2.9 Design for Manufacture and Project Management Flashcards
(18 cards)
Give some pre-production QA procedures used to ensure accuracy
CAD simulations
working drawings with tolerances
mock-up models and mechanical systems
client feedback
peer review
jigs and fixtures
sample prototypes
Give some QC checks carried out during production of a prototype
visual aesthetic checks
dimension checks
machine alignment checks
assembly checks
finish checks
destructive and non-destructive testing
What is QA?
the procedures and policies put in place to reduce waste and to ensure manufactured products are produced accurately within set acceptable tolerances
Name 3 project management systems
TQM, scrum, six sigma
Explain TQM project management
total quality management aims to remove waste and produce products right the first time. Companies using TQM strive for continual improvement. They value the views of the workforce to contribute to the overall effectiveness of the production process. All procedures are clearly communicated to the workforce, and the understanding of these is essential.
Explain scrum project management
the main focus of Scrum is to work in a team to reach goals in short timescale ‘sprints’. The team works on the specified goal and attends daily scrum updates where individuals feed back on progress as well as any issues. The distribution of tasks can be updated based on these issues, and the team can quickly respond to changing customer demand due to the regularity of feedback meetings
Explain six sigma project management
introduced in the 1980s by Motorola, the six sigma system is a set of techniques and tools for process improvement which is designed to minimise defects. The aim is to reduce the number of defects to less than 3.4 in every million. It requires the implementation of a DMAIC procedure to asses and improve each stage of the design and manufacture activity. Each six sigma project has a specific target (e.g. reduce costs)
What are the 5 key stages of six sigma? (think DMAIC)
Define-what is the issue with the process
Measure-Take steps to measure extent of the issue
Analyse-determine where the issues measured occur
Improve-introduce procedure to rectify the issues identified
Control-ensure the modified procedures are implemented and maintained through effective QA
What is lean manufacture?
a systematic approach to production which aims to eliminate all waste from product production. Waste is identified as anything that does not benefit the client and is given the name muda. There are seven forms of muda, which are given the acronym TIMWOOD
What are the seven forms of muda? (think TIMWOOD)
Transport-reducing the distance a product is transported reduces the risk of damage and delay in production
Inventory-any stock on site is at risk of damage or loss in value so inventory should be minimal
Movement-unnecessary movement of employees and equipment increase production time
Waiting-if processes are not split evenly in regards to time then products or workers may be working for others to catch up
Over production-this requires extra storage and may result in wasted investment if the products don’t sell fully
Over processing-the correct equipment should be used for each manufacturing process and any investment must be justified
Defects-any defective products must be removed
explain lean six sigma
DMAIC approach of six sigma is a structured framework to reduce variation in performance whereas the TIMWOOD waste reduction strategy of lean manufacture gives clear guidance on the forms of inefficiency to address . By combining both strategies, companies can improve operational and manufacturing efficiency
What is the difference between lean manufacturing and six sigma
lean is about speed and efficiency (getting rid of waste)
six sigma is about making sure the product is always perfect (getting rid of defects)
What is critical path analysis?
a project management method used to analyse all individual stages within a project, and to plan the effective and time efficient completion of each element within the desired schedule
What is QC?
quality control is the monitoring, checking and testing of materials, components, equipment and products throughout production to ensure they conform to acceptable tolerances specified
Explain some QC methods
material checks-visual, chemical analysis, colour matching
dimensional accuracy checks-using a digital vernier calliper, micrometre or go/no go gauge
What is a go/no go gauge?
a measurement device that checks whether a single measurement fits within a tolerance range, giving a simple pass/fail reading. It requires no calibrating or adjustment and doesn’t require the worker to check for an accurate reading
What is co-ordinate measuring machinery?
a probe scanner allows a manufacturer to check a range of predefined measurements on finished components with extremely high accuracy. Non contact laser scanners allow for thousands of readings per second
Give two methods on non-destructive testing
x-ray and ultrasound analysis
