1.6 Modern Industrial and Commercial Practice Flashcards
What are the 3 scales of production
One off/Job , Batch , Mass/Continuous
What is the one adv and 3 disadv of one off production
Adv
- Creates a bespoke product
Disadv
- Takes more time to manufacture
- Requires more time to manufacture
- Requires more skill to manufacture
What is an example of “Design and the economic use of materials” (Out of 3)
Lightweight furniture frames capitalising on the elasticity of the materials
Hollow children’s toys (By blow moulding / rotational moulding) can reduce the weight and “waste” material used while maintaining strength
Holes in cellular beams can make optimum use of material while also reducing the weight of the structural supports while keeping structural integrity
What are the 3 adv of Mass/Continuous production
Much more time efficient for a larger production
Divides up the tasks needed to manufacture
Highly automated and extensive use of dedicated machinery
Materials can be bulk bought
What is “Vertical in-house production(Vertical integration)”
a company owns the supply chain
What are the 3 things used in batch production to increase speed and production
Jigs, Fixtures and Manual/CNC machines
What is UPS
Unit production system - overhead transporter systems to convey components between workstations
What are the 3 adv of using UPS
Improves the quality of products
Efficient and computer controlled
Reduces the number of handling operations
What are the 4/5 factors to consider for efficient use of materials
Materials - Weights, performance and durability
Quantity of materials being bought
Manufacturing processes
Annual production amounts
What are the 3 principals for “Design and the economic use of materials” (Reducing wastage)
Designing to stock sizes can be beneficial as it reduces the wastage of material
Software can be used to optimize how woodworkers will cut out parts from MDF or plywood as to reduce wastage of material
Manufacturing the product in one piece can reduce the joining processes used and also reduce potential waste material
What are the 3 adv of Vertical in-house production(Vertical integration)
Reduced risk of inflation
Less reliant on suppliers stock
Protection of their brand and improved security of intellectual property rights (IRP)
What are 2 advantages of mechanical systems in “Automated and computer based production”
Mechanical systems reduce costs
Mechanical systems increase time productivity as automated systems repeat the same process
What are the 3 disadv of Vertical in-house production(Vertical integration)
Reduction in flexibility
Increase in administration
Reduction in specialism (Leading to a dilution of expertise)
What is 1 advantage of CNC systems in “Automated and computer based production”
CNC systems are more bespoke and flexible as they can produce a wide range of different parts
What is the adv of “Automated and computer based production”
The adoption of computer systems allows both mass production and bespoke elements without charging the money for a premium one of service
What are some uses of “Planning and control software” (Out of 5)
Spreadsheets, charts and graphs can be obtained automatically from computer software and give an overview of operations
Schedules for complex manufacturing can be organised by mathematical computer software
Barcodes are scanned to transfer information relating to stock
The use of RFID(Radio frequency identification) tags can provide security against theft in retail
The introduction of barcodes can be read more reliably than text when scanning
What is “Modular/cell production”
A number of CNC machines can be combined to provide a CNC module or cell
What is “Just in Time (JiT) “
A method of organising the manufacture of products so that they are made to order
What are the 2 steps in “Stock transportation and delivery” for “Modular/cell production”
Loading material at the start of the process is carried out by a robotic arm. With longer distances AGVs(Automatic guided vehicles) can be used to transport materials from one machine to another.
