable supply chain can help in avoiding any bottlenecks
and ensure customers get their products in the promised time frame
• Services – After sales services is one of the important aspects in any business. If any
kind of problem occur in the product, customer expects it to be fixed quickly. A right
supply chain ensures that customers get the service they want.
INNOVATIVE SUPPLY CHAIN TOOLS:
Staying competitive in supply chain management requires adopting the most advanced
technology. Mary Long, director of the Supply Chain Forum, says, “It takes an understanding
in knowing what to go after to create supply chain efficiencies.” Enterprises such as the Kraft
Heinz Company (the third-largest food and beverage company in North America) and
McCormick & Co. (Baltimore-based maker of spices and seasonings) invest in technology to
create efficient, sustainable, and socially responsible supply chains. Both companies are
designated as a “Shipper of Choice” by Freight Waves, an award that ranks the “industry’s
most innovative and/or disruptive companies.”
Here are some of the emerging technological trends, tools, and innovations used in supply
chain management used by them:
1. Big data →. Massive amounts of data are generated every single day. Each minute,
4.5 million searches are entered in Google, 18.1 million text messages are delivered,
and 188 million emails are sent. Mobile devices such as wearables, smartphones, and
tablets generate a significant amount of the total data usage each day. With so much
information at our disposal, it takes complex computing techniques to gather, sort,
clean, and analyse such large data sets. Data science and analytics allow companies to
use data to gain valuable insights and revolutionize supply chain management. Big
data brings value and assistance to the following areas in supply chain management:

• Quality control;
• Cash flow;
• Real-time deployment;
• Warehouse efficiency;
• Weather patterns;
• Predictive strategies; and
• Inventory, supply, and demand

2. Artificial intelligence and machine learning → AI and machine learning create

fully- or semi-automated processes and procedures for supply chain optimization.
Optimization improves forecasting, planning, implementation, and maintenance in
logistics by using AI and machine learning to emulate human performance and
knowledge. AI and machine learning boost the end-to-end supply chain by:

• Tightening data security;

• Applying predictive modeling to third-party logistics;
• Providing full supply chain visibility to improve management of key performance
indicators (KPI);
• Automating inventory management, shipping transactions, and delivery routing; and
• Improving customer service.
3. Internet of things (IoT) → The IoT — the streamlined connection across various
devices — increases visibility and connectivity, while also reducing costs. Wearables
and mobile devices like Apple Watches, Fitbits, and smartphones, are especially
useful in warehouse settings. Wearables, in particular, provide solutions that lead to
having a "touchless" supply chain: the total elimination of the labor-intensive
selection of items from inventory to fulfill a customer order, also known as “picking.”
Other IoTs allow warehouse and logistics managers to securely track inventory and
monitor equipment. Other benefits include:

• Improved asset utilization;

• Better customer service;
• Streamlined inventory and supply availability; and
• Safer and more reliable work environments.

4. 5Gs → According to Qualcomm, 5G is foundational to further innovation, which is

certainly the case when it comes to supply chain management. Gaining real-time data
is difficult when suppliers lack connectivity. Supply chain visibility becomes spotty
without 5G. And third-party logistics is made possible through the use of 5G because
it elevates mobile networks through multi-Gbps peak rates, ultra-low latency, and
massive data capacity. High-level performance, increased efficiency, and new user
experiences become available when 5G interconnects people, machines, objects, and
devices. 5G further offers the power to:

• Extract larger amounts of data concerning location, temperature, pressure, and other
information that is critical in the end-to-end supply chain;
• Ensure uniformity of information sharing with all stakeholders;
• Resolve issues that would otherwise be aggravated with time delays; and
• Understand exactly where raw materials come from.

5. Advanced supply chain management software → Advanced software has disrupted

the entire supply chain industry. In order to stay competitive, logistics companies
continue to incorporate technology into their supply chain systems. Businesses feel
compelled to track the latest technologies on the market because of consumer
demands on cost and delivery speed, and the increasing popularity of customer rating
metrics. As technology advances, supply chain software becomes more complex,
allowing companies to stay ahead of mistakes, make modifications to orders,
communicate across various media channels, and automate shipping.
Examples are : Logility Voyager Solutions, GAINSystems, OrderEase.
TECHOLOGIES PREDICTED TO IMPACT SUPPLY CHAIN
MANAGEMENT IN FUTURE:
The future of supply chain management will continue to include any emerging technologies
which support efficiency and automation. Here are a few more software trends experts predict
are in the pipeline:

