Manufacturing

Engineering Year 1

SECTION

6 PRINCIPLES OF
MARKING OUT,
MEASUREMENT
AND GAUGING

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MANUFACTURING TOOLS, EQUIPMENT

AND PROCESSES
Manufacturing Processes
Safety, Quality and the Environment

Introduction
In this section, we shall learn about the fundamentals of basic bulk deformation forming
processes and sheet metal work development, which are essential components of the
manufacturing industry, you will be:
• introduced to the principles of deformation forming, the selection of appropriate
forming processes and the development of sheet metal work.
• exposed to hands-on activities to help you practice how to understand the
processes involved in bulk deformation and sheet metal work, the standard
procedures and their applications.
• able to understand and appreciate the importance of maintaining a safe working
environment and the standard safety practices in the manufacturing industry.
• exposed to activities that will help you identify potential hazards and apply
safety measures in a manufacturing setting.
At the end of the section, you will have a comprehensive understanding of the
manufacturing industry, its processes, safety practices and its impact on society.

At the end of this section, you will be able to:

• Discuss rolling, forging and extrusion as bulk deformation processes

• Recognise and identify dies and presses used for sheet metal working operations
• Discuss cutting, bending and drawing as sheet metal working operations
• Identify potential hazards in the workspace
• Describe the social and economic consequences that a manufacturing activity can have
or has had on individuals and society
• Explain how the manufacturing industry affects the local and international economy
(e.g., with respect to job creation, standards of living, sustainability, and conservation of
the environment)

Key Ideas
• Bulk Deformation Forming Processes refers to material forming processes in which the
thicknesses or cross-sections are reduced, or shapes are significantly changed.
• These forming processes encompass practices like rolling, extrusion, cold and hot
forging, bending, and drawing.

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• Safety hazards include fire explosion and electrical hazards, whereas health hazards
include excessive noise, flying materials and carcinogenic materials. It is important
to act quickly to eliminate any potential hazards and respect safety guidelines in the
workplace.
• Among the positive impacts of manufacturing include improvement in the standard of
living of individuals via job creation, growth of communities through CSRs, etc.
• On the other hand, manufacturing companies negatively impact the environment via
the release of pollutants; add to the global warming case by releasing greenhouse gases,
and pose health threats to individual workers from unsafe manufacturing conditions.

ROLLING, FORGING AND EXTRUSION AS BULK

DEFORMATION PROCESSES
The key aspect of these processes is the application of appropriate stresses - tension,
compression and shear - to shape metal products into desired dimensions. We will
consider the appropriate forming processes and the development of sheet metal work
in the manufacturing industry.

Bulk Deformation Forming Processes

• Material forming processes in which the thicknesses or cross-sections are
reduced, or shapes are significantly changed, are referred to as Bulk Deformation
Forming Processes.
• Bulk deformation forming processes are a set of metalworking methods that
involve substantial plastic deformation of the material to achieve a specific
shape while preserving its mass and chemical composition.
• These techniques are distinguished by their three-dimensional deformation,
in contrast to sheet-forming processes, and encompass practices like rolling,
extrusion, cold and hot forging, bending, and drawing.
• The key aspect of these processes is the application of appropriate stresses-
tension, compression and shear - to shape metal products into desired
dimensions.
• The importance of bulk deformation processes in the industry is highlighted
by their cost efficiency, superior mechanical properties of the end product,
operational flexibility, increased productivity and reduced raw material wastage,
resulting in accelerated production rates.

Rolling
• Rolling operations reduce the thickness or cross-section of a material through
compressive forces exerted by rolls.
• In the basic rolling process, a metal is passed between two rolls that rotate in
opposite directions, with the gap between the rolls being somewhat less than
the thickness of the metal being rolled.

