8 Features of Manufacturing Flashcards
What are the 4 scales of production
One-off
Batch
Mass
Continuous
What are the advantages and disadvantages of one-off production
Fully customized to individuals needs, very high flexibility, no expensive commitment to mass production, materials can be chosen
High cost, no high production volume, significant hand finishing required
What are the advantages and disadvantages of batch production
Cost saving to buying materials in larger quantities, some flexibility in production, reduces risk of large investments for equipment, faster than one-off
Products can’t be fully customized, finish quality and complexity is limited, relatively slow, quality of finish and complexity is usually less than mass production
What are the main batch production techniques to make sure the products are the same
Jigs Templates Molds CAD-CAM Vacuum forming
What are the advantages and disadvantages of mass production
Very high cost saving due to limited wastage and scale of purchases, very fast production cycle, low labor skill required, high production quality, mass production techniques enables more complex shapes
Very expensive investment in machinery, highly skilled labor required to make molds, little/ no flexibility, unable to customize product, not appropriate for certain materials (e.g. woods), machinery dedicated to product
What are the main mass production techniques
Pressure Die Casting Injection Molding Rolling Extrusion Blow Molding Friction Welding
What is a go/ no-go gauge
A measuring device that is able to see whether the component is within the specific minimum and maximum tolerances allowed
What 6 aspects might you consider in quality control
Materials Finish Dimensions Function Assembly Safety
What is quality assurance system
This is a overview of the whole quality process - from choice of materials, manufacture techniques, checks and customer support
What are quality assurance techniques
These are the specific techniques used to try and manufacture products consistently to the required standard of quality
When ensuring the quality of a product for a customer what are the 3 main expectations
Price
Performance
Aestetics
What is a Quality Indicator (Q.I)
A factor by which quality can be measured
What is Quality Standard (Q.S)
A value or attribute specified for that indicator (Q.I)
E.g. Technical drawings, work instructions, check sheets, quality tools
What is Tolerance
The acceptable margin of error
What are Critical Control Points (CCPs)
Points during the process where QC occurs
What is ISO
International Standards Organisation
Not a regulatory or enforcing body
Companies have to apply, are assessed and are then certified
Globally respected
What are the advantages of having ISO 9001
Promotes quality and safety in procedures/products
Promote product/system compatibility
Encourage/facilitate international trade
Enhances reputation of organisation
Allows for trade with other ISO 9001 certified organisations
What 2 marks can be put on products if they meet standards of the testing institutions
Kitemark- British standards
CE- European standards
What does TQM stand for
Total
Quality
Management
What is TQM
A system of management based on the principle that every member of staff must be committed to maintaining high standards of work in every aspect of a company’s operations
What does AGV stand for
Automated
Guided
Vehicles
What does ASRS stand for
Automated Storage and Retrieval System
What are the advantages and disadvantages of AGV’s
Reduced labor costs, increased safety, increased accuracy and productivity, modularity
Potentially high initial investment, maintenance costs, not suitable for non-repetitive tasks, decreased flexibility
What are the advantages and disadvantages of ASRS’s
Accuracy, efficiency, productivity, volume utilization
Requires customization, expensive to install
What does JIT stand for
Just
In
Time
What is a JIT system
The just-in-time (JIT) inventory system is a management strategy that aligns raw-material orders from suppliers directly with production schedules. The JIT inventory system contrasts with just-in-case strategies, wherein producers hold sufficient inventories to have enough product to absorb maximum market demand
How do are companies like Land Rover use JIT
Factory only holds 4 hours of manufacturing stock at once
Lorries park up next to each part of the factory so it can be unloaded straight onto the production line
Suppliers only have 30 minutes to unload before the next lorry arrives
The supplier isn’t paid till the lorry is on site to make sure it arrives at the right time
What is Flexible Manufacture Systems
Manufacturing systems that have been set up that allow a company some degree of flexibility to enable it to react to, and then investigate, changes fairly rapidly to the manufacturing process
What is machine flexibility
Systems ability to change to produce new product types
Ability to change order of operations
What is routing flexibility
Ability to use multiple machines
Ability to absorb changes such as capacity and capability
What does TIMWOOD stand for
Transportation (of materials) Inventory Motion (of works/equipment) Waiting Over-processing Over-production Defects
What is Kanban
Kanban is a visual system for managing work as it moves through a process. Kanban visualizes both the process (the workflow) and the actual work passing through that process. The goal of Kanban is to identify potential bottlenecks in your process and fix them so work can flow through it cost-effectively at an optimal speed or throughput
What is the kanban method
- Visualize workflow
- Limit work-in-progress
- Manage flow
(By seeing what you have to do and have already done, efficiency within workers is increased)
What is lean manufacturing and what are the advantages
Lean manufacturing is a methodology that focuses on minimizing waste within manufacturing systems while simultaneously maximizing productivity. The benefits of lean include reduced lead times, reduced operating costs and improved product quality
What are the advantages of quick response manufacturing
Reduced time to market (lead time) which in turn has the following benefits: The ability to keep up with trends/fashion/demand/orders, Increased Market Share (ability to capitalize on early interest and orders that require a short turn around), Recoup money quickly and improve cash flow
Allows customization/flexibility/adaptability
Reduced retooling costs (due to FMS)
Labor costs reduced (due to automated nature of FMS)
Reduced human error/waste ((due to automated nature of FMS)
Storage costs reduced (due to JIT)
Ultimately it should therefore encourage repeat business (due to improved customer satisfaction, confidence and improved reputation)
What is quick response manufacturing
Quick response manufacturing is a concept whereby business set up their design and manufacture to allow them to respond to changes in their market and customer requirements with minimal delay
What is Enterprise Resource Planning
Enterprise Resource Planning is a system that helps companies integrate and manage all their financial, supply chain, manufacturing, operations, reporting, and human resources activities.
What is Product Data Management
Product Data Management is the use of software to manage product data and process-related information in a single, central system. This information includes computer-aided design (CAD) data, models, parts information, manufacturing instructions, requirements, notes and documents. The ideal PDM system is accessible by multiple applications and multiple teams across an organization.
What is over the wall designing
During the industrial revolution, technology became more complex. The complexity forced forced employees of companies to specialize in different areas of the product design process. No longer could one person be responsible for the design, manufacture and sales of a product. The era of the craftsmen gave way to the era of the specialist. Large companies began to organize their into departments with different responsibilities. Each department worked on a product until they had completed their tasks and then they handed off the project to the next department. Not only was this serial process very slow but it also caused many problems when the communication between departments broke down. The breakdown of communications led to projects being thrown back over the walls that divided the departments for rework.