What are 4 disadvantages of stockpiling
Stockpiling can cause a financial burden
Stockpiling can cause stock to be outdated by newer technologies
Stockpiling can cause stock to be vulnerable to damage and theft
Stockpiling requires space to store the stock which be expensive
What are the 5 ideas behind JIT(Just in time) manufacturing
Lean manufacture - The idea of reducing waste and maintaining the minimal possible stock levels
Supplier relationships - The supplier relations must be higher with JiT as to control the production of the product
Plant configuration and layout of machinery - Suppliers selected are often in close proximity to the factory where assembly takes place
Kanban (Signal card) - Stock may be labelled which can give indication of current levels
Muda (Wastefulness) - The reduction of stock in JiT can reduce wastage
What is “Quick response manufacturing”
A production technique used to ensure customers take rapid delivery of their order
What are the 4 characteristics of “Quick response manufacturing”
QRM makes use of CAD and rapid prototyping of 3D printers
QRM is appropriate for low volumes of products with elements of customisation
QRM smoothly transitions into the production stage
QRM is flexible with multi skilled workers
What is “Flexible manufacturing systems”
Systems that facilitate production changes to parts or products
What are 4 characteristics of “Flexible manufacturing systems”
FMS uses SMED(Single minute exchange dies) to facilitate changes to a die or press in response to demand changes
FMS makes extensive use of modular cell production for easy transfer of production
FMS uses SMED that reduce idle periods and maximize time efficiency
SMED offers financial advantages as keeping expensive machinery in operation for the maximum time is a key element in running a facility
What is “Computer Integrated Manufacture (CIM)”
The use of computer systems to control all the stages (design, planning, manufacture, storage and distribution) of bringing a product to the market ‘just in time’
What are the 7 steps of “Computer Integrated Manufacture (CIM)”
Electronic point of sale (EPOS) system - EPOS systems are used to record sales of products and feed the information to the manufacturer for restocking purposes
Master production schedule (MPS) software - The order is then recorded in MPS which determines the number of products to be made in a given time period.
Software generates a lead time and a delivery date to the customer
AVGs then are programmed to collect stock from warehouses and deliver them to production lines 24/7. Overhead gantries also help deliver stock when needed(Free up floor space)
Materials and parts are tracked using scanners barcodes and RFID tags. The use of consumables(Fasteners) automatically triggers reordering from supplying via Kanban
Finished items are transferred back to a warehouse (often computer controlled)
Software is used to plan optimum loading patterns for freight containers and then coordinate an economic delivery.
What are “Bought-in components”
Components can be bought in where it is not practicable to manufacturer the product due to complexity
What are 4 properties / advs of “Bought in components”
CAD files - Suppliers can supply manufacturers with there component CAD files which can alloy manufacturers to better integrate the component into their designs
Bulk buying - With bought in products components can be bought in bulk which reduces unit cost
Standards - International standards(ISO) or British standards(BSI) can be used to standardise components and reduce confusion and problems
Available to order - With bought in components they are more available and reliable to order, reducing cost and time
What is a “Sub-assembly”
A self-contained unit or combination of components which is separately manufactured prior to being incorporated into the final product
What are the 2 ideas and advantages of Sub assemblies
Focus manufacturer efforts and investment - Many sub-assemblies can be very complex and intricate meaning it would be uneconomical to try and manufacture the sub-assemblies themselves as a high level of investment and knowledge would be required
Speed up the manufacturing process - Sub assemblies can speed up the manufacturing process where parts are made in the same factory
What are the 8 “Ease of Manufacturing techniques”
Standardised parts and sizes across different versions and buy in components where possible
Use of subsystems in a modular approach which makes it easy to find faults
Avoid wasteful machinery and time consuming fabrication techniques where possible-simple geometric shapes and forms are easier to machine
Employ self finishing materials such as polymers to avoid finishes and coatings
Strengthen castings and mouldings with ribs to save material
Moulded posts/bosses can be used to secure parts using self tapping screws with a reduce part count
Use of integral polymer snap fittings to secure parts without having to use adhesives or separate mechanical fasteners
Embossed or debossed moulded information to reduce the need for printing labels
What are the 15 areas of “Modern Industrial and Commercial Practice”
Scales of production
UPS
Vertical inhouse
Efficient use of materials
Design and the economic use of materials
Automated and computer based production
Planning and control software
Modular/Cell production
JIT
Quick response manufacturing
Flexible manufacturing systems
Computer Integrated Manufacture (CIM)
Standardised components
Sub assemblies
Ease of Manufacture