• Autonomous mobile robots (AMR) → Supply chain giants like Amazon have
discussed the use of AMRs in the past, but they haven't been widely adopted across
the industry. While warehouse management systems will continue to organize things
like scheduling loading and unloading, AMRs may emerge as a tool to optimize the
picking process.
• Truck collaboration → Truck manufacturers and shippers are preparing for a
recession and would be wise to invest in manufacturing and collaboration software
systems. More advanced systems allow for trucking companies to strengthen the way
they monitor the market, automate processes, and cut costs.
• Distributed inventory → Current inventory software isn't providing the analysis
needed to keep up with distributed inventory, making it harder for companies to keep
up with innovative shipping demands. A tool called distributed inventory flow
forecasting (DIFF) predicts the flow of materials, enabling businesses to maximize the
order fill rate and maintain reduced inventory.
• Driverless vehicles and drone delivery → Driverless and drone delivery options
provide companies with a solution to a variety of issues. Not only does this lower
costs by lowering the amount of human intervention, but it also gives more access to
remote and hard-to-reach rural areas. While some have been skeptical about this
technology in the past, it may be a positive solution for the future, particularly in light
of the worsening shortage in available human drivers.
• 3D printing → 3D printing is a game changer for certain industries. 3D printing can
be used to replicate and produce replacement parts for products using metals and
plastics. Rather than stocking items in a large warehouse to be shipped all over the
world, companies can contract with local 3D printing shops to print and deliver
products within a matter of days. The benefits for inventory and space management
transfer to the consumer level as well, improving customer satisfaction.
• Blockchain → With the exchange of goods across different countries, there is often a
lack of transparency. Invoices and shipments can take several months to process,
never mind the complexity of greater volume across many organizations. Blockchain
has the potential to transform the supply chain industry by providing more traceability
and security. Widely popularized by its cryptocurrency ability, the blockchain can
also assist companies by managing contracts and agreements, and monitoring
financial transactions and products.
 2. MANUFACTURING SKILLS GAP:
In a 2018 study by Deloitte and the Manufacturing Institute it was predicted that by 2028
there would be in excess of two million unfilled positions in manufacturing—a deficit created
by what is being called the “Manufacturing Skills Gap.” The changing landscape of the
manufacturing industry, paired with an outdated reputation and quickly developing
technology, has created this gap between the skills that manufacturing workers have and
those needed by employers. If this disparity is not addressed, the manufacturing industry
could see supply shortages, supply chain breakdowns, and rising costs.

Why has the Skills Gap Grown so Large?

The Manufacturing Skills Gap is a “mismatch” between the skills needed by employers, and
those needed by the labour force. The Skills Gap has been growing over the past decades,
and has not been reduced due to two primary reasons:
1. An Aging and Reduced Workforce
First, as baby boomers exit the work force, there are not enough workers entering
manufacturing to fill the gaps left by retirees. Exiting workers are often skilled, with years of
experience under their belts, and it is difficult to find replacements with a similar level of
knowledge and expertise. For years, manufacturing has been seen as an undesirable field; its
reputation has not been able to keep pace with the technological transformation of the
industry since the introduction of robotics, automation, and other newly-developed
technologies. The manufacturing industry is no longer the industrial grind of the past, but is
instead an area where technically-minded, innovative, and forward-thinking technicians and
operators can flourish.

2. Changing Skills-Sets Due to New Technology

This introduction of new technology has also amplified the Skills Gap, as often those who
do choose to go into manufacturing do not enter the workforce with the skills to operate and
program the advanced technologies being adopted. Necessary skill-sets are becoming
increasingly specific, and technicians need to be able to work not only with machines, but
may need to interact with robots, troubleshoot complex electronic malfunctions, and program
automated systems as part of their day-to-day routine. Cross-functional employees with
overlapping skills are key, and the shortage of this type of skilled worker means most
businesses are currently unable to fill all their labour needs.

How can the Skills Gap be Closed?

In order to close the Manufacturing Skills Gap and maintain the manufacturing industry’s
momentum, there are a number of steps that should be taken. Technicians of all skills levels
will be needed, and it is imperative that manufacturing be presented as the highly technical,
high-earning profession that it has become. This can be done by focusing on three major
areas.
1. Revitalizing and Showcasing the Industry
First, manufacturing must be introduced to young people as a viable and desirable industry to
build a career in—it must be clear that manufacturing is an area in which one can enjoy great
success and earning potential, as well as being personally rewarding. Technology
developments must be front-and-center, allowing students to understand the complexity of
modern warehouses and the environments in which they will work. To do this, businesses
must begin to showcase the new technologies that are being developed within the
manufacturing industry, while also placing an emphasis on skill building and continuing
education. This will ensure people entering the industry understand working conditions, are
prepared for an engaging work environment, and knowledgeable of the tasks that will be
required.

2. Keeping Workers Engaged in Manufacturing

Another way to close the Skills Gap is to ensure that workers are not exiting the industry, but
instead are developing their skills and advancing their career within manufacturing. In order
to do this, businesses must work to keep their employees engaged in their work. Offering
mentorship programs, advanced training, and opportunities for advancement can all assist in
keeping employees engaged and interested in their industry. Continuous learning is key to
employee engagement and satisfaction, and technicians should always be maintaining and
improving their knowledge and skills throughout their career.

3. Investing in People, not Only Technology

Finally, the focus must be on people. While new technology continues to be introduced
within the manufacturing field, this tech cannot be operated without human workers
alongside them. While technology will continue to advance, it is people who are needed to
continue growing the manufacturing industry, and businesses should invest in their
employees alongside adopting the newest technologies. Even the largest gains in automation
and robotics technology cannot make up for the skills, critical thinking, and creativity of
human manufacturing technicians.

How can Workers Take Advantage of the Skills Gap?

According to the Deloitte Study, in upcoming years “it is not the need for STEM degrees, but
rather the ability to program machines on the plant floor” that will be needed to bridge this
gap. “Due to the influx of automation and advanced technologies” there will be a high need
for those skilled in programming for robotics and automation, working with tools and
technology, and with the ability to think critically. The demand for skilled technicians who
are well trained and able to use new technologies is huge, and is set to continue to grow in the
coming decade. Successful technicians will need to be trained in both advanced technologies
and problem solving to meet these needs.
It is clear that the coming decade will be an exciting time for workers in the manufacturing
field. Alongside technological advances there will be more job availability and greater
demand for skilled technicians. To take advantage of this demand, technicians should ensure
they are honing their skills across the industry, seeking out ways to broaden their
knowledge… and encouraging their peers to do the same. Cross-training within different
disciplines will be important—check out this blog on becoming a Manufacturing Triple
Threat—as it will allow workers to not only fill the jobs that exist, but be prepared for the
positions that will exist in the future.

