7 - Manufacturing Processes and Techniques

Question 1

Describe Just-in-time (JIT) Manufacturing

Answer 1

Just-in-time (JIT) manufacturing, also known as just-in-time production or the Toyota production system (TPS), is a methodology aimed primarily at reducing flow times within production as well as response times from suppliers and to customers. A strategy companies employ to increase efficiency and decrease waste by receiving goods only as they are needed in the production process, thereby reducing inventory costs.

Question 2

Define lean manufacturing

Answer 2

Lean manufacturing or lean production, often simply “lean”, is a systematic method for the elimination of waste within a manufacturing system.

Question 3

Briefly outline how ICT and digital technologies are changing digital manufacturing

Answer 3

Customised manufacture systems

Rapid prototyping
* Fused deposition modelling (3D Printing)

Additive and digital manufacture methods

Stock control, monitoring, purchasing logistics in industry
* Production, planning and control (PPC) systems

Question 4

Describe metal forging

Answer 4

A manufacturing process whereby metals are shaped using compressive fources, typically through hammering, pressing or rolling

Question 5

Describe the use of technology in Production, Planning and Control (PPC)

Answer 5

• Computers are used to; plan and control production, organise component availability and coordinate suppliers.
• An efficient supply chain network (SCN) is vital to ensure the flow of materials, especially in JIT systems.
• A Master Production Schedule (MPS) software carries out lots of functions, including; ordering low stock items, delivers components to production lines at precise times, scheduling workers, networking departments and coordinating suppliers and customers.

Question 6

Describe 3 ways of cutting metals

Answer 6

hack saw
banch shears
tin snips

Question 7

What is ISO 9001?

Answer 7

ISO 9001 is a globally recognized standard for quality management. It helps organizations of all sizes and sectors to improve their performance, meet customer expectations and demonstrate their commitment to quality. Its requirements define how to establish, implement, maintain, and continually improve a quality management system (QMS).

Question 8

QC, QA, TQM

Answer 8

Quality control
Monitoring, checking and testing quality
* A more reactive approach

Quality assurance
* A proactive approach of planning of procedures and policies to ensure quality first time.
* Effective QA procedures reduce QC issues & rejects
* E.g. using materials from ISO 9001 quality management standard suppliers, pre-production mould flow analysis
* Incorporation of embossed mould identification and batch marks to trace faults

Question 9

Describe visual inspections in quality control

Answer 9

• Stock material checked for imperfections before manufacturing commenced
• Quality of welds inspected
• Checking for differences in material quality
• Profile projectors can be used

Question 10

Desribe digital manufacturing

Answer 10

• CAM
• CNC machines
• Automation
• Stock control systems??

Question 11

Computer Integrated Manufacture

Answer 11

Demand forecast - optimum suppliers identified (e.g. to support JIT)

Stock control
* Monitoring, costing, ordering of materials (e.g. with barcode stock tracking)
* Computerised warehouse organisation with AGVs, forklifts
* Optimise loading patterns for freight containers and delivery schedules - reduce downtime due to lack of stock
* EPOS that automate re-stocking
* Optimise levels of buffer stock