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• Rolling is used to convert thick materials or metals into blooms, slabs or billets,
which are later rolled to produce plates, sheets, strips, rails, wire rods, bars,
pipes, etc.
• The process of rolling involves more than just mechanically reducing material
thickness., it also includes intricate interactions between the material’s
microstructure and the applied stresses, resulting in texture evolution and
refinement of the microstructure.
• In the case of thread rolling, materials experience significant microstructural
changes as they are primarily stretched at the top and bottom of the formed
thread parts, improving the performance of these parts.
• The complexity of the rolling process and its influence on material properties
highlight its importance in bulk metal forming.
• Rolling not only shapes materials but also boosts their mechanical properties by
carefully controlling deformation and microstructural evolution.
Figure 6.1 shows the basic metal rolling process and some products produced by the
metal rolling process respectively.

Fig. 6.1: The basic metal rolling process

Fig. 6.2: Some products produced by the metal rolling process

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Forging
Forging is a term applied to a family of processes that induce plastic deformation
through localised compressive forces applied through dies.
• The forging equipment can take the form of hammers, presses or special forging
machines. Forging is the oldest known metal-working process.
• Common forging processes include open–die drop-hammer forging, impression-
die drop-hammer forging, automatic hot forging and roll forging, etc. This
method falls under the category of bulk deformation, encompassing techniques
that convert material of basic shapes into specific forms without changing its
mass or chemical composition through three-dimensional deformation.
• Forging methods consist of procedures like closed-die forging, where multiple
dies compress a billet into a more intricate shape, often resulting in excess
material called flash that needs to be removed, indicating material wastage and
additional processing stages.
• The forging procedure can be complex, involving significant plastic deformation
at high temperatures to achieve the desired shape and size.
• Forging plays a vital role in diverse sectors, such as automotive, military and
aerospace, due to its capacity to manufacture consistent, high-quality parts at
affordable prices and with high reproducibility.
• The process entails intricate die designs and demands a thorough comprehension
of material flow, die filling and the effects of forging on microstructure and
mechanical properties.
Figure 6.3 presents an image of open-die and closed-die forging processes.

Fig. 6.3: Open die forging vs Closed die forging processes

Extrusion
In the extrusion process, the metal is compressed and forced to flow through a suitably
shaped die to form a product with a reduced but constant cross-section. Extrusion may
be carried out directly or indirectly.
In direct extrusion, a solid ram drives an entire billet to and through a stationary die
and must provide additional power to overcome the friction between the surface of the
moving billet and the confining chamber.

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In indirect extrusion, a hollow ram pushes the die back through a stationary, confined
billet.
• Extrusion is a versatile method extensively employed in the manufacturing of
various long, semi-finished components like bars, tubes, wires and strips, either
performed at ambient temperature or elevated temperatures.
• This technique entails the alteration of materials through the implementation
of severe plastic deformation (SPD) methods, which play a pivotal role in
the creation of bulk materials with refined microstructures and improved
mechanical characteristics.
• The process of extrusion can be categorised into different approaches, each
presenting distinct advantages, drawbacks, and applications, spanning from the
fabrication of intricate shapes to the enhancement of material attributes.
• A notable variation of extrusion is friction extrusion, which leverages heat
generated by friction and shear strain to process metallic materials, providing a
distinctive means of enhancing material properties by handling powders, chips
and bulk materials.
Figure 6.4 shows a schematic of a direct extrusion process.

Fig. 6.4: A schematic of a direct extrusion process

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Activity 6.1

Make a search on the internet, watch the video or read from the textbook on the
following rolling, forging and extrusion processes using the links below and the
book provided.
• https://www.youtube.com/watch?v=pkJxrZPeP_0
• https://www.youtube.com/watch?v=5EeuYai8Ax8
• https://www.youtube.com/watch?v=ix8BDa_nMaU
• https://www.iitg.ac.in/engfac/ganu/public_html/Metal%20
forming%20processes_full.pdf
Prepare a PowerPoint presentation to be presented to your class highlighting the
principles, advantages, disadvantages and applications of each process.

