1.6 Modern, Industrial and Commercial Practice Flashcards
economic use of materials
- 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
scale of production (def)
consideration of the no. of products to be made, using particular manufacturing methods to suit a particular market
batch production (def)
manufacture of groups of products to increase efficiency and economy
division of labour (def)
efficient organisation of a workforce so that individuals specialise in particular tasks
line production (def)
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
mass production (def)
manufacture of large numbers of products in factories that are usually highly mechanised
unit production system (UPS) (def)
use of overhead transporters for component transfer between workers to improve factory efficiency (usually in textile industry)
quick response manufacturing (QRM) (def)
use of mainly computer-based technology to facilitate efficient, competitive production of low-volume, customised products
vertical in-house production (def)
organisation of manufacture to reduce dependence on externally sourced parts and sub-assemblies
just in time (JiT) (def)
manufacture of products as needed, in response to existing orders
one off (bespoke) production (def)
design & manufacture of products to individual specifications
flexible manufacturing systems (FMS) (def)
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)
modular/cell production (def)
use of groups of CNC machines robots & AGVs to facilitate efficient, flexible manufacturing
standardised components (def)
parts such as screws & light bulbs that are made to a common standard to ensure interchangeability
bought-in components (def)
product parts that are sourced from external suppliers rather than being manufactured in-house
sub-assembly (def)
self-contained element of a product that is made separately and incorporated in to final assemble stages
one-off (bespoke) production (more detail)
- 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
batch production (more detail)
- 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
mass/line production (more detail)
- 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
unit production systems (more detail)
- 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
quick response manufacturing (QRM) (more detail)
- 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
vertical in-house production (more detail)
- supply chain is owned by company (manufacture own components instead of buying in)
- organise factories to include facilities for manufacturing what they need
vertical in-house production (advantages)
- 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
vertical in-house production (disadvantages)
- reduced specialisation- potential to dilute expertise
- increased admin
- reduced flexibility
white space (def)
time spent not working on the product
related to QRM
methods which enable QRM?
- CAD & CAM
- rapid prototyping
- flexible manufacturing cells
- multi-skilled workers
benefits of QRM to customer?
- short lead time (without reducing quality)
- easy customisation of products
systems needed to facilitate QRM?
- RFID
- CAD software, rapid prototyping machinery
- CNC machinery (flexible)
advantages of QRM?
- 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
JiT (just in time)
- 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
JiT (disadvantages)
- 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
kanban
- 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
modular/cell production
- 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
SMED
- 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
FMS (advantages)
- 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
FMS (disadvantages)
- 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
benefits of a computerised system?
- work out most efficient schedule (maximise production)
- customer gets products in shortest time possible
- machinery is more cost effective as downtime reduced
standardised components (advantages)
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
standardised components (disadvantages)
- 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
impact of changing standards?
- replacement components may be no longer available (eg Apple- charging ports, headphone jack)
- standards changed to allow for developments in technology
ASRS (automated storage and retrieval systems)
- 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
advantages of AGVs/ASRS?
- faster
- more efficient use of space (shelves can be closer together as humans don’t need to get in)
disadvantages/considerations of AGVs/ASRS implementation?
- cost
- loss of jobs
- need to hire specialists (maintenance etc)
- time taken to set up new system
- training workers to use new software
computer integrated manufacture (CIM)?
- computer systems control all stages of production for design to distribution
- includes: CAD, prototyping, material costing, CAM, quality control, warehouse organisation, distribution