While the Skills Gap may be a daunting hurdle in the advancement of the Manufacturing
industry, it can be bridged by careful investments in building a new generation of educated
technicians with the proper skills. In the coming years there will be a huge demand for
manufacturing experts, with jobs to fill at all skill levels. Manufacturing businesses should be
constantly looking for ways to showcase the industry to prospective workers, revamping the
industry’s reputation and drawing the best talent into developing manufacturing fields.
Alongside employers, workers should seek out continuous learning opportunities, build their
skills, and keep up with industry trends to ensure that they are there to fill the gap.
 3. MAXIMIZING AUTOMATION:
Automation is the creation and application of technologies to produce and deliver goods and
services with minimal human intervention. The implementation of automation technologies,
techniques and processes improve the efficiency, reliability, and/or speed of many tasks that
were previously performed by humans.
Automation is being used in a number of areas such as manufacturing, transport, utilities,
defense, facilities, operations and lately, information technology.

STRATEGIES USED BY COMPANIES TO MAXIMIZE

AUTOMATION:
There are certain fundamental strategies that can be employed to improve productivity in
manufacturing operations technology. These are referred as automation strategies.

a. Specialization of operations → The first strategy involves the use of special purpose
equipment designed to perform one operation with the greatest possible efficiency.
This is analogous to the concept of labor specializations, which has been employed to
improve labor productivity.
b. Combined operations → Production occurs as a sequence of operations. Complex
parts may require dozens, or even hundreds, of processing steps. The strategy of
combined operations involves reducing the number of distinct production machines or
workstations through which the part must be routed. This is accomplished by
performing more than one operation at a given machine, thereby reducing the number
of separate machines needed. Since each machine typically involves a setup, setup
time can be saved as a consequence of this strategy. Material handling effort and non-
operation time are also reduced.
c. Simultaneous operations → A logical extension of the combined operations strategy
is to perform at the same time the operations that are combined at one workstation. In
effect, two or more processing (or assembly) operations are being performed
simultaneously on the same work part, thus reducing total processing time.
d. Integration of operations → Another strategy is to link several workstations into a
single integrated mechanism using automated work handling devices to transfer parts
between stations. In effect, this reduces the number of separate machines though
which the product must be scheduled. With more than one workstation, several parts
can be processed simultaneously, thereby increasing the overall output of the system.
e. Increased flexibility → This strategy attempts to achieve maximum utilization of
equipment for job shop and medium volume situations by using the same equipment
for a variety of products. It involves the use of the flexible automation concepts.
Prime objectives are to reduce setup time and programming time for the production
machine. This normally translates into lower manufacturing lead time and lower
work-in-process.
f. Improved material handling and storage systems → A great opportunity for
reducing non-productive time exists in the use of automated material handling and
storage systems. Typical benefits included reduced work-in-process and shorter
manufacturing lead times.
g. On-line inspection → Inspection for quality of work is traditionally performed after
the process. This means that any poor-quality product has already been produced by
the time it is inspected. Incorporating inspection into the manufacturing process
permits corrections to the process as product is being made. This reduces scrap and
brings the overall quality of product closer to the nominal specifications intended by
the designer.
h. Process control and optimization → This includes a wide range of control schemes
intended to operate the individual process and associated equipment more efficiency.
By this strategy, the individual process times can be reduced and product quality
improved.
i. Plant operations control → Whereas the previous strategy was concerned with the
control of the individual manufacturing process, this strategy is concerned with
control at the plant level of computer networking within the factory.
j. Computer integrated manufacturing (CIM) → Taking the previous strategy one
step further, the integration of factory operations with engineering design and many of
the other business functions of the firm. CIM involves extensive use of computer
applications, computer data bases, and computer networking in the company.
BENEFITS OF AUTOMATION TO COMPANIES:
At Productivity, we know that change can often be overwhelming and frightening. Our
experts are here to prove that there are a multitude of benefits when you upgrade to
automation.
1. Lower operating costs
Robots can perform the work of three to five people, depending on the task. In addition to
savings on the cost of labor, energy savings can also be significant due to lower heating
requirements in automated operations. Robots streamline processes and increase part
accuracy, which means minimal material waste for your operation.

2. Improved worker safety

Automated cells remove workers from dangerous tasks. Your employees will thank you for
safeguarding them against the hazards of a factory environment.

3. Reduced factory lead times

Automation can keep your process in-house, improve process control and significantly reduce
lead times compared to outsourcing or going overseas.

4. Faster ROI
Automation solutions are based on your unique needs and goals and pay for themselves
quickly due to lower operating costs, reduced lead times, increased output and more.

5. Ability to be more competitive

Automated cells allow you to decrease cycle times and cost-per-piece while improving
quality. This allows you to better compete on a global scale. Additionally, the flexibility of
robots enables you to retool a cell to exceed the capabilities of your competition.

6. Increased production output

A robot has the ability to work at a constant speed, unattended, 24/7. That means you’ve got
the potential to produce more. New products can be more quickly introduced into the
production process and new product programming can be done offline with no disruption to
existing processes.
 7. Consistent and improved part production and quality
Automated cells typically perform the manufacturing process with less variability than
human workers. This results in greater control and consistency of product quality.

8. Smaller environmental footprint

By streamlining equipment and processes, reducing scrap and using less space, automation
uses less energy. Reducing your environmental footprint can save real money.

9. Better planning
Consistent production by robots allows a shop to reliably predict timing and costs. That
predictability permits a tighter margin on most any project.

10. Reduce need for outsourcing

Automated cells have large amounts of potential capacity concentrated in one compact
system. This allows shops to produce parts in-house that have previously been outsourced.

