Systems and Control

Question 0

QRM?

Answer 0

Quick response manufacturing

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Question 1

AMT?

Answer 1

Advanced manufacturing technology

Question 2

Quick response manufacturing - ADVANTAGES?

Answer 2

Lower working capital needed (stock minimised)
Quicker response attractive to potential clients - gain larger market share
Reduces cost of quality - minimises waste

Question 3

Quick response manufacturing - DISADVANTAGES?

Answer 3

More reliance on suppliers to react to demand - poor supply could result in inability to meet demand
Large demand changes can cause problems - may be unable to high production volume efficiently
Requires role changes - may cause friction

Question 4

Concurrent manufacturing?

Answer 4

-

Question 5

House of quality?

Answer 5

Customer requirements - list of requirements (surveys etc)
Technical requirements - measurable product characteristics
Planning matrix - importance of requirements and competitor performance
Interrelationship matrix - relationship between customer and technical requirements
Technical correlation - if technical requirements compromise design
Technical priorities / benchmarks / targets - quality targets against specification measured

Question 6

FMS?

Answer 6

Flexible manufacturing systems

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Question 7

Flexible manufacturing systems - ADVANTAGES?

Answer 7

Increased productivity (automation)
Shorter lead time
Lower labour costs
Improved quality (automated)

Question 8

Flexible manufacturing systems - DISADVANTAGES?

Answer 8

High set up costs

Require lots of planning

Question 9

CIM?

Answer 9

Computer integrated manufacture
Systems that combines separate technologies - all teams can share information and communicate
Includes designing in CAD, planning most efficient workflow, controlling operations of machines, ordering stock and invoicing customers

Question 10

Computer integrated manufacture - DISADVANTAGES?

Answer 10

Dependence on computer data to integrate in operations - compatibility problems with different CIM brands
Data may become corrupt - cause machinery to malfunction (product data management system used)

Question 11

PDM?

Answer 11

Product data management systems
Manages product data passing from design to manufacture
Includes 3D models, CAD drawings, CNC programs etc
When change made to 1 database - changes everything (tracks changes)

Question 12

Product data management - ADVANTAGES?

Answer 12

Reduced time to market (data instantly available)
Improved productivity
Improved control - assures everyone working on latest version

Question 13

ERP?

Answer 13

Enterprise resource planning systems
Integrates all departments and data onto 1 computer
Links data from different departments together - all information needed instantly available (customer credit rating, product stock level, delivery schedule)

Question 14

Enterprise resource planning management systems - ADVANTAGES?

Answer 14

More information kept up to data without errors

Question 15

Enterprise resource planning management systems - DISADVANTAGES?

Answer 15

Expensive set up
Lots of training required
Dependent on all departments working together

Question 16

Lean manufacturing and JIT

Answer 16

No warehouses full of materials waiting to be used (arrive when needed)
Product produced when needed
JIT: right materials/components arrive at right time in the right amount
Reduces waste and overstocking = efficient
Relies on accurate data/forecasts - error could stop production

Question 17

5 stages of lean manufacturing?

Answer 17

Value - focus on what customer is prepared to pay for
Value system - 
Flow
Pull
Perfection

Question 18

Pull tools - Kanban?

Answer 18

Cards indicate when to ‘pull’ materials through production
‘Pull’: producing in response to demand
‘Push’: producing whether or not they’re needed
Production Kanban: operations to be carried out
Transportation Kanban: location it needs to go

Question 19

Kanban - ADVANTAGES?

Answer 19

Reduces number of work in progress products

Restricts supply until it’s needed

Question 20

Perfection tools - Kaizen?

Answer 20

Small changes made to production process to give improvements
Carried out on regular basis - continuous improvement

Question 21

Flexible manufacturing cells?

Answer 21

Grouping similar products into families - processed on the same equipment = manufacture sped up
Product progressively processed from 1 workstation to another
Modular - cell can be closed to be upgraded (another can take its place)

Question 22

Types of manufacturing cells?

Answer 22

Functional: perform specific function - cutting holes, milling
Group technology (mixed model): operations for different product lines
Product focused: focus on 1 product - manufactured through series of operations

Question 23

CAQ?

Answer 23

Computer aided quality control systems
Coordinate measuring machine (CMM) - accurate measurements:
-probe: touches surface to determine size
-optical/laser: checks size and creates 3D image
Optical character recognition: recognises writing
Barcode readers: ensure correct components go together

Question 24

Computer aided manufacture - ADVANTAGES?

