8 Features of Manufacturing

Question 1

What are the 4 scales of production

Answer 1

One-off
Batch
Mass
Continuous

Question 2

What are the advantages and disadvantages of one-off production

Answer 2

Fully customized to individuals needs, very high flexibility, no expensive commitment to mass production, materials can be chosen

High cost, no high production volume, significant hand finishing required

Question 3

What are the advantages and disadvantages of batch production

Answer 3

Cost saving to buying materials in larger quantities, some flexibility in production, reduces risk of large investments for equipment, faster than one-off

Products can’t be fully customized, finish quality and complexity is limited, relatively slow, quality of finish and complexity is usually less than mass production

Question 4

What are the main batch production techniques to make sure the products are the same

Answer 4

Jigs
Templates
Molds
CAD-CAM
Vacuum forming

Question 5

What are the advantages and disadvantages of mass production

Answer 5

Very high cost saving due to limited wastage and scale of purchases, very fast production cycle, low labor skill required, high production quality, mass production techniques enables more complex shapes

Very expensive investment in machinery, highly skilled labor required to make molds, little/ no flexibility, unable to customize product, not appropriate for certain materials (e.g. woods), machinery dedicated to product

Question 6

What are the main mass production techniques

Answer 6

Pressure Die Casting
Injection Molding
Rolling
Extrusion
Blow Molding
Friction Welding

Question 7

What is a go/ no-go gauge

Answer 7

A measuring device that is able to see whether the component is within the specific minimum and maximum tolerances allowed

Question 8

What 6 aspects might you consider in quality control

Answer 8

Materials
Finish
Dimensions
Function
Assembly
Safety

Question 9

What is quality assurance system

Answer 9

This is a overview of the whole quality process - from choice of materials, manufacture techniques, checks and customer support

Question 10

What are quality assurance techniques

Answer 10

These are the specific techniques used to try and manufacture products consistently to the required standard of quality

Question 11

When ensuring the quality of a product for a customer what are the 3 main expectations

Answer 11

Price
Performance
Aestetics

Question 12

What is a Quality Indicator (Q.I)

Answer 12

A factor by which quality can be measured

Question 13

What is Quality Standard (Q.S)

Answer 13

A value or attribute specified for that indicator (Q.I)

E.g. Technical drawings, work instructions, check sheets, quality tools

Question 14

What is Tolerance

Answer 14

The acceptable margin of error

Question 15

What are Critical Control Points (CCPs)

Answer 15

Points during the process where QC occurs

Question 16

What is ISO

Answer 16

International Standards Organisation
Not a regulatory or enforcing body
Companies have to apply, are assessed and are then certified
Globally respected

Question 17

What are the advantages of having ISO 9001

Answer 17

Promotes quality and safety in procedures/products
Promote product/system compatibility
Encourage/facilitate international trade
Enhances reputation of organisation
Allows for trade with other ISO 9001 certified organisations

Question 18

What 2 marks can be put on products if they meet standards of the testing institutions

Answer 18

Kitemark- British standards

CE- European standards

Question 19

What does TQM stand for

Answer 19

Total
Quality
Management

Question 20

What is TQM

Answer 20

A system of management based on the principle that every member of staff must be committed to maintaining high standards of work in every aspect of a company’s operations

Question 21

What does AGV stand for

Answer 21

Automated
Guided
Vehicles

Question 22

What does ASRS stand for

Answer 22

Automated
Storage
and
Retrieval
System

Question 23

What are the advantages and disadvantages of AGV’s

Answer 23

Reduced labor costs, increased safety, increased accuracy and productivity, modularity

Potentially high initial investment, maintenance costs, not suitable for non-repetitive tasks, decreased flexibility

Question 24

What are the advantages and disadvantages of ASRS’s

Answer 24

Accuracy, efficiency, productivity, volume utilization

Requires customization, expensive to install

Question 25

What does JIT stand for

Answer 25

Just In Time

Question 26

What is a JIT system

Answer 26

The just-in-time (JIT) inventory system is a management strategy that aligns raw-material orders from suppliers directly with production schedules. The JIT inventory system contrasts with just-in-case strategies, wherein producers hold sufficient inventories to have enough product to absorb maximum market demand

Question 27

How do are companies like Land Rover use JIT

Answer 27

Factory only holds 4 hours of manufacturing stock at once Lorries park up next to each part of the factory so it can be unloaded straight onto the production line Suppliers only have 30 minutes to unload before the next lorry arrives The supplier isn't paid till the lorry is on site to make sure it arrives at the right time

Question 28

What is Flexible Manufacture Systems

Answer 28

Manufacturing systems that have been set up that allow a company some degree of flexibility to enable it to react to, and then investigate, changes fairly rapidly to the manufacturing process

Question 29

What is machine flexibility

Answer 29

Systems ability to change to produce new product types | Ability to change order of operations

Question 30

What is routing flexibility

Answer 30

Ability to use multiple machines | Ability to absorb changes such as capacity and capability

Question 31

What does TIMWOOD stand for

Answer 31

``` Transportation (of materials) Inventory Motion (of works/equipment) Waiting Over-processing Over-production Defects ```

Question 32

What is Kanban

Answer 32

Kanban is a visual system for managing work as it moves through a process. Kanban visualizes both the process (the workflow) and the actual work passing through that process. The goal of Kanban is to identify potential bottlenecks in your process and fix them so work can flow through it cost-effectively at an optimal speed or throughput

Question 33

What is the kanban method

Answer 33

1. Visualize workflow 2. Limit work-in-progress 3. Manage flow (By seeing what you have to do and have already done, efficiency within workers is increased)

Question 34

What is lean manufacturing and what are the advantages

Answer 34

Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity. The benefits of lean include reduced lead times, reduced operating costs and improved product quality

Question 35

What are the advantages of quick response manufacturing

Answer 35

Reduced time to market (lead time) which in turn has the following benefits: The ability to keep up with trends/fashion/demand/orders, Increased Market Share (ability to capitalize on early interest and orders that require a short turn around), Recoup money quickly and improve cash flow Allows customization/flexibility/adaptability Reduced retooling costs (due to FMS) Labor costs reduced (due to automated nature of FMS) Reduced human error/waste ((due to automated nature of FMS) Storage costs reduced (due to JIT) Ultimately it should therefore encourage repeat business (due to improved customer satisfaction, confidence and improved reputation)

Question 36

What is quick response manufacturing

Answer 36

Quick response manufacturing is a concept whereby business set up their design and manufacture to allow them to respond to changes in their market and customer requirements with minimal delay

Question 37

What is Enterprise Resource Planning

Answer 37

Enterprise Resource Planning is a system that helps companies integrate and manage all their financial, supply chain, manufacturing, operations, reporting, and human resources activities.

Question 38

What is Product Data Management

Answer 38

Product Data Management is the use of software to manage product data and process-related information in a single, central system. This information includes computer-aided design (CAD) data, models, parts information, manufacturing instructions, requirements, notes and documents. The ideal PDM system is accessible by multiple applications and multiple teams across an organization.

Question 39

What is over the wall designing

Answer 39

During the industrial revolution, technology became more complex. The complexity forced forced employees of companies to specialize in different areas of the product design process. No longer could one person be responsible for the design, manufacture and sales of a product. The era of the craftsmen gave way to the era of the specialist. Large companies began to organize their into departments with different responsibilities. Each department worked on a product until they had completed their tasks and then they handed off the project to the next department. Not only was this serial process very slow but it also caused many problems when the communication between departments broke down. The breakdown of communications led to projects being thrown back over the walls that divided the departments for rework.