design for manufacture and project management

Question 1

what do designers halfto ensure that the product they desighn is….

Answer 1

to mmet the vustomer and legal requirements
can be produced with equipment and technology avalable
can be produced on a budget
can be produced within the required time scale

Question 2

what dose PDS mean

Answer 2

product design specification

Question 3

what would teh desighner do if they needed ±0.0001 acuracy

Answer 3

they would outsorce to somone who can
or
lower their standards

Question 4

what needs to happen for sucsessfull manufactore

Answer 4

a clear schedual of production with deadlines
QC imbeded into the process
type of inspecition depends on the scale of production

Question 5

accuracy of prototype designs: pre production

Answer 5

CAD simlations (FEA,CFA)
working drawings with tollerance
mock up models and mechanical systems
client feedback
peer riview

Question 6

accuracy of prototype designs: production

Answer 6

visual aesthetic checks
appropriately accurate dimensional checks
machine tooling and alignment checks
assembly checks of multiple components
quality checks of manufactured finish

Question 7

testing during scales of manufactor: pre-production

Answer 7

CAD simulations
working drawings with tollerence
sample prototypes
templates, jigs, fixtures
focus groups and survays
NDT and destructive testing

Question 8

ensuring acuraccy during slaces of production: production

Answer 8

visual asthetic cheaks
sample dimension cheaks
tollerence dimenion cheaks
machene tools and alighnment callabrators
machene tooling replacements
specific sampling and requirement cheaks
cheaks of quality in the final finish

Question 9

what is QA

Answer 9

quality assurance id the procedures and policies put into place to reduce waste and ensure manufactored products are produced accurately within set tollerences

Question 10

some examples of QA policies some companys may follow

Answer 10

only sourcing from companies with an ISO 9001 quality management standard
setting specific temp ranges
setting rigid maintenance schedules for machinery to ensure machinery is within tolerance

Question 11

what will happen if QA increases

Answer 11

QC issues and waste will derease

Question 12

what CAD and CAE is used in QC

Answer 12

CAD softwears to cheak the models and iff tehy fit
FEA
CFD computational fluid dynamics

Question 13

what do moulds have to help aid furthure QA

Answer 13

base of glass bottles have the number of the mould they have been produced in
this is so if there is a product falier then it can be traced back to the mould

Question 14

what is TMQ

Answer 14

total quality management

Question 15

what are the project managagement systems

Answer 15

total quality management
scrum
six sigma
lean manufactor
lean six sigma

Question 16

TQM

Answer 16

total quality management
a project management system focusing on QA through the full involvement of the workforce in continual improvement

Question 17

scrum

Answer 17

agile manufactor
working in a team to meet short time scales “sprint”
work on a specific team goal and attends daily meetings
they can quickly respond to customer feedback due to daily team meetings

Question 18

six sigma

Answer 18

set of techniques and tools desighns to minimise defects
the aim to reduce defective products
includes a DMAIC procedure

Question 19

what is a DMAIC

Answer 19

Define- the issue in the process
Measure- take steps to measure the extent of the issue
Analyse- determine where the issue measure occured
Improve- intoduce procesures to rectify the issue identified
Control- ensure modification proceders are implamented and maintained throught effective QA

Question 20

whats six sigmas main target

Answer 20

reduce cost or increase profets

Question 21

lean manufactor

Answer 21

a systamatic approach to production which aims. to eliminate waste from production. waste is defined as anything that dose not benefit the client and is given the name “muda”. there are 7 forms of muda defined as TIMWOOD

Question 22

lean manufactor : what dose TIMWOOD stand for

Answer 22

transport
inventry
movement
waiting
over production
over processing
defects

Question 23

lean manufactor : T

Answer 23

transport
when a product is being transported its at risk of damage
reduction of transport distance reduces risk, damage, delay and energy

Question 24

lean manufactor : I

Answer 24

inventory
the main aim of JIT manufactor is to reduce inventory on site at any time. any stock on site is at risk of dammage or loss of value

Question 25

lean manufactor : M

Answer 25

Movement unlike transport movement is about employese and their eqipment when asembling prodcuts unnesesary movemnt slows production rates and should be minimised

Question 26

lean manufactor : w

Answer 26

waiting if the process fo manufactor isnt split evenly there may be a “bottleneak” and leaves workers waiting for outhers to keep up.