Answer 24

Greater control over production - allows fully automated production No humans = safer working environment - less risk, lower costs, improved productivity, accuracy, fewer errors Flexible production - CNC machinery can be reprogrammed quickly (reduced set up) Production can be determined by demand - can react quickly Improved productivity and reliability - machines more consistent in maintaining high quality Reduced manufacturing time - most efficient production determined by software

Question 25

Computer aided manufacture - DISADVANTAGES?

Answer 25

Expensive start up cost Causes unemployment (less human involvement) Lower worker morale - machine babysitting jobs

Question 26

Automated material handling systems?

Answer 26

Transportation of materials and components Stages: unloading from truck, move to assembly line, testing etc Need specialist equipment for each stage (unloading requires fork-lift truck) Automated systems use robots and replace humans - work automatically (without significant intervention) Downsizes workforce

Question 27

ASRS?

Answer 27

Automated storage and retrieval systems Robotic system - sorts, stores and retrieves items in warehouse Computer controls transportation Stock stored in racking systems Selects correct component from rack, retrieve it by crane and place in conveyor/automated guided vehicle Lowers labour costs and gives employees skills to control system

Question 28

AGV?

Answer 28

Automated guided vehicle Moves parts between machines Independently powered vehicles guided by frequency wires buried in floor or laser guided navigation

Question 29

Automated guided vehicle - TYPES?

Answer 29

Towing - pull trailers Unit load - decks ...? Pallet - transport palletised loads (wood grid floor) Fork lift - lift loads at different heights Light load - transport light loads through light manufacturing environment (work in areas of little space) Assembly line - adaption of light load ...

Question 30

Impact of manufacturing technologies on employment?

Answer 30

Reduction of workforce - machines increasingly efficient Doesn't eliminate skilled professionals (product designers) Computers increase skill required - CAD etc Production lines have become more automated - staff need more skill flexibility (multi-skilled) Manufacturing is creative - everything needs to be designed (more efficient = save money or helping it sell more)

Question 31

Robots in automated manufacturing systems?

Answer 31

Computer systems control industrial machinery - replacing human operators Manipulates and transports parts/tools to manufacture More flexible than CNC machines Can assemble work and complete processes such as welding Equipped with sensory feedback (vision) Will intelligently work with humans to judge when it's safe to operate - to need for guards

Question 32

Levels of complexity of manufacturing robot tasks?

Answer 32

...

Question 33

Robots for manufacturing - ADVANTAGES?

Answer 33

Ideal for repetitive tasks requiring precision Used in hazardous environments not suitable for humans Can carry heavy loads Reprogrammable - flexible in responding to change Programmed once - used forever No human error (losing concentration) Work continually - cost effective

Question 34

Robots for manufacturing - DISADVANTAGES?

Answer 34

Can't learn or make decisions when the required data doesn't exist Not as flexible as humans - harder to program Very expensive Humans can't enter robot working areas (safety) High cost making robot cells safe Different robot brands work differently - maintenance crew need different specialist training for each No standard robot programming language - problems working between different brands

Question 35

Industrial applications of artificial intelligence?

Answer 35

Exhibit human intelligence | Learn and adapt through experience

Question 36

Expert systems?

Answer 36

Apply reasoning skills to reach a conclusion (process large amounts of data) Simulations generate realistic simulated worlds where design testing can be done (no physical prototyping) Combined with voice recognition - designers could talk to computer to solve problem (act as coworker)

Question 37

Autonomous robots?

Answer 37

Robots could learn the skills needed for any particular environment - rather than programming for each specific repetitive task Must manipulate and 'feel' objects like humans - typical robots have 6 degrees of freedom - perform small range of tasks Human type hands have 20 degrees and touch sensors with AI systems - decide best way to manipulate object

Question 38

Flow chart?

Answer 38

Schematic representation of a process | Indicates what should happen at each stage

Question 39

Open loop control system?

Answer 39

No feedback information on quality at each stage Process continues without interference from control system - even when output changes Can't detect / correct errors in the process Used in basic processes - low cost

Question 40

Closed loop control system?

Answer 40

Feedback makes decisions about changes to process Improved tracking of performance Early detection of faults Require no human intervention - automatic