In order to facilitate the achievement of the required quality and cost objectives for the manufacture of a component design solution it is necessary to carry out the interrelated activities of selecting candidate processes and tuning a design to get the best out of a chosen manufacturing route. These are difficult decision-making tasks that few experts do well, particularly in the situation of new product introduction.
Failure to get this right often results in late engineering change, with its associated problems of high cost and lead time protraction, or having to live with components that are of poor quality and/or expensive to make.
There is a need for specialist knowledge across a range of manufacturing technologies to enable the correct design decisions to be made from the breadth of possibilities. The difficul- ties faced by businesses in this area are frequently due to a lack of the necessary detailed knowledge and the absence of process selection methods.
The main motivation behind the text is the provision of technological and economic data on a range of important manufacturing processes. Manufacturing PRocess Information MAps (PRIMAs) provide detailed data on the characteristics and capabilities of each process in a standard format under headings including: material suitability, design considerations, quality issues, general economics and process fundamentals and variations. A distinctive feature is the inclusion of process tolerance capability charts for processing key material types.
Another distinctive feature of the book is the inclusion of a method for estimating compo- nent costs, based on both design characteristics and manufacturing process routes. The cost associated with processing a design is based on the notion of a design independent basic processing cost and a set of relative cost coefficients for taking account of the design applica- tion including geometry, tolerances, etc. The overall component cost is logically based on the sum of the material processing and material purchase cost elements. While the method was primarily designed for use with company specific data, approximate data on a sample of common manufacturing processes and material groups is included to illustrate the design costing process and quantify the effect of design choices and alternative process routes on manufacturing cost.
The work is presented in three main parts. Part I addresses the background to the problem and puts process selection and costing into the context of modern product introduction processes and the application of techniques in design for manufacture. Part II presents the manufacturing process information maps (PRIMAs) and their selection. Part III is concerned