20 Modern Industrial And Commercial Practice Flashcards
Scales of production
One off: Def? Give examples What is a DIS of One of production, 2 Give 4 reasons why this may be
One off:
aka job production
It is unique and individually manufactured & designed products
Eg luxury cruise ship, wedding cake, disabled person chair, virtuoso players violin
There is INCREASED EXPENSE+ more COMPLEX PRODUCTION cuz it requires:
Individual client consultation
Skilled workers
Setting up individual manufacturing process
Less economies of scale
so CLIENT, WORKERS, MANUFACTURING, ECONOMIES
Batch production
Def and eg
What allows it to be faster and more accurate
When can additional products be added easily?
It is efficient and cost effective manufacture by using simultaneous manufacturing processes
Eg pottery, furniture, jet engines, high quality loudspeakers, electric guitars
Jigs, fixtures, CNC machines = faster & more accurate production
Once manufacturing set up has been established, additional products can be easily made
Mass/line production Def? How much can this production method make (low medium or high amount?) What does 'line' refer to Eg 4 main, 3 others
Division of labour is used, where workers carry out single process in turn. Used to set up highly organised manufacturing system.
Allows p. To be made on high quantities
Henry ford pioneered this to reduce times
‘Line’ to linear matter of most production lines
Eg CARS, Robin day pp chairs, CLOTHING, PHONES, Tv, ready meals, IKEA Billy book cases
UPS unit production systems AO What materials is this system used on Name 4 qualities or ADV of this What does it do What does it reduce, what does it optimise and what does it improve
Used in textiles
Uses an overhead transporter system (that is efficient, organised, synchronised and CNC controller)
This uses hanging carriers to convey the garment components between work stations
Reduces handling operations, Optimises labour and equipment use, improves quality
Some bs u gotta mem
QRM Quick response manufacturing
What is it and what does it reduce
Lead times Def
Why is it necessary to reduce lead times and hence completion of designs & development
What 3 things are given priority during the process
Is a manufacturing strategy for reducing lead times
Lead time = time taken to respond to orders, must be short
Rapid completion of design & development necessary to reduce delays
CREATIVITY, QUALITY, CUSTOMER NEEDS given high priority during process
Vertical in house production
Def?
Outsourcing Def
What does verticle in house reduce the need of
What must factories be able to now do if they employ VIH
ADV? Price supplier ipr qa
DIS? Ask sir
Means that company owns/is the supplier Making complex products involves decisions regarding sourcing parts and sub systems Outsourcing = using external suppliers Verticle in house reduces need for this Therefore factories must be able to make all components required ADV: Reduce risk of PRICE increase Reduce risk of SUPPLIER going out Improves IPR protects band - mem QA easier to implement - mem
DIS:
Specialisation reduced, diluting expertise?
Increased administration?
Reduced flexibility?
Efficient use of materials
Waffle :
Cost effective + profitable manufacturing depends on? 2 things
Scale of production governs how ….?
What can CNC provide
What can premade elements improve in manufacturing
Cost effective + profitable manufacturing depends on efficient use of materials and most appropriate selection of manufacturing methods
Sustainability important
Scale of production governs decision on how p. made
CNC systems provide flexibility in responding to customers requirement
Pre made elements can improve efficiency of manufacture
Materials, cost, form, manufacturing processes and scale of production
How can thinner material impact manufacturing
How can large scale of manufacture impact cost
LOOK at tables in revision guide for how spec for product can dictate material used:
What preferred material and justification and interior material for:
Drill. Hinged lid for freezer container.
TABLE on relationship between material, cost, form, manufacturing processes and scale: consider how these affect manufacture costs:
High cost of moulds
Low skill and high skill work
The spec for product dictates material
Thinner material reduce cost but safety must be considered
Large scale manufacture can benefit from economies of scale
Drill - HSS cuz it retains sharpness, better at High temps than high carbon steel, long lasting
Hinge- pp used cuz better then HDPE at low temps, excellent fatigue resistance, very good mould flow.
