Analysis and Specification of Manufacturing Process - Coursework Example

Analysis and Specification of Manufacturing Process Name Date Course Summary Casting and forging are the main methods used during the manufacturing process of 30”MKIII highlift foot valve body. Casting is the most preferred methods due to its advantage. Casting has also been selected as the method for manufacturing body of the footvalve. The process involves creating a mould, melting the steel, pouring the molten steel, cooling, removing the parts from the mould, welding and machining. The processes are simple but require a lot of expertise. The total cost of manufacturing a single unit is $ 110. It can be sold at a price of S 130 in order to obtain profitability. Introduction The 30”MKIII highlift footvalve requires high levels of effectiveness in order to ensure that it functions correctly. This is dependent on the manufacturing process used. Various factors have to be considered during the manufacturing process. Different methods are used by different organizations to manufacture the body of the footvalve. Fort Vale Engineering Ltd in Burnley is a leading manufacturer of valves (Fort Vale Engineering Ltd, 2015). It utilizes unique methods during the manufacture of the footvalves. This is mainly for the purposes of ensuring that it meets the specifications of the customers. The paper is a report about the manufacture of a 30”MKIII highlift footvalve body in relation to Fort Vale Engineering Ltd. Discussion Possible manufacturing methods Casting Casting is one of the methods that are used in the manufacture of the body of the foot valve. Casting is an effective method and it can lead to the manufacture of the footvalve body through different types of metals. The stainless steel as well as iron can also be used during the process. This method is flexible and it ensures that the required quality is met during the manufacturing process. Casting is a method that is widely used by most of the manufacture and this includes Fort Vale Engineering Ltd (Fort Vale Engineering Ltd, 2015). This method is cost effective as a result of using a wide range of materials. The steel casting method is effective as it also ensures that the required strength is attained. The casting method does not require much labour as compared to the other methods. Dimensional accuracy can also be achieved through the use of the casting method. 30”MKIII highlift footvalve When casting steel, sand or ceramic mould with the shape of the footvalve body parts is usually developed. Steel is heated to molten state before being poured on the ceramic or sand mould. It is then allowed to cool for a specified period of time before the body is removed. When using this method, the mould must be strong enough to support the weight of the molten metal. The use of moulding is effective in ensuring that the better tolerance and dimensions are obtained during the manufacturing process (Fort Vale Engineering Ltd, 2015). When using this method, special attention is required for the purposes of ensuring that the air bubbles are not formed as it may affect the quality of the footvalve body. This method is also effective in terms of ensuring that excellent surface finish is obtained. Forging Forging is also a method that can be used during the manufacture of footvalve body. This method mainly involves the use of mechanical tool to develop different parts of the body in order to come up with the body of the footvalve (Strauss, 2013). The hammer and other mechanical tools are usually using during the forging process. Forging requires a lot of manual work and the final product may not meet the required tolerance and dimension. The items may not be of the same size and shape when forging is used. It is difficult to control the strength of the material when using this method. Manufacturing method selection Casting is the best method that can be used during the manufacture of footvalve body. The use of this method is effective as it ensures that excellent dimensional tolerances are obtained. The surface finish are also improved through the use of casting is an important requirement for the footvalve body. This method is relatively easy to use and it ensures that the body gains maximum strength through the cooling process. Excellent mechanical properties of the footvalve body can be achieved when the casting method is used (Rywotycki, et al, 2012). This enhances the dimensional tolerance as well as the surface finish. Uniformity is an important aspect when dealing with the needs of the customers. The casting method ensures that all the footvalve body is uniform in shape and dimensional tolerance. The need for additional handwork is reduced when casting method is utilized. This is useful in lowering the cost of production and labour. Casting ensures that the design specification is obtained due to the uniformity involved. Any modifications can be carried out easily through when using this method. This is an indication that the method has the ability