Activity 6.2

Visit a nearby metal workshop, for a more practical demonstration on how to

perform metal rolling, forging and extrusion processes. Under supervision of the
workshop craft master, perform these three operations at the workshop.
a. Rolling
b. Forging
c. Extrusion processes.
Take a video or picture of yourself during the operations.

Activity 6.3

Choose one of these forming processes as a project work to produce (design

and construct) a prototype of your choice to solve a real-life problem in your
community.
Follow the procedures and steps below to complete your prototype. Ensure that
you accurately report your observation.

1. Plate Rolling
Plate rolling is the process of forming flat metal plates into curved or cylindrical
shapes using specialised machinery called plate rollers or plate bending machines.
This process can be used to create pipes, tanks, cylindrical shells for pressure
vessels, wind turbine towers, and structural components in construction
Setup: Positioned the rollers in a in a triangular configuration. place a flat metal
plate is between three or more rollers

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First Rolling: Ensure that the plate passes through the rollers and is rotated by
them. Adjust the gap between the rollers to control the degree of curvature.
Bending: The rollers apply pressure to the plate, bending it as it passes through.
Multiple passes are typically required, gradually increasing the pressure to achieve
the desired curvature.
Final Shape: Readjusting the positions of the rollers and the pressure applied,
the plate can be formed into cylindrical, conical, or other curved shapes.
Hope you have been able to produce your desired prototype

2. Closed-Die Forging (Impression-Die Forging)

Closed-die forging, also known as impression-die forging, is a process where the
metal workpiece is placed between two dies that contain the shape of the desired
final product. Unlike open-die forging, the metal is mostly confined, allowing
for the creation of more complex and precise shapes. The process involves high
pressure to force the material into the cavity of the dies.
Steps:
• Heating the Workpiece: Heat the metal to a high temperature usually
below the melting point to make it malleable. This is typically done in a
furnace. The temperature depends on the material for steel, it can range
between 1000°C and 1250°C (hot forging).
• Placing the workpiece in the die: Place the heated workpiece in the
lower die, which contains the negative impression (cavity) of the final
product.
• Applying Force: Apply great force on the upper die containing part of
the shape of the product, by the use of hydraulic presses or mechanical
hammers. The metal is squeezed between the upper and lower dies, and the
material is forced to flow into all the cavities of the dies, taking the shape of
the final product.
• Flash Formation: Excess material, known as flash, often forms around
the edges where the die halves meet. The flash cools faster than the rest of
the workpiece due to its thinness, and this helps in confining the rest of the
material within the die cavity.

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USES OF DIES AND PRESSES IN BASIC SHEET

METAL WORKING OPERATIONS
This lesson looks at cutting, bending and drawing as sheet metal working operations.

Components of a Stamping Die

The working components of a stamping die are the punch and the die. These are
attached to the upper and lower portions of the die set, respectively called the punch
holder (or upper shoe) and die holder (or lower shoe). The die set also includes guide
pins and bushings to ensure proper alignment between the die and the punch during
the stamping operation. Figure 6.5 shows a schematic of a simple stamping die.

Types of Stamping Dies

• Dies (or stamping dies) are classified based on the following criteria: Number
of separate operations to be performed in each press actuation: A simple die
performs a single blanking operation with each stroke of the press; a compound
die performs two separate operations at a single station; a combination die
performs two operations at two different stations in the die.
• How the die operations are accomplished: A progressive die performs two or
more operations on a sheet-metal coil at two or more stations with each press
stroke, thus the part is fabricated progressively.

Fig. 6.5: A schematic of a simple stamping die.

Presses for Sheet Metal Forming

A press used for sheet metal forming is a machine tool with a stationary bed and a
powered ram (or slide) that can be driven towards and away from the bed to perform
various cutting and forming operations. It has a frame, which establishes the relative
positions of the bed and the ram, with the ram being driven by mechanical or hydraulic
power. The frame may be of the gap frame type, the solid gap frame type, the adjustable
bed frame type, the straight-sided frame type, etc.

