2.9 Design For Manufacure And Project Management Flashcards
Designers must ensure the products they design:
Meet customer and legal requirements
Can be produced with the equipment and technology available
Can be produced to budget
Can be produced within the required timescale
Planning for accuracy
Development must allow for testing against the design spec either using cad simulations or full size models
Evaluated for suitability of accuracy and achievable level of accuracy
Requires a clear schedule or production and quality control checks and deadlines embedded into production. Altered at scale of production
Examples of quality assurance to ensure accuracy
Cad simulations
Working drawings with tolerances
Mock up models and mechanical systems
Client feedback
Peer review
Only sourcing materials form component from suppliers that hold iso 9001 quality management standard
Setting specific temp ranges for product moulding ensuring effective filling of cavities and speed of cooling
Setting rigid maintenance schedules for machinery to ensure futures are machining within tolerances
More QA means less qc checks are needed
Qc checks
Visual aesthetic
Accurate dimension checks using vernier calliper of individual parts and overall product
Machine tools and alignment checks
Assembly checks
Quality checks of finished
Sampling of customer or legal requirments
Pre production checks
Cad simulations Working drawings Sample prototypes Templates, jigs and fixtures produced NDT and destructive testing
Project management systems
Ensures products completed within budget and to agreed time scales. Looks to improve efficiency and reduce waste
Total quality management (TQM)
Value views of their workers, encourage workers to work in a team where individuals can solve their problem and contribute to the effectiveness of product without fear of expressing their views
Scrum (agile manufacture)
Work to reach goals in short timescale ‘sprints’. Act as one dedicated team receiving continuous feedback. Team attend daily scrum updates where people feedback progress towards team goals and distribution of tasks can be updated based on issue.
Responds to change quickly based on frequent meetings
Six sigma
Disciplined, data driven approach for eliminating defects (driving towards six standard deviations between the mean and the nearest spec limit) in any process
Six sigma principles
Define: what is the issue with the process?
Measure: take steps to measure the extent of the issue
Analyse: determine where the issues occur
Improve: introduce procedures to rectify issue raised
Control: ensure the modified procedures are implemented
Lean manufacture
A systematic approach to production to reduce waste from product production. Waste is anything that doesn’t benefit the client given the name ‘muda’
The seven forms of ‘muda’ TIMWOOD
Transport - risk of damage or loss, reducing distance of travel, reduce these risks and chance of production being delayed due to traffic
Inventory: stock held on site is at risk of damage or loss
Movement: unnecessary movement of employees and equipment increases production time
Waiting: if processes aren’t split evenly there may be workers waiting for others to catch up
Overproduction: overproducing excess products that may never be required for sale wasting materials and production costs
Over-processing: using the correct equipment for each process
Defects: any defective product removed relying on qc and QA
Lean six sigma
Combing both processes, companies aim to improve operational and manufacturing excellence
Uses of six sigma
Banking, logistics, manufacturing and hospitality
Critical path analysis (CPA)
Project management method used to analyse all individual stages within a project and plan the effective and time efficient completion of each element within the desired schedule
Splitting tasks and arranged in time order. Identifies waste in a task. Identify take that can be completed at the same time
