1.6 Modern Industrial and Commercial Practice

Question 1

What are the 3 scales of production

Answer 1

One off/Job , Batch , Mass/Continuous

Question 2

What is the one adv and 3 disadv of one off production

Answer 2

Adv
- Creates a bespoke product
Disadv
- Takes more time to manufacture
- Requires more time to manufacture
- Requires more skill to manufacture

Question 3

What is an example of “Design and the economic use of materials” (Out of 3)

Answer 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

Question 3

What are the 3 adv of Mass/Continuous production

Answer 3

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

Question 3

What is “Vertical in-house production(Vertical integration)”

Answer 3

a company owns the supply chain

Question 3

What are the 3 things used in batch production to increase speed and production

Answer 3

Jigs, Fixtures and Manual/CNC machines

Question 4

What is UPS

Answer 4

Unit production system - overhead transporter systems to convey components between workstations

Question 4

What are the 3 adv of using UPS

Answer 4

Improves the quality of products
Efficient and computer controlled
Reduces the number of handling operations

Question 4

What are the 4/5 factors to consider for efficient use of materials

Answer 4

Materials - Weights, performance and durability
Quantity of materials being bought
Manufacturing processes
Annual production amounts

Question 5

What are the 3 principals for “Design and the economic use of materials” (Reducing wastage)

Answer 5

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

Question 5

What are the 3 adv of Vertical in-house production(Vertical integration)

Answer 5

Reduced risk of inflation
Less reliant on suppliers stock
Protection of their brand and improved security of intellectual property rights (IRP)

Question 5

What are 2 advantages of mechanical systems in “Automated and computer based production”

Answer 5

Mechanical systems reduce costs
Mechanical systems increase time productivity as automated systems repeat the same process

Question 6

What are the 3 disadv of Vertical in-house production(Vertical integration)

Answer 6

Reduction in flexibility
Increase in administration
Reduction in specialism (Leading to a dilution of expertise)

Question 7

What is 1 advantage of CNC systems in “Automated and computer based production”

Answer 7

CNC systems are more bespoke and flexible as they can produce a wide range of different parts

Question 8

What is the adv of “Automated and computer based production”

Answer 8

The adoption of computer systems allows both mass production and bespoke elements without charging the money for a premium one of service

Question 9

What are some uses of “Planning and control software” (Out of 5)

Answer 9

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

Question 10

What is “Modular/cell production”

Answer 10

A number of CNC machines can be combined to provide a CNC module or cell

Question 11

What is “Just in Time (JiT) “

Answer 11

A method of organising the manufacture of products so that they are made to order

Question 12

What are the 2 steps in “Stock transportation and delivery” for “Modular/cell production”

Answer 12

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.

Question 13

What are 4 disadvantages of stockpiling

Answer 13

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

Question 14

What are the 5 ideas behind JIT(Just in time) manufacturing

Answer 14

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

Question 15

What is “Quick response manufacturing”

Answer 15

A production technique used to ensure customers take rapid delivery of their order

Question 16

What are the 4 characteristics of “Quick response manufacturing”

Answer 16

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

Question 17

What is “Flexible manufacturing systems”

Answer 17

Systems that facilitate production changes to parts or products

Question 17

What are 4 characteristics of “Flexible manufacturing systems”

Answer 17

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

Question 18

What is “Computer Integrated Manufacture (CIM)”

Answer 18

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’

Question 19

What are the 7 steps of “Computer Integrated Manufacture (CIM)”

Answer 19

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.

Question 20

What are “Bought-in components”

Answer 20

Components can be bought in where it is not practicable to manufacturer the product due to complexity

Question 21

What are 4 properties / advs of “Bought in components”

Answer 21

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

Question 22

What is a “Sub-assembly”

Answer 22

A self-contained unit or combination of components which is separately manufactured prior to being incorporated into the final product

Question 23

What are the 2 ideas and advantages of Sub assemblies

Answer 23

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

Question 24

What are the 8 “Ease of Manufacturing techniques”

Answer 24

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

Question 25

What are the 15 areas of “Modern Industrial and Commercial Practice”

Answer 25

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