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A Level DT > 1.6 Modern, Industrial and Commercial Practice > Flashcards

1.6 Modern, Industrial and Commercial Practice Flashcards

1
Q

economic use of materials

A
  • tessellation (reduce waste)
  • use of stock forms
  • one piece manufacture (strong, uses less material) (eg blow & rotational moulding)
  • minimised material use (eg I-beams- depends on being strong in certain areas so material can be reduced in other places)
  • modern furniture- light, elastic, steel/wood frames (uses elasticity for comfort rather than expensive upholstery)
  • reduction in material thickness (eg glass bottle)- FEA
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2
Q

scale of production (def)

A

consideration of the no. of products to be made, using particular manufacturing methods to suit a particular market

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3
Q

batch production (def)

A

manufacture of groups of products to increase efficiency and economy

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4
Q

division of labour (def)

A

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

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5
Q

line production (def)

A

manufacture of large numbers of products in factories set up so that processes can be efficiently carried out by workers/teams organised in a specific sequence

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6
Q

mass production (def)

A

manufacture of large numbers of products in factories that are usually highly mechanised

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7
Q

unit production system (UPS) (def)

A

use of overhead transporters for component transfer between workers to improve factory efficiency (usually in textile industry)

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8
Q

quick response manufacturing (QRM) (def)

A

use of mainly computer-based technology to facilitate efficient, competitive production of low-volume, customised products

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9
Q

vertical in-house production (def)

A

organisation of manufacture to reduce dependence on externally sourced parts and sub-assemblies

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10
Q

just in time (JiT) (def)

A

manufacture of products as needed, in response to existing orders

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11
Q

one off (bespoke) production (def)

A

design & manufacture of products to individual specifications

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12
Q

flexible manufacturing systems (FMS) (def)

A

production using work cells of CNC machines & robots that can be used to make a wide range of different products (typically one off/small batch)

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13
Q

modular/cell production (def)

A

use of groups of CNC machines robots & AGVs to facilitate efficient, flexible manufacturing

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14
Q

standardised components (def)

A

parts such as screws & light bulbs that are made to a common standard to ensure interchangeability

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15
Q

bought-in components (def)

A

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

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16
Q

sub-assembly (def)

A

self-contained element of a product that is made separately and incorporated in to final assemble stages

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17
Q

one-off (bespoke) production (more detail)

A
  • product required for a unique situation
  • more expensive
  • more difficult to produce
  • individual consultation with client required
  • more skilled workers needed
  • each process needs to be set up individually for each unique component
  • manufacture takes longer
    EG: wedding dress, custom yacht, chair for child with serious disability
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18
Q

batch production (more detail)

A
  • processes are carried out simultaneously on a number of different products to make processes more efficient & cost effective
  • jigs, fixtures etc used alongside manual & CNC machines (more accurate & faster)
  • EG: pottery, wooden furniture, jet engines
19
Q

mass/line production (more detail)

A
  • division of labour
  • Henry Ford created first large scale production line (model T could be produced in 1.5 hrs rather than 12.5)
  • cars- manufacture can be automated to increase efficiency
    EG: robin day PP chair, clothing, phones, self-assembly furniture
20
Q

unit production systems (more detail)

A
  • mostly in textile industry
  • uses overhead transporter system (hanging carriers convey components to workstations)
  • computer controlled (usually)
  • requires careful organisation & synchronisation
  • reduces number of handling operations
  • RFID used to track components around factory
  • live info allows bottlenecks to be identified
  • workstations left uncluttered
21
Q

quick response manufacturing (QRM) (more detail)

A
  • focus on going through design process and developing products as quickly as possible
  • needs of customer given high priority
  • allows response to market & customer with minimal delay
  • relies on:
    > concurrent design (manage development to ensure Right First Time)
    > flexible manufacturing systems (FMS)
    > JiT
  • reduced lead time:
    > keep up with trends/demand
    > increased market share
    > recoup money quickly & improve cash flow
22
Q

vertical in-house production (more detail)

A
  • supply chain is owned by company (manufacture own components instead of buying in)
  • organise factories to include facilities for manufacturing what they need
23
Q

vertical in-house production (advantages)

A
  • risk of price increase of components reduced
  • less susceptible to suppliers going out of business
  • protection of brand and improved security of intellectual property rights
  • easier to implement quality assurance strategies
24
Q

vertical in-house production (disadvantages)

A
  • reduced specialisation- potential to dilute expertise
  • increased admin
  • reduced flexibility
25
Q

white space (def)

A

time spent not working on the product

related to QRM

26
Q

methods which enable QRM?