11. Optimal utilization of floor space

Robots are designed on compact bases to fit in confined spaces. In addition to being mounted
on the floor, robots can be mounted on walls, ceilings, rail tracks and shelves. They can
perform tasks in confined spaces, saving you valuable floor space.

12. Easy integration

Productivity will work with you to provide a complete system – hardware, software and
controls included. Your cell will be proven out at Productivity and shipped production-ready
– allowing you to start making parts as soon as it’s installed in your shop.

13. Maximize labor

Over the next three decades, statistics show that more than 76 million baby boomers will
retire and only 46 million new workers will be available to replace them. During this time,
your demand for labor will continue, making automation a real and viable solution.
COMPANIES USING MODERN AUTOMATION TECHNOLOGIES:
Here are some Manufacturing Companies using Modern Technology so to maximize the
Automation and completely negotiating manual work:
1. Adidas
2. Rockwell Automation
3. Titan Engineering & Automation Ltd.
4. Voltas Ltd.
These are few Modern Technologies that are widely used by them:
1. INTERNET OF THINGS:
The Industrial Internet of Things (IIOT) utilizes relevant information and essential tasks are
completed through tablets, smartphones, and other edge devices. In real-time, businesses can
use this performance data to adapt and change their operations into a more streamlined
process externally and internally for both long-term and short-term goals. Due to this super
connectivity, faster response times are facilitated from all departments and brings with it
improved agility for operations of every size. Smart machines are not only better than
humans at capturing and analyzing data in real-time, but they are also better at
communicating important information that can be used to drive business decisions faster and
more accurately. IIoT in manufacturing holds great potential for quality control, supply chain
traceability, sustainable and green practices, and overall supply chain efficiency. Predictive
maintenance, asset tracking, improved field service, enhanced customer satisfaction, and
facility management are the top touted benefits of IoT.

2. ROBOTICS:
The robots will command a greater presence in shaping the manufacturing industry as these
entities become cheaper, smarter, and more efficient in their roles on the factory edge. With
advances in robotics technology, these machines are allowed to take on more complex traits,
including heightened dexterity, machine learning, memory, and the ability to collaborate
more effectively. Hence, these robots will usher in a new set of standards that every
manufacturer will need to adapt to remain relevant. Robots have been relied upon as an
essential part of manufacturing. Robotic presence provides incredible benefits, including
enhanced accuracy, speed, and tireless labor. However, they cannot do it all. As a result,
these smaller and agiler implements on the manufacturing edge are engineered to work
collaboratively alongside their human counterparts and are referred to as collaborative
robotics.

3. ARTIFICIAL INTELLIGENCE:
The artificial intelligence technology is already in our daily lives in the form of self-driving
cars and industrial robotics. The technology in manufacturing applications will become the
new standard by which large sets of data are analyzed and predictive maintenance is
undergone. In short, to survive, the companies will have no choice but to "go digital". The AI
algorithms can also be used to optimize manufacturing supply chains, thus helping companies
anticipate market changes. By looking for patterns linking location, weather patterns,
consumer behavior, political status, socioeconomic and macroeconomic factors, the AI
algorithms formulate estimations of market demands. The manufacturing industry will have
the biggest impact of AI coupled with automation.
 4. ADVANCED MATERIALS & ADDITIVE MANUFACTURING:
The advanced materials and additive manufacturing are known by the more common name of
3D printing, which is emerging advanced manufacturing technology. 3D printing can now
build large and complex structures like housing in less than a day, unlike the old processes
that used to take weeks to accomplish on a small scale. Using new special consumables
materials is the main development direction of additive manufacturing, such as 3D printing.
The technique is relatively easy to metals and tough to high strength alloys. It's relatively
more difficult to some ceramics and may be harder to the nanoceramics. Some new nano
modifier 3 printing materials are prepared to solve the problems of 3D printing materials,
such as limited properties and applications. To characterize the obtained NiCrAlY, WC-
10Co-4Cr and ceramic powders and coatings, scanning electron microscopy (SEM),
microhardness and friction and wear tests are used. The results obtained show that the
optimized process can be used to prepare the nano modifier materials successfully. The
coatings possess high bonding strength and good wear resistance. High strength alloy
materials and even nano-ceramic materials are prepared with nano-modification and
nanostructured spherical particles powder through 3D printing.
4. INCREASED GLOBAL MANUFACTURING COMPETITIVENESS:
The International Institute for Management Development defines competitiveness as "a field
of economic knowledge which analyzes the facts and policies that shaped the ability of a
nation to create and maintain an environment that sustains more value creation for its
enterprises and more prosperity for its people."
The World Economic Forum defines global competitiveness as "the ability of a country to
achieve sustained high rates of growth in gross domestic product (GDP) per capita.

Factors Affecting Global Competitiveness:

Business firms abide by the rules and regulations formed by the government. The government
assumes a very important role in enhancing competitiveness. Governments must promote
trade by reengineering systems and procedures. Governments should be more responsive,
reducing bureaucratic red tape.
Physical infrastructure plays a critical role in improving the global competitiveness of a
country. This will lead to the smoother movement of people, products, and services,
facilitating faster delivery of goods and services.
The business environment should be as such that it improves coordination among public-
sector agencies. The best methods include providing support and incentives for R&D
activities, HRD and education, encouraging innovativeness and creativity, facilitating the
improvement of industrial blocks, and productivity enhancements of SMEs.
High total factor productivity (TFP) is a boon for economic growth. It shows the synergy
and efficiency of both capital and HR utilization and promotes national competitiveness.
Productivity campaigns are important because they promote public-awareness and provide
mechanisms to use the productivity tools and techniques.
Intensifying R&D activities that contribute to creativity, innovation, and indigenous
technological development is also an important factor.
STRATEGIES USED BY COMPANIES TO EXPAND THEIR
PRODUCT/SERVICE GLOBALLY:
1. NIKE
Nike has been able to evolve its global presence through the careful selection of international
sponsorships such as its previous long-standing relationship with Manchester United.
Although sponsorship spending can be fairly unpredictable -- demand costs tend to surge due
to triggers like championships and tournaments -- these partnerships have certainly helped the
brand capture the attention of a global audience.
Nike's NikeID co-creation platform serves as another strategy that the company is using to
appeal to international markets.