In table consider:
High cost of mould, need to recoup this investment with sales, takes time
Low skill need to use jigs
High skill need for welds
Design and the economic use of materials
How can software be used to use materials more economically
How can standard size parts be more economical
How are rotation, blow moulding, and the use of I beams and cellular beams more economical
What do modern furniture use in terms of structure to be more economical
How has glass been made more economical
Software used to plan how parts can be ecenomically nested in 1 sheet to reduce waste and unusable cut offs
Use standard sizes of boards, metals etc to avoid wastage and additional machining
Rotation and blow moulded p. use 1 piece, min amount of material possible, and are strong
I beams and cellular beams(with holes) are strong and use min material
Modern furniture use lightweight elastic steel or wood frames and suspended seats rather than traditional materials and labour intensive upholstery
Amount of raw material in glass bottles reduced by 30% by reducing thickness
Manufacturing process that increase accuracy and reduce waste:
Accuracy and uniformity of components are needed for effective function and seamless integration with other design elements.
How does this apply to Car engine parts? And KD fittings?
What do automated machinery use to make the same product again and again?
When may cnc machines require flexibility
Car engine parts must fit perfectly to function and allow easy maintenance and repair
KD fitting holes must be aligned perfectly to allow construction
Lack of accuracy of thickness of soft drinks =incorrect capacity and screw top dimensions must be within tolerance to ensure effective seal
Automated machinery use cams and levers to make many identical components eg screws. Flexibility is unnecessary in this situation
CNC machines are used for flexible automated production when a range of parts are needed in a short amount of time
Comparing bulk and one off
Give 5 KW associated with one off .
Explain bulk and how it may be viable
How can CAD/CAM allow for personal touches and individual specs for a product without being as expensive as bespoke 1 off production.
One off = bespoke skilful labour intensive expensive individually specified
Bulk is large quantities so automated manufacturing techniques become viable and bulk purchases reduce costs
The IKEA Billy book case good eg of bulk production.
CAD CAM facilitates mass customisation of p. such as sports shoes, cars, computers, ordered online and allows for personal touches and individual specs without being as expensive as bespoke one off
The use of computer systems to plan and control AO
What is the main thing used to organise everything
What is always readily available that shows schedules and operations
Which 2 things facilitates the quick reliable transfer of data on stock info and what else does it do
What improves retail security
PLANNING and CONTROL software used too organise complex manufacturing processes
SPREADSHEETS and CHARTS always available to give overview of schedules and operations
Barcodes and RFID(radio frequency identification) facilitate reliable transfer of components and stock info.
Improves speed of response to demand changes
IC (intergration circuits) in rfid tags improve security in retail
Industrial manufacturing systems and their users in the production of given products
AO Modular/cell production
What does it do/what does a cell do and make
What are AGV vehicles and what do they do
What do robots do and what’s special about them
How are they linked with the CNC machines to work with them effectively
It combines CNC machines in a group.
The cell is programmed to get carry out a sequence of operations to make parts, eg engine components
AGV (automated guide vehicles) transport parts to and from buffer zones
Robots with 6 axis if movement load and unload machines
These devices are programmed along with the CNC machines
JIT Def What is this ideal for? Products and services What do jit strategies include: Management meetings supplier stock ECS 1 dis Give 6 or strategies used
Just in time production/lean
It is organising the manufacture of products rather than stockpiling and hoping for sales
This is ideal for multiple configuration products eg vehicles, pc, also ideal for fast food
Jit strategies include:
Increased management and worker cooperation
Regular feedback meetings
Careful selection of suppliers that are close to plant
Reduced waste and stock
Optimised layout of machinery
Visual or electronic control systems used
Dis: depends on reliability of suppliers and transport infrastructure
Higher quality, ‘first time right’ approach, reduction of waste, continuous monitoring, manufacturing improvements, error reduction strategies used.
Jit Harley Davidson
What was the result of too many struck pilled items, 3
What did jit enable Harley Davidson too do
Motorcycle company used jit Too many stockpiled items resulted in: Higher than necessary materials cost Massive storage requirements Damaged and redundant stock
Jit allowed Harley to react flexibly to customer requirements, so motorcycles only made when order recieved