A
  • CAD & CAM
  • rapid prototyping
  • flexible manufacturing cells
  • multi-skilled workers
27
Q

benefits of QRM to customer?

A
  • short lead time (without reducing quality)

- easy customisation of products

28
Q

systems needed to facilitate QRM?

A
  • RFID
  • CAD software, rapid prototyping machinery
  • CNC machinery (flexible)
29
Q

advantages of QRM?

A
  • reduced lead time
  • allows customisation/adaptability
  • reduced retooling costs (moulds etc can be produced in-house)
  • reduced labour costs (automated nature of FMS)
  • reduced human error & waste (automated FMS)
  • storage costs reduced (due to JiT)
  • encourages repeat business
30
Q

JiT (just in time)

A
  • components arrive just in time for production (saves warehouse space)
  • company only purchase what is needed
  • components MUST arrive on time
  • components need to be ordered when needed
31
Q

JiT (disadvantages)

A
  • if components are delayed whole production line held up losing time & money
  • if stock is not kept track of properly risk of running out, holding up production
  • more planning required to ensure products will be made in time
32
Q

kanban

A
  • controls flow & movement of materials & components
  • small consumable items (nuts, bolts, etc) kept in reusable bins, each bin has a barcode & barcode is scanned when removed from storage so more can be ordered
  • helps control stock
33
Q

modular/cell production

A
  • CNC cell is a group of CNC machines set up in a loop around the production line
  • parts are transferred between machines by robotic arms
  • AGVs (automatic guided vehicles) used to transfer parts long distances
  • linked using computer systems, synchronised using RFID
  • AGVs linked to modules so components arrive on time/AGVs not waiting for process to be finished
34
Q

SMED

A
  • single minute exchange dies
  • part of FMS
  • allow dies to be changed quickly (less than 10 mins)
  • facilitated by use of quick release locking devices & multi-purpose parts
  • before SMED machines would have been idle for hours while dies changed
    > increases efficiency
    > machines working for max time possible
35
Q

FMS (advantages)

A
  • allows for mass customisation
  • increased efficiency > more products made > more profit
  • shorter lead time (customers get products faster)
  • products cost less to buy due to faster production
36
Q

FMS (disadvantages)

A
  • high set up cost
  • specialist workers required > higher cost of labour/pay for specialist training
  • more planing time needed for most efficient use of machinery
37
Q

benefits of a computerised system?

A
  • work out most efficient schedule (maximise production)
  • customer gets products in shortest time possible
  • machinery is more cost effective as downtime reduced
38
Q

standardised components (advantages)

A 
CONSUMER
- easy (& cheap) to repair products
- products can be upgraded more easily
MANUFACTURER
- components can be bought in bulk
- less machinery needed
- easy to find substitute suppliers
39
Q

standardised components (disadvantages)

A
  • less variety in products
  • many standardised components made in same factory/region so if there is an issue (eg major earthquake) hold ups can occur
40
Q

impact of changing standards?

A
  • replacement components may be no longer available (eg Apple- charging ports, headphone jack)
  • standards changed to allow for developments in technology
41
Q

ASRS (automated storage and retrieval systems)

A
  • storage, distribution & sales monitored by computer systems:
    > RFID (radio frequency identification)
    > AGVs
    > EPoS (electronic point of sale)
  • ASRS guided to designated place in warehouse where component is stored, components are stored on closely packed shelving
42
Q

advantages of AGVs/ASRS?

A
  • faster

- more efficient use of space (shelves can be closer together as humans don’t need to get in)

43
Q

disadvantages/considerations of AGVs/ASRS implementation?

A
  • cost
  • loss of jobs
  • need to hire specialists (maintenance etc)
  • time taken to set up new system
  • training workers to use new software
44
Q

computer integrated manufacture (CIM)?

A
  • computer systems control all stages of production for design to distribution
  • includes: CAD, prototyping, material costing, CAM, quality control, warehouse organisation, distribution

A Level DT (21 decks)

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