2. COCA-COLA
Coca-Cola is a great example of a brand using international marketing efforts. Though a large
corporation, Coca-Cola focuses on small community programs and invests a lot of time and
money in small-scale charity efforts.

For example, in Egypt, Coca-Cola has built 650 clean water installations in the rural village
of Beni Suef and sponsors Ramadan meals for children across the Middle East. In India, the
brand sponsors the Support My School initiative to improve facilities at local schools.
3. RED BULL
Austrian company Red Bull does such a great job with global marketing that many
Americans assume it’s a local brand. How?
One of its most successful tactics is to host extreme sports events all over the world. From the
Red Bull Indianapolis Grand Prix to the Red Bull Air Race in the United Kingdom to the Red
Bull Soapbox Race in Jordan, the brand's powerful event marketing strategy takes them here,
there, and everywhere.

4. SPOTIFY
As of 2018, Spotify was newly considered one of the best global companies in the world,
according to Interbrand. We've all heard of Spotify (no pun intended), but how did it
suddenly, and so quickly, expand from Sweden into other countries?
Spotify's business model is focused on helping you find something new.
It's one thing to select a genre of music to listen to -- it's another thing to select a "mood" to
listen to. The screenshot above is part of Spotify's "Browse" page, where you can listen not
just to "country" and "hip-hop," but also music that caters to your "workout" or "sleep"
preferences.
By changing how they describe their content, Spotify gets users to listen to music that goes
beyond their favorite genres, and instead satisfies habits and lifestyles that people share all
over the world. This allows international artists to access listeners from other countries
simply because their product is being categorized a different way.
Spotify now has offices in 17 countries around the world.
5. FINDING & KEEPING LABOR:
Although automation and robotics can help fill the labor gap, human capabilities will still be
needed to analyze and solve problems as well as manage outputs. With the baby boomer
generation entering retirement, the manufacturing industry is facing a looming labor shortage.
This is one of the biggest threats facing the manufacturing sector today.

POSSIBLE SOLUTION:
To overcome the shortage of qualified workforce, manufacturers must be creative in
recruiting employees by relying on various online platforms to post job openings. Producers
must be truly selective when choosing prospective employees and ensure that they are able to
work quickly, on target, under pressure, and do not object to shift work schedules.
In addition, manufacturers must be able to provide their new and existing employees with
regular training to help increase their potential.

SOME METHODS ADOPTED BY COMPANIES TO IMPROVE THEIR HIRING:

1) Use non-traditional platforms
Although LinkedIn is undoubtedly a useful tool, there’s a clear advantage to searching for
candidates on other platforms as well. Nathan Lewis uses local platforms such as Facebook
Marketplace and Craigslist to network and search for talent. “You would be pleasantly
surprised to see the caliber of candidates on these non-traditional platforms.”

Mercedes Santana uses Instagram hashtags for candidate sourcing. “This is a great way to
source candidates that may not be very active on other platforms, like LinkedIn. For example,
[you can] start with a broad search type [such as] #UX... Additionally, for hard to find highly
technical candidates, you can search more specifically—by coding schools, for example.”
2) Online recruitment
The most obvious advantages of online sourcing are sheer volume, scale, and speed.
According to Mercedes Santana, founder and CEO of The Expert Recruiter Group, “You can
make contact with 100 people via email within 20 minutes. You can identify contact
information for 50 people in less than 30 minutes. Offline, completing both of these activities
would take up your entire workday.”

With online recruitment, you have the opportunity to run mass campaigns on social media.
You can also easily connect with candidates all over the country and the world through job
ads, giving you a far better chance of finding the right match—especially if the job is remote.
Online recruitment can be useful for screening as well as sourcing. Screening candidates via
video chat is both convenient and more personal than a phone call. Online recruiting also
allows you to use more sophisticated screening methods, such as skills testing or asking
candidates to send audio/video files. It is also easier to measure your recruitment sources.

3) Offline recruitment
Offline recruitment allows you to create deeper relationships and find “hidden talent”,
especially among groups and passive candidates that may not be very active online. It also
gives you an edge in competitive fields where candidates are already saturated with online
offers.

A. INTERNAL RECRUITMENT STRATEGIES USED BY COMPANIES:

1. Internal job ads
Most organizations have an internal jobs board. This is an easy way to ensure that all
employees know about new vacancies and have the chance to apply. If your organization
doesn’t have an internal jobs board, consider creating one—it shows employees they have a
clear path for growth within your company. In a 2018 study by LinkedIn Learning, 94
percent of employees said they would stay at a company longer if it invested in their career
development.

2. Promoting deserving candidates

Another internal recruitment method is singling out high-performers for promotion. If a
management position opens up, looking within the existing team is an easy way to identify
suitable talent. This is a great way to prevent “job stagnation”: a study by Glassdoor showed
that every additional 10 months that an employee “stagnates” in their role makes them 1
percent more likely to leave the company.