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Fig. 6.6: A schematic of a general gap frame press

PRINCIPLES OF CUTTING, BENDING AND

DRAWING IN SHEET METAL WORKING
OPERATIONS
Cutting in Sheet Metal Working
The cutting of sheet metal is achieved by the shearing action of two sharp cutting edges.
The upper cutting edge (the punch) sweeps down past the stationary lower cutting
edge (the die). As the punch begins to push into the sheet metal, plastic deformation
occurs in the sheet metal surface, and as the punch moves downward, penetration
occurs, in which the punch compresses the sheet and cuts into the metal due to the
occurrence of fracture in the sheet

Fig. 6.7: A schematic of the cutting operation in a sheet metal working.

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Bending in Sheet Metal Works

Bending in the context of sheet metal operations refers to the straining of the metal
around a straight axis. During this operation, the metal on the inside of a neutral plane
is compressed while the metal on the outside of the neutral plane is stretched. Bending
operations are performed using punch and die tools. V-bending and edge-bending as
shown below:

Fig. 6.8: Schematics of (a) a V-bend and (b) an Edge-bend

Drawing in Metal Sheet Operations

Drawing refers to forming a flat metal sheet into a hollow or a concave shape, by
stretching the metal. A blank holder is used to hold down the blank while the punch
pushes into the sheet metal.

Fig. 6.9: A schematic of a deep drawing technique.

Activity 6.4

Search on the internet, or watch the videos linked below, or reading from the
textbook on dies and presses used in casting operations.
• https://www.youtube.com/watch?v=xbynUVj3hAE
• https://technologystudent.com/despro2/forging21.html

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Make a neat sketch of dies and presses showing all the parts for presentation in
your class. During these presentations discuss the operational principles of dies
and presses.

Activity 6.5

Visit a nearby metal workshop, for more practical on sheet metal formation
operation processes. Under supervision of the workshop craft master, perform
these three operations at the workshop.
a. Vee bending
b. Deep drawing
c. Edge-bending
Take a video or picture of yourself during the practical session.

Activity 6.6

Choose one of these forming processes as a project work to produce a prototype

of your choice. (metal brackets, hinges, flanges, latches, clips, cover plates)
Follow the procedures and steps below to complete your prototype. Ensure that
you accurately report your observation.
Metal brackets
To make metal brackets in a bench fitting workshop, the process is more manual
and relies on hand tools and basic machinery.
1. Marking out processes: Choose a suitable metal sheet based on the size
and strength required. With the help of scribes, calipers, steel rules, and
engineer’s squares, carefully mark out the shape and dimensions of the
bracket on the metal. Use a centre punch to mark points where holes will be
drilled.
2. Cutting processes: Use a hacksaw to cut along the marked lines. For larger
or thicker pieces, you might use the power hacksaw machine. File to size
and remove any burrs.
3. Forming processes: Place the metal plate in a bench vice or use a bending
jig to bend the plate to the required angles,
4. Drilling processes: Hold the plate firmly in drill vice and drill through to
create circular holes where required. Start with a small drill bit and work
your way up to the desired size. Deburr all sharp edges.
5. Assembling Processes (If Necessary): Join parts together by means
of rivets or bolts and nuts

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6. Finishing processes: Use a hand file to remove any remaining rough edges
or burrs. Apply advanced coating finishes, such as anti-corrosion oil or paint
the metal using brushes or spray paint for basic protection.
Check the dimensions using a caliper or steel rule and ensure that the bracket
meets the required specifications.
NOTE: Follow the same steps/ processes to fabricating the following items
• hinges
• flanges
• cover plates
Now, think about any product you may want to design and fabricate to help your
class or community.

