2.9 Design For Manufacture And Project Management

Question 1

What is quality control

Answer 1

• Refers to monitoring, checking and testing of materials, components, equipment and products throughout production
  
  • This is to ensure that they conform to acceptable tolerances specified within the QA policies
  • QC inspections take place throughout the production process
  • QCs are performed in conjunction with strict guidance documentation —> produced by the company and client

Question 2

QC material checks

Answer 2

• The beginning of any production process all materials must be checked
  ○ Simple visual checks on the materials and data sheets supplied
  ○ Chemical analysis on small volumes of the materials —> checking for levles of moisture or specific elements that may affect the product
  ○ Colour matching may also be required for polymer pigments or paint finishes

Question 3

QC dimensional accuracy checks

Answer 3

• Throughout the production process, relevant QC checks will be implemented to ensure the equipment is working accurately.

Question 4

QC digital measuring devices

Answer 4

• Checks may be carried out with flexible measuring equipment
  ○ Like digital caliper or micrometer where a range of measurements can be checked

Question 5

What is quality assurance

Answer 5

QA refers to the procedures and policies put in place to reduce waste, to ensure manufactured products are produced accurately within set tolerances

Question 6

With effective QA the number of QC issues will decrease, give examples of what QA measures can be done

Answer 6

• Only sourcing materials and components from suppliers that hold the ISO 9001 quality management standard (QMS)
  
  • Setting specific temperature ranges for product moulding to ensure effective filling of cavities and sleeps of cooling
  • Setting rigid maintenance schedules for machinery to ensure cutters are matching within tolerances

Question 7

QA Virtual modelling

Answer 7

• Using CAD software, components can be modelled and assembled to check that they fit, and review any possible issues with the assembly process —> can be done with sectional and wireframe views combined with exploded diagrams
  
  • Can be used to stimulate a manufacturing process
  • Using the software designers/ engineers can design the layout of production cells

Question 8

AQ finite element analysis

Answer 8

• Uses computer modelling to carry out component stress analysis
  
  • Can be used to analyse the stresses that a component will face during its working life —> although this may be tested on the real product because some enviromental condition may not be effectively modelled in the software
  • Can highlight potential weak points in a product which might need further development

Question 9

COMPUTATIONAL FLUID DYNAMICS (CFD)

Answer 9

• Specific forms of CFD such as MFA (mould flow analysis) can be used to check the flow of materials within moulding machinery —> this is essential to ensure the correct cooling and widths of channel are used to allow the molten materials to fill the cavities in the time required