4. Employee referrals
This is a hybrid of internal and external recruiting methods. Asking for employee referrals
helps you identify potential candidates who may already be a great culture fit. They have
essentially been "pre-vetted" by your own employees. If you have a strong company culture
that empowers employee advocates, than this is a great recruitment strategy. However, if your
company culture needs to undergo a change, this may not be the best strategy to improve
your hiring process.
B. EXTERNAL RECRUITMENT STRATEGIES USED BY
COMPANIES:
1. Career events
Career events can help you connect with candidates in a face-to-face, personal setting. At job
fairs held by universities and industry groups, you’ll meet a specific group of highly-qualified
candidates who are interested in finding a position. Daniel Miller, co-founder of Recruiter,
says he often connects with top talent at tradeshows and conferences. “These individuals refer
me to other professionals, and business happens.”

2. Networking meetings
Building off of career fairs and events, another way to conduct external recruiting for the best
candidates is by asking for referrals from others in your network or industry. Once these
connections are made, host coffee meetings, phone calls, or online video meetings to get a
feel for the candidate goals and their current job search. If that person is not a right fit, they
may have others in their network to help your search, too.
MANUFACTURING COMPANIES USING MODERN TECHNOLOGIES
IN MANUFACTURING PROCESS:
1. FORMING
Forming, metal forming, is the metalworking process of fashioning metal parts and objects
through mechanical deformation; the workpiece is reshaped without adding or removing
material, and its mass remains unchanged. Forming operates on the materials science
principle of plastic deformation, where the physical shape of a material is permanently
deformed.
ELECTROMAGNETIC FORMING:
Based on the use of new materials it is necessary to find the available forming technology for
specific material properties. Electromagnetic Forming (EMF) is a metal working process that
relies on the use of electromagnetic forces to form metallic work-pieces at high speeds.

WORKING:
In this process, a transient electric current flow through a coil due to the sudden discharge of
a capacitor bank via high-speed switches. The coil current induces a magnetic field and a
current in the nearby conductive work-piece (sheet metal, tube or hollow profile) which is
directed opposed to the coil current. The magnetic field, together with the eddy current,
induces Lorentz forces that drive the deformation of the work-piece.

In an EMF process, the material can achieve velocities in the order up to 100 m/s in less than
0.1 ms. EMF is expected to help overcoming some formability barriers that prevent more
widespread use of materials such as aluminum in lightweight structural applications.
Depending on the geometry and the arrangement of the work-piece and the tool coil, this
forming principle can be used for the compression and expansion of tubes or other hollow
profiles as well as for the forming of flat or 3-dimensionally preformed sheet metals.
USES OF ELECTROMAGNETIC FORMING:
EMF can be used for joining by forming similar and dissimilar material combinations. In fact
joining profile shaped parts has been identified as the most promising process variant for
industrial applications. Since only one joining partner needs to be electrically conductive, the
potential material combinations include metal / metal as well as metal/non-metal hybrid
structures (e.g., aluminum – fiber reinforced plastic-connections, copper-ceramic
connections, metal-glass-connections and others). The resulting joints can be based on
interference-fit, form-fit, or – in case of metal/metal connection – even on metallic bonding
realized by magnetic pulse welding.

ADVANTAGES OF ELECTROMAGNETIC FORMING TO COMPANIES OVER

TRADITIONAL FORMING:
1. It gives a high rate of production
2. Non-contact: unlike other mechanical processes in which a tool contacts a workpiece, in
EMF the magnetic field that applies the pressure requires no lubrication, leaves no tool marks
and therefore requires no cleanup after forming. One exception that does require lubrication
is when the workpiece is driven against a mandrel and then removed.
3. Spring-back: the material is loaded into its plastic region, resulting in permanent
deformation, so that the spring back often associated with mechanical processes is virtually
eliminated, because there is no mechanical contact.
4. Strength: joints made by this process are typically stronger than the parent material.
5. The EMF process allows increased ductility for certain aluminum alloy because of the lack
of mechanical stress and friction normally encountered with mechanical processes.
APPLICATIONS:
Electromagnetic forming is chiefly used to expand, compress, or form tubular shapes. It is
occasionally used to form flat sheet, and it is often used to combine several forming and
assembly operations into a single step.

DIE MATERIALS:
The die used in electromagnetic process should be made of low electrical conductivity to
minimize the magnetic cushion effect. Dies are generally made of the following materials:
Steel or epoxy resin. Steel dies have longer life. but the disadvantage of steel dies is that
magnetic cushion effect is not entirely prevented. Air is often evacuated from the die to
ensure good reproduction of detail, and prevent distortion caused by entrapped air, which is
particularly likely to occur with thin gauge material.
2. JOINING:
Commonly the Joining process in Manufacturing Industries are carried out by Joining
process. Welding is a fabrication process whereby two or more parts are fused together by
means of heat, pressure or both forming a join as the parts cool. Welding is usually used on
metals and thermoplastics but can also be used on wood. The completed welded joint may be
referred to as a weldment. The parts that are joined are known as a parent material. The
material added to help form the join is called filler or consumable.
Consumables are usually chosen to be similar in composition to the parent material, thus
forming a homogenous weld, but there are occasions, such as when welding brittle cast irons,
when a filler with a very different composition and, therefore, properties is used. These welds
are called heterogeneous.
The completed welded joint may be referred to as a weldment.
There are many upcoming trends in the Welding process but one of them is the Friction Stir
Welding (FSW) which is being widely used in Manufacturing Industries especially outside
India.