POTENTIAL HAZARDS IN THE WORKSPACE

Recognising and understanding hazards is critical to maintaining a safe and efficient
work environment. Staying alert to potential risks can significantly reduce the likelihood
of accidents and injuries, ensuring the well-being of you and your colleagues.
This knowledge is vital not only for your personal safety but also for compliance with
health and safety regulations designed to protect everyone in the workplace.

Introduction to workplace hazards.

A workplace hazard can be defined as the possibility of harm or danger occurring at
the workplace, and it encompasses all aspects of technology and activities that have a
certain degree of likelihood of negatively affecting the health and safety of workers at
the workplace.
A workplace hazard can cause damage to property, injury, or death in extreme cases.
Hazards in the workplace can arise from various origins, such as being in contact with
harmful substances, using risky tools and machinery, or engaging in activities requiring
repetitive motions, strenuous lifting, or exposure to severe environmental conditions.
The spectrum of hazards present in work settings extends beyond chemical risks to
encompass kinetic and potential energy dangers, electrical hazards, geological and
meteorological threats, as well as health risks.

Categories of Workplace Hazards

Hazards at the workplace can be placed into two (2) broad categories according to the
OSHA (Occupational Safety and Health Administration) in the USA.

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Safety Hazards and Health Hazards.

• Safety Hazards: Safety hazards are situations that can cause immediate injury
to or death of a worker. These include machinery (Unguarded and moving
machinery parts that a worker can accidentally touch), flying materials,
anything that can cause spills or trips, such as cords running across the floor
or ice, anything that can cause falls, such as working from heights, including
ladders, scaffolds, roofs, or any elevated work area, fire and explosion hazards,
and electrical hazards (such as frayed cords, missing ground pins, and improper
wiring).
• Health Hazards: These are hazards associated with long-term exposure to
certain situations or substances. These hazards can produce acute (immediate)
or chronic (long-term) effects. Health hazards include excessive noise, wood
dust (carcinogenic), chemicals, improperly adjusted workstations and chairs,
frequent lifting, poor posture and vibration from machine operation.

Identifying/Recognising Potential Hazards in a Work-

place
Identifying any form of potential hazard in the manufacturing environment can be
much easier to carry out by trying to find answers to the following basic questions at
any point in the workplace:
• What work is being done? Understanding the kind of work being done is an
important step to being able to identify the potential hazards associated with
the work.
• What kind of possible injury, damage or danger can occur? List all the
potential hazards that can occur depending on the nature of the work being
done.
• What can or has to be done to avoid the potential hazard? After listing all
the possible hazards that can occur, write down all the precautions that can be
taken to avoid such hazards or to reduce risk if the hazard should occur.

Fig. 6.10: A workplace with several hazardous situations: what are the various hazards in this picture?

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KNOWING THE GENERAL SAFETY PRACTICES IN

THE MANUFACTURING ENVIRONMENT AND THE
IMPORTANCE OF FOLLOWING THEM
Safety
Safety is simply a state of being at little or no risk of injury or any form of danger.
It is the process of protecting employees from work-related illness and injury. In the
manufacturing environment, a wide range of safety practices are implemented to
safeguard workers and ensure the production of safe goods.
These practices, including compliance with Good Manufacturing Practices (GMP), play
a fundamental role in the creation of safe food and healthcare items by coordinating
all aspects of the facility to guarantee safety throughout the production process, from
sourcing raw materials to distribution. It is imperative to provide training and education
to employees to enhance the safety culture and behaviour, ultimately fostering a secure
environment in the workplace.
The manufacturing industry is prone to various hazards such as machine-related risks,
musculoskeletal disorders, occupational illnesses stemming from noise and chemical
exposure, and incidents of workplace violence, all of which require thorough safety
protocols to be put in place.

Who is Responsible for Workplace Safety?

It is very important to understand that safety is a culture and a habit everyone needs to
have irrespective of who/where you find yourself. In the manufacturing environment/
workplace:
• Safety is everyone’s responsibility.
• Management (employer) is responsible for the safety of workers.
• Workers need to be trained to work safely.
• All injuries are preventable.
• Mistakes that lead to accidents can be always prevented.
• Safety guidelines specific to every site in the workplace must be available all the
time, and workers must be obliged to follow them.

