1.6-Manufacturing processes Flashcards
explain one-off production
custom made items
expensive
individual consultation and design work
more skilled workers likely required
manufacturing process has to be set up individually for each unique component
greater manufacturing time
no economies of scale
explain batch production
manufacturing procvesses are carried out simultaneously on a number of products for greater efficiency (e.g. jet engines, pottery)
jigs and fixtures
CNC machines
accurate and faster production
explain mass/line production
division of labour using a sequence of stages as a product proceeds through a manufacturing process. A production line allows a product to move between different manufacturing stages
explain unit production systems
used extensively in manufacture of textile products and are based on the principle of using an overhead transporter, incorporating appropriate hanging carriers, to convey the components that are required for the manufacture of a product. Can be manually or computer controlled and reduces the number of handling operations
explain quick response manufacturing
a strategy for drastically reducing the time between a product being a concept and being completed. Focuses on going through the design process and developing products to meet needs quickly as the design process usually takes a lot of time
explain vertical in-house production
the supply chain of a company is owned by that company. Minimises the need for external suppliers and organise their factories to include the facilities to manufacture every part of the product
what are the advantages and disadvantages of vertical in house production?
protection of IPR
easier QA
less risk of unexpected price increase for components
less risk of suppliers going out of business
reduction in flexibility
less specialisation
What are RFID tags?
radio frequency identification tags are used to facilitate the transfer of info relating to components and stock to and from computer systems. They contain a small integrated circuit (IC) that can communicate info in both directions when used with a scanner and provides security against theft. Barcodes are easier to read than text when scanned at an angle
explain modular/cell production
computer controlled manufacturing cells are set up to combine a number of CNC machines in a group. This group known as a CNC module/cell can be programmed to carry out a sequence of operations on a number of CNC machines. Loading material, transferring work pieces and moving the final product is carried out by a robotic arm. When longer distances are involved, AGVs are used
what is an AGV?
automatic guided vehicle
explain JIT manufacture
manufacture of products is made to order so that stock levels are kept at a minimum and waste is reduced. Useful for products that can be bought in different configurations
explain the strategies used to implement JIT manufacturing
increased consultation between management and workers
regular feedback meetings to ensure improvement
selection of suppliers in close proximity to the factory
reduction of waste and stock
optimisation of machinery configuration and layout
stock labelling items which gives instant visual/electronic indication of current levels
what is Kanbans?
stock labelling items which gives instant visual/electronic indication of current levels
explain quick response manufacturing
makes extensive use of CAD, rapid prototyping with 3D printers in the development stage, flexible manufacturing cells and multi-skilled workers. It builds on JIT, six sigma, and TQM. Particularly appropriate for companies producing low volumes of products that have elements of customisation.
explain flexible manufacturing systems
makes use of extensive modular/cell production and other systems that facilitate easy transfer of production from one part or product that is being made, to another. This makes it possible to quickly respond to changes in demand. Uses single minute exchange dies that allow the changing of dies in a machine very quickly in response to demand.
what are SMED
single minute exchange dies (dies and moulds can be changed in less than 10 mins)
how are computer systems used for production, distribution and storage?
inventory tracking with RFID
software to plan optimal loading patterns for freight containers
EPOS to record sales and feed this to warehouses for restocking
what is CIM?
computer integrated manufacture
benefits of bought in components
can be bought in bulk (lower cost)
no need to set up your own manufacturing facility
high consistency
saved time
what is sub-assembly?
a self contained element of a product that is made separately and incorporated in the final assembly stages