FRICTION STIR WELDING:

In Friction Stir Welding, a cylindrical shouldered tool with a profiled probe is rotated and
slowly plunged into the joint line between two pieces of sheet or plate material, which are
butted together. The parts have to be firmly clamped onto the worktable in a manner that
prevents the joint faces from being forced apart. Frictional heat is generated between the wear
resistant welding tool and the material of the work piece as shown in Figure [D-(b)]. This
heat causes the latter to soften without reaching the melting point and allows passing of the
tool along the weld line as shown in Fig. D(c). The plasticized material is transferred from the
leading edge of the tool to the trailing edge of the tool probe and is forged by the intimate
contact of the tool shoulder and the pin profile. It leaves a solid phase bond between the two
pieces.

Welding of Steel by Friction Stir Welding

ADVANTAGES OF FRICTION STIR WELDING:
• Good mechanical properties in the as welded condition.
• We could weld metal without melting it, maintaining its original properties despite the
joining process.
• We could weld together metals those previously could not be joined.
• We could eliminate the rivets in airframe structures and make better use of metal
products in all forms by simplifying the manufacturing process, lowering its cost, and
reducing component inventory by eliminating parts.
• Improved safety due to the absence of toxic fumes or the spatter of molten material.
• No consumables - conventional steel tools can weld over 1000m of aluminum and no
filler or gas shield is required for aluminums.
• Easily automated on simple milling machines → lower setup costs and less training.
• Can operate in all positions (horizontal, vertical, etc), as there is no weld pool.

APPLICATIONS OF FSW:
Because of the potential of advantages over arc welding in some applications associated with
this processes, FSW has received interest from many areas of industry working with
aluminum. The advantages include the ability to produce long lengths of welds in aluminum
without any melting of the base material. This provides important metallurgical advantages
when compared to conventional arc welding. Melting of the base material does not occur
with FSW and this eliminates the possibility of solidification cracking which is often a
problem when arc welding some aluminum alloys. Other advantages may include: low
distortion associated with lower heating during the welding process; elimination of porosity
problems that are challenging when arc welding aluminum; minimum edge preparation, as
butt joints are typically performed with a square-butt preparation; and, the absence of welding
consumables such as shielding gas or filler material.

1. SHIP BUILDING & MARINE INDUSTRIES:

The shipbuilding and marine industries are two of the first industry sectors that have adopted
the process for commercial applications. The process is suitable for the following
applications:
o Panels for decks, sides, bulkheads and floors.
o Aluminum extrusions.
o Hulls and superstructures.
o Helicopter landing platforms.
o Marine and transport structures.
2. SPACE SHUTTLE:
Friction Stir Welding is the most recent upgrade to the Space Shuttle ‘s Gigantic External
Tank, the largest element of the Space Shuttle and the only element not reusable. The new
welding technique being marketed to industry utilizes frictional heating combined with
forging pressure to produce high-strength bonds virtually free of defects.

3. NUCLEAR PLANTS:
As nuclear plants around the world grow older there are increasing incidences of stress
corrosion cracking (SCC) problems. In PWRs such cracking is well known and often
associated with reactor pressure vessel parts (e.g. primary water SCC at reactor nozzle
locations).
Figure: - FSW Applications in Nuclear Plants (a) Stainless Steel Water Storage Tanks and (b)
Stress Corrosion Cracking Problems.

4. AEROSPACE INDUSTRIES:
Friction stir welding has many potential aerospace applications. Research in rivet
replacement, repair of aging aircraft, fabricated structures, and tooling for assembled
structures is undertaken to support the increased adoption of FSW by aerospace companies.
Nowadays, the aerospace industry is welding prototype parts by friction stir welding. This
offers significant advantages compared to riveting and machining from solid, such as reduced
manufacturing costs and weight savings.
The friction stir welding process can therefore be considered for:
• Wings, fuselages, empennages.
• Cryogenic fuel tanks for space vehicles.
• Aviation fuel tanks.
5. AUTOMOBILE & TRANSPORTATION:
Friction stir spot welding shows promise as a joining technology for aluminum sheets used in
automotive applications to reduce weight and increase fuel economy. Many Research work
centers are aiming for improving the speed of the process while reducing forces and
maintaining high material properties. The friction stir welding process is currently being
experimentally assessed by several automotive companies and suppliers to this industrial
sector for its commercial application. A joint EWI / TWI Group Sponsored Project are
investigating representative joint designs for automotive lightweight structures.

The potential applications of FSW in automobiles and land transports are as under:
Engine and chassis cradles
Wheel rims
Truck bodies
Tail lifts for Lorries
Mobile cranes
Armor plate vehicles
Fuel tankers
Caravans
3. CASTING:
Casting manufacturing is a process in which liquefied material, such as molten metal, is
poured into the cavity of a specially designed mold and allowed to harden. After
solidification, the workpiece is removed from the mold to undergo various finishing
treatments or for use as a final product. Casting methods are typically used to create intricate
solid and hollow shapes, and cast products are found in a wide range of applications,
including automotive components, aerospace parts, etc.

DIE CASTING FOR AUTOMATIVE INDUSTRY:

Though the list of uses for HPDC is constantly growing, the number of applications surged
beginning with the Great Recession of 2008. This growth is expected to continue, with
components designed as die castings are projected to grow faster than those designed for
other casting processes.

A larger, underlying reason for the growth of die cast parts in the automotive industry is the
growing interest in improving fuel consumption, which can be accomplished by reducing the
weight of vehicles. In fact, trends in engineering place a focus on lightening the weight of
vehicles. Other emphasis lies on retained stiffness, more electronic safety protections, and
smaller carbon footprints with maximized internal space.
Simultaneous to these benefits are the positive side effects of less overdesign for crash, the
need for smaller engines and powertrains, and changes in frame design and collision
scenarios.