Some General Safety Practices at a Manufacturing Workplace:

• Wear Personal Protective Equipment (PPE).
• Use equipment and tools properly.
• Keep work areas and emergency exits clear.
• Eliminate fire hazards.
• Take work breaks from time to time (avoid overworking).
• Prevent objects from falling by keeping them in appropriate places.
• Prevent slips and trips by making sure that spills are cleaned and that aisles are
clear.

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Identifying Safety Signs and Symbols at the Workplace

Safety signs are essential tools for communicating safety conditions at the workplace.
Safety signs serve as visual indicators of potential hazardous situations in the workplace
and required precautionary measures to be taken to avoid any accident or harm to
employees and visitors.
The following are some of the important safety signs to watch out for at the
manufacturing workplace:

Exit Sign
This safety sign is used to indicate the location of an exit or escape route from a building
in an emergency.

Fig. 6.11: Exit Sign

Slips, Trips and Falls

This sign in the workplace alerts employees and visitors to the potential dangers of
slipping, tripping, or falling in a specific area. They are placed in areas where there is
a higher risk of falling.

Fig. 6.12: Slip, Trip and Fall Sign

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Authorised Personnel Only Sign

This sign is used to restrict access to specific areas or rooms that contain sensitive
information, hazardous materials, or equipment that could pose a risk to personnel.

Fig. 6.13: Authorised Personnel Only Sign

Personal Protective Equipment (PPE)

The PPE sign indicates areas where PPE is required. It is placed in areas where there is
a risk of physical harm.

Fig. 6.14: Personal Protective Equipment (PPE)

Danger Flammable Sign

This is a safety sign used to warn workers and visitors of flammable substances. They
are placed in areas where there is a risk of fire explosion.

Fig. 6.15: Danger Flammable Sign

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Prohibition Signs
Prohibition signs are universal symbols used to identify actions or behaviours that
are not permitted in a specific area. The circular design is immediately recognisable,
usually with a red border and a diagonal line slashing through it.

Fig. 6.16: Prohibition Sign

Warning Signs
Warning signs inform people about possible risks or dangers and serve as a precautionary
warning. They can be identified by specific images or text that describe the nature
of the danger. They are characterised by their yellow or amber triangular shape with
a bold exclamation mark in the middle. For example, to warn people about possible
falling objects, a warning sign outside a construction site could show an image of a
falling brick.

Fig. 6.17: Prohibition Sign

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Activity 6.7

1. Watch and observe the activities in the following videos:

a. https://www.youtube.com/shorts/X3Zqxus7hj8
b. https://www.youtube.com/shorts/gSMWeA5PchM?feature=share
c. https://www.youtube.com/shorts/R2lbWpIudSM?feature=share
d. https://www.youtube.com/shorts/QARI1uURASo?feature=share
e. https://www.youtube.com/watch?v=_F__Mxklpw8
2. Identify potential hazards in the videos provided and note them down.
3. Form small groups with your colleagues and discuss your findings.
4. Prepare a presentation to share your findings with the rest of the class. This
could be a slide presentation, a poster, an oral presentation or even a short
video or role-play.

Activity 6.8

1. Visit your school’s workshop or a local manufacturing workshop.

2. During the visit, observe and list potential hazards you noticed.
3. Identify and note the various safety practices followed at different locations
within the workshop.
4. Form small groups with your colleagues and discuss your findings and
categorise potential hazards into safety and health hazards
5. Prepare a presentation to share your findings with the rest of the class. This
could be a slide presentation, a poster, an oral presentation or even a short
video or role-play.

