1.6 Modern and Industrial Scales of practice

Question 1

one off

Answer 1

A product designed for a unique situation, using a highly skilled worker. More expensive because takes a long time and no economy of scale, client consultation is required.

Question 2

batch

Answer 2

Where the manufacture of products is carried out simultaneously on a number of products in order to make the process more efficient. Jigs and fixture and other aids will be used alongside manual and cnc machines.

Question 3

mass

Answer 3

The production of large quantities of a standardized article by an automated mechanical process

Question 4

Division of labour

Answer 4

The efficient organisation of a workforce so that individuals specialise in particular manufacturing tasks.

Question 5

Unit production systems

Answer 5

The use of overhead transporters for component transfer between workers to improve factory efficiency. Often computer controlled.

Question 6

Quick response manufacturing

Answer 6

The use of mainly computer-based technology to facilitate efficient competitive product of low-volume customised products.

Question 7

Vertical in-house production/ Vertical integration

Answer 7

The organisation of manufacture to reduce the dependence of externally sources parts and sub-assemblies

Question 8

Advantages of verticle in house production

Answer 8

Reduced risk of unexpected price increases for components
Less reliant on suppliers
Protection of brand and intellectual property rights (IPR)

Question 9

Dis-Advantages of verticle in house production

Answer 9

Reduction in specialisation, leading to the dissolution of expertise.
increased in administration
decrease in flexibility

Question 10

Modular/Cell production

Answer 10

Used to combine a number of CNC machines in a group. A CNC module or cell can be programmed to carry out a sequence of a number of CNC machines.

Question 11

JiT manufacture

Answer 11

The manufacture of products as needed in response to existing orders

Question 12

Flexible manufacturing systems

Answer 12

Production using work cells of CNC machines and robots that can be used to make a wide range of different products, typically one-off bespoke items or in small batches

Question 13

Standardised Components

Answer 13

Parts such as screws and light bulbs that are made to a common standard to ensure interchangeability

Question 14

Bought-in Components

Answer 14

Product parts that are sourced from external suppliers rather than being manufactured in-house.

Question 15

Examples of Changing standards that caused compatibility problems

Answer 15

Apple removing 3.5mm headphone jack
Cameras using different types of batteries so older batteries cant be used.
Removal optical drives on laptops so DVDs can’t be used.

Question 16

Sub-Assembly

Answer 16

A self-contained element of a product that is made separately and incorporated in the final assembly stages

Question 17

Line Production

Answer 17

The manufacture of a large number of products in factories set up so that processes can be efficiently carried out by workers and teams organised in a specific sequence.

Question 18

Strategies used to implement JiT

Answer 18

Increased consultation, discussion and co-operation between management and workers
Regular feedback meetings to ensure continuous improvement
Reduction of waste and stock (muda)

Question 19

Computer integrated manufacture

Answer 19

The efficient use of computer systems to control all the stages if bringing a product to market from design.

Question 20

Advantages of bought in components

Answer 20

Be bought in bulk, reducing unit cost
Reduced cost for setup their manufacturing facility
There will be a greater level of consistency
Time will be saved

Question 21

Example of how a CNC cell would operate for a drive shaft

Answer 21

1. Low carbon steel is delivered by an AGV and loaded by a robot
2. Turned by a CNC lathe
3. A robot transfers the part to the next machine
4. Grooves and flats are smoothed by a CNC milling machine
5. A robot transfers the next part
6. Smoothed by CNC grinder
7. The finished part is removed by robot and ready for transfer by AGV

Question 22

Why are AGV’s used

Answer 22

Makes it possible to use space very efficiently and facilitates round the clock production

Question 23

JiT process for a car

Answer 23

1. A customer configure the car on a website to select all option for the vehicle
2. The information is digitally transferred to the cars manufacturers planning and control software that generates the order and organises necessary parts and places the manufacturing process in an available time slot.
3. The lead time generated by the software and is given to the user by the dealer.
4. Manufacturer of the vehicle commences with an RFID tag is used as an electronic tag to ensure correct parts are available and appropriately assembled as the vehicle proceeds along the assembly line.
5. The car is delivered to the local dealer on a transporter software planning an optimum schedule or economical delivery.