of meeting the manufacturing practicalities. The chances of errors are low when using this method as it is easy to correct any error. This method is economical and it eliminated any wastage of materials. This is because any extra material or items that have not met the specifications can be melted and reused for the same purpose. Casting is cheaper as compared to the other methods as the materials can be recycled (Sołekn & Trębacz, 2012). The strength of the footvalve body can be controlled when casting is used. This ensures that the required specifications are met in terms of the strength. Excellent casting properties can be achieved through controlled heating and cooling. This method can also lead to mass production within a short period of time. Process plan The first process is to create a mould for the purposes of casting. This can be achieved through placing a pattern in sand in order to create a mould. This process requires a lot of expertise as it determines the outcome of the process. A bounding agent such as clay can also be mixed with the sand for the purposes of developing the mould (Lopez, et al, 2014). The pattern and sand can then be incorporated in a gating system. The steel can then be transformed into a molten state through controlled heating until it reaches the required temperature. The pattern that had earlier been created can then be removed and the molten metal poured on the mould cavity developed. The metal can then be allowed to cool under in order to develop the final product. The metal can be allowed to cool on its own or through a controlled process. Casting process After the metal has cooled, the sand mould can be broken away and the casting removed. This process has to be carried out with a lot of care so as to avoid any damages to the parts. This method is usually used to create different parts of the body separately. After all the parts have been moulded welding can be carried out in order to develop the full body of the footvalve. The welding process required is however minor but it should be carried out with a lot of expertise in order to avoid leakages. The final step involves machining which is primarily removing any excess metal parts as a result of the welding process or accumulated during the moulding process. The machining process is requires the use of specified machines (Lopez, et al, 2014). After the machining process, the body of the foot valve will be ready for packaging and sale. Costing and pricing The pricing of a product is dependent on the costs incurred during the manufacturing process (Kotler & Armstrong, 2013). The material that will primarily be used for the manufacturing of the footvalve body is steel. Labour will also be required in terms of the development of the moulds as well as melting the steel. Welding and machining will also attract some costs in terms of the labour. Overhead costs may also be incurred when developing the single footvalves and it has to be considered. Unexpected costs may also be incurred during the manufacturing process and it has to be factored it. The total cost will be used for the purposes of determining the price of each unit. The final price of the footvalve has to be affordable and reasonable while at the same time the company has to make some profits. The table below indicates the costs that are likely to be incurred for each unit during the manufacturing process. Item Cost($) Materials required to manufacture the footvalve 50 Cost of labour 30 Overhead cost 10 Mark ups 10 Transport costs 10 Total costs 110 In order for the organization to make a reasonable profit from each valve, it can be sold at a process of $ 130. This will be profitable to the organization as thousands of units will be developed and sold on a daily basis. Conclusion In conclusion, it is evident that the manufacture of the footvalve body can be carried out through the use of different methods. Expertise is required during the manufacturing process. Casting is one of the methods that are commonly used during the manufacturing process. This method is effective due to the advantages that it has. Various steps have to be considered during the moulding process. It is evident that the pricing is dependent on the costs. List of References Strauss, K, 2013, Applied science in the casting of metals, Elsevier, NY. Rywotycki, M, et al, 2012, Identification of the boundary conditions in the continuous casting of steel, Archives of Metallurgy and Materials, 57(1), 385-393. Sołek, K, & Trębacz, L, 2012, Thermo-Mechanical model of steel continuous casting process, Archives of Metallurgy and Materials, 57(1), 355-361. Lopez, P, et al, 2014, Recent Developments of a Numerical Model for Continuous Casting of Steel: Model Theory, Setup and Comparison to Physical Modelling with Liquid Metal, ISIJ international, 54(2), 342-350. Fort Vale Engineering Ltd, 2015, Products: Footvalves, Retrieved on 14th November 2015 from, . Kotler, P, & Armstrong, G, 2013, Principles of Marketing 15th Global Edition, Pearson, NY. Read More