Activity 6.9

1. In groups, study the safety signs in the charts provided.

Fig. 6.18: Safety sign chart A

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Fig. 6.19: Safety sign chart B

2. Start a discussion about the safety signs in the charts provided. The
discussion should focus on the identification and explanation of the safety
signs and where they are used.
3. Initiate another discussion about the current safety situation in the
classroom, map out potential hazards and suggest safety improvements.
4. Create safety charts or maps based on your observations and the provided
visuals.
5. Prepare a presentation to share your findings with the rest of the class. This
could be a slide presentation, a poster, an oral presentation or even a short
video or role-play.

Activity 6.10

1. Using the resources listed below, research on general workplace safety

procedures;
a. Videos on workplace safety practices
b. Textbooks and journal articles
c. Posters and charts
d. Internet resources on workplace hazards
2. Identify and note the various safety practices followed at different locations
within a typical manufacturing facility.
3. Create safety charts or maps based on your research.
4. Form small groups with your colleagues and discuss your findings.
5. Prepare a presentation to share your findings with the rest of the class. This
could be a slide presentation, a poster, an oral presentation or even a short
video or role-play.

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SOCIAL AND ECONOMIC CONSEQUENCES OF

MANUFACTURING ACTIVITIES ON INDIVIDUALS
AND SOCIETY
Manufacturing activities are an essential part of economic development and social
progress. However, they entail a range of social and economic consequences that can
have a significant impact on individuals and communities.
Understanding these consequences is critical to developing sustainable manufacturing
practices that balance economic benefits with social well-being.
It must also be noted that the manufacturing industry plays a crucial role in shaping the
local and international economy. Understanding these impacts is critical to promoting
a balanced manufacturing approach that supports economic growth while ensuring
social and environmental responsibility. This knowledge is crucial for promoting
sustainable development and global economic cooperation.
Let’s explore how we can mitigate the negative impacts while maximising the positive
outcomes of manufacturing activities. We shall examine both the negative and positive
impacts of manufacturing on the individual and society in the economic and social
dimensions.

Positive Social and Economic Impacts on the Individual

and Society
• Manufacturing activities have improved the standards of living and financial
well-being of individuals and homes through the provision of employment for
both skilled and unskilled labour.
• Manufacturing industries promote the development of communities through
their corporate social responsibilities (CSRs).
• Manufacturing activities have contributed to the growth of populations and
communities due to the surge of migration to industrialised communities.
• Manufacturing activities have enhanced the growth of agricultural communities
as agricultural products are the basic raw materials for many manufacturing
industries.
• The manufacturing sector contributes greatly to the surge in technological
advancement of society, which in turn promotes productivity in other industries.
For example, the manufacturing of vehicles, computers and other machinery
has led to the growth of transportation networks, digital infrastructure, and
automation technologies, all of which have revolutionised how goods and
services are delivered, information is accessed, and tasks are performed across
various sectors.

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Negative Social and Economic Impacts of Manufacturing

Activities on Individuals and Society
• Deaths of individual employees from accidents such as explosions and fire
accidents.
• Increase in atmospheric temperature (Global Warming) leading to Climate
Change due to an increase in emission of greenhouse gases.
• Destruction of water bodies and viable lands due to improper disposal of wastes
from manufacturing activities.
• Release of air pollutants, leading to the contraction of respiratory diseases and
skin infections etc.
• Increased/intensified social problems such as access to housing (because of
urbanisation) etc.

Fig. 6.20: Emission of harmful gases into the atmosphere by manufacturing industries

Fig. 6.21: Deforestation by manufacturing industries

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Fig. 6.22: Discharge of industrial sewage into a water body

EFFECTS OF MANUFACTURING ACTIVITIES

ON LOCAL AND GLOBAL ECONOMIES WITH
RESPECT TO JOB CREATION, STANDARDS OF
LIVING, SUSTAINABILITY, ENVIRONMENTAL
CONSERVATION
Job Creation/Employment
The manufacturing industry creates more jobs/employment (for both skilled and
unskilled labour) and enhances the economic growth of the local and global economies
as it adds more value to the primary sector outputs, increasing the national GDP (Gross
Domestic Product).

