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AQA A level Product design p2-Designing and making principles > //2.9-Design for manufacture and project management > Flashcards

//2.9-Design for manufacture and project management Flashcards

1
Q

What things allow for successful planning of accurate and efficient manufacture of products

A
  • detailed design spec-facilitating testing throughout design process
  • evaluation of manufacturing accuracy required
  • clear production schedules with appropiate QC inspections
  • pre production QA
  • prototype production accuracy QC checks
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2
Q

What is quality control

A

monitoring, checking and testing procedures using throughout production, specified by the strict guidance documentation of client requirements

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3
Q

What is quality assurance

A

procedures and policies which ensure that products meet specification criteria

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4
Q

Name a few ways that pre production QA procedures ensure accuracy

A
  • CAD stimulations, a variety of modelling techniques and cost calculations
  • working drawings with tolerances
  • client feedback, peer reviews, focus groups and surveys
  • templates, jigs, fixtures
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5
Q

Name some ways prototype production accuracy QC checks can be used in conjunction with client feedback

A
  • visual aesthetic checks
  • dimension and machine tool checks using verniers, micrometers
  • checks of component fit and quality of finish
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6
Q

Decisions that are made regarding the strategy for ensuring the accuracy of commercially produced products will mainly depend on factors such as…

A
  • the scale of production
  • the particular manufacturing methods used
  • the type of products being made
  • the skill level of the workforce
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7
Q

Example of small scale production-bespoke furniture/musical instruments

A
  • slight inaccuracies-add to bespoke nature
  • attention to dimensional accuracy essentialfor critical, functioning elements
  • range of measuring devices such as gauges
  • templates-marking out of instrument bodies
  • traditional tools e.g. jack planes for furniture manufacture for hand/eye co-ordination
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8
Q

Example of medium scale production-batch production of aircraft/prestige vehicles

A
  • extensive use of jigs and fixtures for consistency in batch
  • relaince on high skill levels and use of sophisticated measuring devices
  • batch production facilitates effective ‘first right time and every time’ monitoring
  • high accurate CNC machinery utilised
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9
Q

Example of large scale production-mass production of glass or polymer drinks bottle

A
  • sample testing of dimensions and other important elements during/after manufacture
  • constant monitoring of processes-for zero fault regime
  • effective machine tool maintenance, replacement and alignment procedures
  • mould replacement cycle for inevitable wear
  • need for regular checking for weights and measure legislation complaince
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10
Q

Examples of QA procedures and policies to ensure products are ‘right first time and everytime’

A
  • materials and components from ISO 9001 Quality Management Standard suppliers
  • checking correct temperatures for effective cavity fillng
  • rigid machinery and cutter maintenance schedules
  • pre production CAD modelling to check fit and assembly
  • finite element analysis to analyse effect of stresses
  • MDF to predict material flow
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11
Q

What is total quality management

A

a system to improve QA by harnessing workforce expertise

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12
Q

How does total quality management improve efficiency and reduce waste

A
  • aims to remove waste and make products right first time by continuous improvement
  • workforce’s views, feedback, teamwork and communication are prioritised
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13
Q

What is scrum

A

the use of workforce teans to respond quickly to issues in product design and manufacture

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14
Q

How does scrum improve efficiency and reduce waste

A
  • team goals are specified and individuals feed back progress at daily update meetings
  • regularity of feedback meetings facilitates quick response to issues that arise
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15
Q

What is Six Sigma

A
  • system for process improvement to reduce defects to fewer than 3.4 in every million
  • procedure monitors, assesses and improves each stage of design and manufacture
  • 5 stages-DMAIC
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16
Q

5 stages of Six Sigma-DMAIC

A

1) Define the issue requiring improvement
2) Measure the extent of the issue
3) Analyse where the measured issues occur
4) Improve by introducing rectification procedures
5) Control the modified procedures though effective QA

17
Q

What is a critical path analysis-CPA

A

anaysis of stages in a project to ensure time-efficient completion

18
Q

Stages in CPA

A
  • a sequential order of tasks is established for a project or process
  • uneccessary waiting time identified
  • parallel processing opportunities exploited for maximum efficiency
19
Q

Process for a singke workeer manufacturing a wood sign

A
  • cut wood
  • set up wood on router
  • shape the sign on router
  • remove sign from router
  • this continues right until the end with total time
  • each task may depend on another e.g. setting up the wood on router depends on cutting the wood
20
Q

CPA for manufacturing a wood sign

A
  • A5-cut wood to size
  • B5-set up wood on router
  • C15-shape sign on router
  • A indicates the task, nuber indicates the time
21
Q

Why is a red line used in CPA

A
  • this indicates the minimum time
  • it shows that optimum organisation of manufacture could achieve a reduction
  • this is because parallel processes are undertaken during CNC manufacturing, as there is the availability of multipple workers and the use of sub assemblies
22
Q

How can compliance of materials with the manufacturer’s specification be checked

A
  • simple visual checks
  • chemical analysis of samples
  • colour matching for pigments or paints
23
Q

How can dimensional accuracy be checked

A
  • use of digital measuring devices e.g. micrometers

- interval sample testing in a QC department

24
Q

What is tolerance

A

the level of accuracy acceptable in a particular situation

  • depends on the material used for parts, as well as size and function
  • fine tolerances important when interchangeability of parts required
  • expressed as X±Y (X=exact size, Y=allowable error)
  • components not within tolerance rejected by QC/QA measures
  • go/no go gauges check specific tolerances in mass
25
Q

How can a go/no go gauge be used for quality control

A
  • these check a single measurement for tolerance range, with a pass/fail reading
  • gauge is made with minimum and maximum dimensions so it is easy to use
  • quicker than vernier calliper or micrometer as reading not required
  • no need for adjustment or recalibration
26
Q

4 different co-ordinate measuring machinery used for quality control measures

A
  • probe scanners-check predefined measurements. Highly accurate with automatic comparison with computer 3D CAD model
  • non contact lasers can scan thousands of readings per second
  • CMM used to check tooling accuracy for QA tool change procedures
27
Q

4 different digital measuring devices for quality control

A
  • digital vernier calipers/micrometers-readout of dimension being measured. These facilitate dimenional accuracy checks
  • ‘interval’ production line sample testing
  • vernier calipers-external, internal and depth measurement readings with ±0.02mm accuracy
  • screw thread- ±0.01mm accuracy
28
Q

What is non destructive testing and the two stages

A
  • carried out on products. Product not destroyed during testing. Used to find defects in the material
  • ultrasonic (sound waves, different sounds indicate faults)
  • x ray (x ray beam passes through material amd image projected onto a display screen
29
Q

Example of monitoring, checking and testing-glass container-customer specifications

A
  • type and clarity of glass to be used

- volume of liquid to be held, overall sie and closure type

30
Q

Example of monitoring, checking and testing-glass container-concept development

A
  • lead time reduced by concurrent approach

- use of 3D CAD software linked to rapid prototyping machines

31
Q

Example of monitoring, checking and testing-glass container-mould design and sampling

A
  • 3d CAD integrates standard parts and machine size constraints
  • production machine settings and maintenance schedules
  • go/no go gauges and fixtures prepared and checked
  • sample moulds checked
32
Q

Example of monitoring, checking and testing-glass container-production

A
  • sample testing of raw materials
  • furnace temperature monitoring to ensure correct viscority
  • container checked, using camera analysis
  • visual checks for flaws and correct flow and thickness of glass

AQA A level Product design p2-Designing and making principles (13 decks)

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