Manufacturing of Engine using High Pressure Die Casting (HDPC)

TECHNOLOGIES & PROCEDURES:
As die casting alloys improve, so do die casting technologies and related procedures. From
the modern HPDC process, three unique die casting methods have emerged: squeeze casting,
semisolid metal casting and vacuum die casting. These methods are all actively used in high
integrity, high volume commercial production, and they all work to remedy die casting
defects—namely air entrapment, gas porosity, and solidification shrinkage —that are
particularly worrisome for automobile manufacturers.

Air entrapment is very detrimental to structural strength. Squeeze casting, with its larger gate
areas, discourages air entrapment by allowing for planar die filling. Equally harmful to the
performance of die cast parts is porosity. Vacuum die casting, wherein a vacuum system
extracts air from a die cavity as it is filled, decreases air entrapment—it also allows for lower
temperature molten metal and more efficient cavity filling.

As injected metal cools in the mould, the gases it absorbed while in a liquid state are released
and become trapped. Because the exterior of a die casting cools first, it has a fine
microstructure, low porosity, and higher strength, while the core of the part is left with a
drastically higher porosity — this is known as the skin effect. This inhomogeneous porosity
distribution undermines the integrity, strength, and other properties of a die cast part.

Semi-solid casting solves this issue. A semi-liquefied, as opposed to fully liquefied, metal is
used. The metal absorbs less gas before injection, consequently releasing less during cooling.
The result is die cast parts with extremely low rates of porosity.

Apart from the updated HPDC methods themselves, advancements are being made in the
ancillary technologies that go along with them. For one, conformal cooling systems are
becoming more prevalent. In conformal cooling, special channels surrounding the primary
part cavity are included in a die. The channels can be filled with coolant, yielding a number
of benefits: more uniform cooling, which leads to lower porosity; stronger, higher quality
parts; and reductions of cycle times that can reach 30% or even more, hugely important for
the fastpaced, high-volume automotive industry.

Beyond that, general process controls for conventional HPDC and emerging HPDC methods
alike are advancing. They are helping die casters decrease defect rates, improve various
strength values, and manufacture parts with thinner walls and more complex geometries than
ever before.
4. MACHINING:
ELECTROCHEMICAL MACHINING:
Electrochemical machining (ECM) is a metal-removal process based on the principle of
reverse electroplating. In this process, particles travel from the anodic material (workpiece)
toward the cathodic material (machining tool). A current of electrolyte fluid carries away the
deplated material before it has a chance to reach the machining tool. The cavity produced is
the female mating image of the tool shape.

ECM Process

Parts made by ECM Process

ADVANTAGES OF ECM PROCESS:
The components are not subject to either thermal or mechanical stress.
No tool wear during ECM process.
Fragile parts can be machined easily as there is no stress involved.
ECM deburring can debur difficult to access areas of parts.
High surface finish (up to 25 µm in) can be achieved by ECM
process.

ELECTRIC DISCHARGE MACHINING (EDM):

Electrical discharge machining (EDM) is one of the most widely used nontraditional
machining processes. The main attraction of EDM over traditional machining processes such
as metal cutting using different tools and grinding is that this technique utilizes
thermoelectric process to erode undesired materials from the workpiece by a series of discrete
electrical sparks between the workpiece and the electrode.

The traditional machining processes rely on harder tool or abrasive material to remove the
softer material whereas non-traditional machining processes such as EDM uses electrical
spark or thermal energy to erode unwanted material in order to create desired shape. So, the
hardness of the material is no longer a dominating factor for EDM process.

EDM Machine
APPLICATIONS OF EDM:
The EDM process has the ability to machine hard, difficult-to-machine materials. Parts with
complex, precise and irregular shapes for forging, press tools, extrusion dies, difficult internal
shapes for aerospace and medical applications can be made by EDM process. Some of the
shapes made by EDM process are shown in Figure below.
 Figure: Difficult parts made by EDM Process

ADVANTAGES OF EDM PROCESS:

By this process, materials of any hardness can be machined;
No burrs are left in machined surface;
One of the main advantages of this process is that thin and
fragile/brittle components can be machined without distortion;
Complex internal shapes can be machined
CONCLUSION:
From this Project, we can conclude some following important things;
• There are different Manufacturing Industries working towards the betterment and
advancement of our country.
• There are different processes in the Manufacturing Industries and each of them has
their own requirements.
• There are different companies in India as well as in the world who use different
Manufacturing Processes depending upon the product that they make and these
processes may or may not be dependent on each other.
• No Process is 100% perfect. There are certain defects and problems associated with
each Manufacturing Process and companies use different strategies and Modern
Technological Methods to eliminate or reduce these problems.
• The Challenges of different Industries are Random and companies use different
methods to reduce these processes like as Friction Stir Welding, Electric Discharge
Machining etc. and many more.
• Marketing Strategies also play a significant role in maintaining the awareness of a
certain product and so the company as well. Companies like Nike, Spotify have set
the examples of the Marketing Strategies that could be beneficial to the
Manufacturing Industries as well.
Manufacturing Industries have largely expanded on the basis of the Technological
Advancements that has helped not only boosting their outputs and profits but also reduced the
manual work up to a relatively larger extent. It is because of the Innovations and Inventions
that has made the work of these continuously operating Industries easier and faster. However
there are still some processes that are still operated manually and to find the solutions of this
problem is the biggest challenge of them all especially for the Small Scale Industries.
This project has helped in the understanding of the Basics of the different Manufacturing
Process, defects and recent challenges that are associated with them and how the companies
are dealing with these issues by making use of the modern Technology and the different
Marketing Strategies that has helped them to stand Globally and be a tough Competition to
others in the world.