Standards of living
In addition to job creation, people have access to cheap and varied goods. People also
have better access to education, health services, etc., due to urbanisation. Households
have more income to boost their standards of living.

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Sustainability
Most traditional/conventional manufacturing processes are economically and
environmentally unsound as they usually result in the depletion of natural resources,
hence, demoting both economic and environmental sustainability. Most manufacturing
companies are now adopting economically and environmentally-sound processes to
promote sustainable manufacturing.

Conservation of Environment
Generally, manufacturing activities are the major cause of depletion of natural resources
and the deterioration of the environment. To protect the environment, and guard the
fundamental natural resources from exhaustion, manufacturing companies need to be
conservation conscious; the forest, water bodies and wildlife has to be strictly protected.

Activity 6.11

Using the internet, watch these videos, or read from the textbook on the positive
and negative social and economic impacts of manufacturing companies’ activities
on individuals and society using the links below and the book provided.
• https://www.youtube.com/watch?v=CuJ4E1UMk3c
• https://www.youtube.com/watch?v=sx81vcCliFA
• https://www.youtube.com/watch?v=LxKiAnT1zDw
• https://www.youtube.com/watch?v=sg22hhnfN2Y
Prepare a report based on the headings below and present your findings to your
class or peers
a. Introduction
b. Positive effect of manufacturing industries
c. Negative effect of manufacturing industries
d. Conclusion
e. Recommendations

Activity 6.12

Generate ideas on the role of manufacturing companies in local communities

putting into consideration the social and economic impact.
Follow the guidelines below to generate ideas. Introduce the discussion by listing
some manufacturing companies in your area
Prompt questions:
a. What products do these companies produce?
b. What raw materials do they use?

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SECTION 6 PRINCIPLES OF MARKING OUT, MEASUREMENT AND GAUGING

c. What do these companies do that you think are good and they must
continue?
d. What do they do that you think are not good and must be stopped
immediately?
e. What are the various solid, liquid and gaseous pollutants produced by
these companies?
f. How have these manufacturing companies influenced and affected the
social structure of your community? Consider aspects like employment
opportunities, community health, social services, infrastructures such
as roads, school and hospital buildings, donations, etc.
Write a report to the chief of your community on the role of manufacturing
companies in local communities, putting into consideration the social and
economic impact.

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Review Questions

1. Prepare a presentation explaining the principles, advantages, disadvantages,

and applications of rolling, forging, and extrusion processes.
2. Given a scenario where a metal needs to be shaped into a long, thin product,
which process would be more suitable: rolling or extrusion? Justify your answer
3. Explain the positive impact of the manufacturing industry on the local and
international economies.
4. Explain the negative impacts of the manufacturing industry on local and
international economies.
5. How can the manufacturing industry improve upon the lifestyle of the local
community?
6. How does adherence to workplace safety practices generally enhance the
manufacturing process?
7. Write an essay on the importance of safety practices in a manufacturing
environment.

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Extended Reading
• Galbraith, J. K. (2007). The new industrial state (4th ed.). Princeton University Press.
• Thompson, R. (2007). Manufacturing processes for design professionals. Thames &
Hudson.
• Duflou, R. (Ed.). (2020). Sustainable manufacturing: Challenges, solutions and
implementation perspectives. Springer.
• https://www.youtube.com/watch?v=KWNt68f376E
• Shezard, Z. (2023). 12 most important workplace hazard safety signs. HSE Blog. Retrieved
August 17, 2023, from https://www.hseblog.com

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ACKNOWLEDGEMENTS

LIST OF CONTRIBUTORS
Name Institution

Engr. Ali Morrow Fatormah Mfantsipim School, Cape Coast

Ebenezer Adusei Kumasi Technical University

Benjamin Atribawuni Asaaga Kwame Nkrumah University of Science and Technology

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