Question 27

lean manufactor : O (1)

Answer 27

over production the main part of JIT is the lack of storage requirements. if manufactors over produce “just in case” extra storage will be required and the products may never be required for sale

Question 28

lean manufactor : O (2)

Answer 28

over processing select appropreate machenery justified for use e.g if a person was to buy a new iphone and not use all the fetures of the new phone they could have baught a lower model or cheaper one

Question 29

lean manufactor : D

Answer 29

defects any defective products to be removed this is key within six sigma relying on QA and QC

Question 30

what is lean sigma

Answer 30

by using both the DMAIC and TIMWOOD ideas together to create efficiency and good working practices

Question 31

What is CPA

Answer 31

Critical path ananlysis A project management method used to analysis all individual stages within a project and plan the effective time efficient completion of each element with desired schendual

Question 32

What need to be identified to create a CPA

Answer 32

The stages of the process Time needed on a stage Dependencies on outher sections to be completed

Question 33

When displaying a CPA its displayed as a three section circle with a branch off of it within the circle there are three numbers and on the off branch above the branch there is a letter and below a number what do they all mean

Answer 33

The left side of the circle - the number stage of process The upper right segment of the circle - EST of stage The lower right of the circle - is the LFT of the stage The upper letter on the branch - the numeral stage of the process The lower branch number - is the estimated time for the one process

Question 34

What approach would work well with CPA

Answer 34

Scrum

Question 35

What is QC

Answer 35

Quality controls The monitoring , checking and testing of materials, components , equipment and products through production to ensure they conform to acceptable tolerances It takes pace through the production process

Question 36

What are the material checks

Answer 36

Simple visual checks chemical analysis on small sections of materials (checking things such as moister) Colour matching

Question 37

Digital measuring devices

Answer 37

Veneer caliber or micrometer Done in interval sampling techniques Vernerir callipers have a ±0.01

Question 38

Go? No go gauge

Answer 38

Checking dimensional accuracy on mechanical parts such as gaps or holes or thickness within projects Gives a simple pass or fail reading Go is measured apart the widest tolerance and the no go gauge is measured the smallest tolerance Simple devices with little to no training Needed

Question 39

What’s a CMM

Answer 39

Co-ordinate measuring machinery E.g probe scanner, allows manufacturers to check a range of pre defined measurements on finished components (extremely high accuracy) Non-contact laser scanning - scans go strait to cad and are the highest level of accuracy

Question 40

Non-destructive testing

Answer 40

Methods to cheat internal structure of materials without destroying them this is such as welded items that would cause major harm if fracture was to occur Ultra sound and x-ray technologies are used for this Ultra sound is preferred

Question 41

Monotouring, checking and testing through production case study

Answer 41

Allied glass Produces 600m glass bottles per year for premium brands Use a wide range of QC

Question 42

Customer specifications: allied glass

Answer 42

Go though specification looking at size, volume, shape, aesthetics and liquids to be held in the container

Question 43

Concept development: allied glass

Answer 43

Design development is done in-house = reduced lead time New product development NPD team employs a concurrent approach guiding the customer through production limitations and presenting with models from paid prototyping

Question 44

Mould design and sampling: allied glass

Answer 44

CAD soft wear develops moulds to fit the parameters of the current machinery. The bottle has standardised components such at bottle neck allowing improved QA due to experience of tried and tested methods for those components

Question 45

Main stages of the testing rageme: allied glass

Answer 45

Working drawings with tolerance Sample prototypes Sample dimensions cheating using flexible measuring equipment Visual aesthetic checks Machine tooling and align meant collaborations Machine maintenance and tool replacement NDT and destructive testing Testing, fixtures and jigs Specific sampling regularity and procedures set by company or legal requirement’s

Question 46

Production: allied glass

Answer 46

QA checked through production Use diffent components need to make sure that the iron component isn’t to high as the bottle will turn green A lot of pre determened tolerances in heat etc Ability to switch out dies in machines

Question 47

QC testing: allied glass

Answer 47

Every container is checked by camera analysis for glass imperfections Every 1hr a bottle is taken from the production line for testing volumes, stress dimensions and several outher QCs