8.3Accuracy, Efficiency and Systems of Production

Question 1

Production Scheduling and Production Logistics

Answer 1

Computer-based production scheduling and production logistics help make the production process smooth. The idea is that if there are small issues in the process the computer can iron them out. By producing a production schedule a company can determine whether or not a delivery promise can be met. It gives the workers undertaking the manufacturing process itself of what should be done so that their productivity might be measured, therefore maximising the potential of the workforce.

Question 2

Robotics in Production

Answer 2

Flexible manufacturing systems (FMS)

The use of models allows manufacturers to be flexible, as these robots can be programmed to manufacture a range of different models.

Question 3

Robots can be programmed to do:

Answer 3

The same job all of the time on one type of product
The same job on different products
Entirely different jobs

Question 4

There are three main configurations of robots used in industry today:

Answer 4

First Generation
Second Generation
Third Generation

Question 5

There are three main configurations of robots used in industry today:
First Generation

Answer 5

These are simplistic robots that are programmed to carry out one task with no sensors detecting their environments.

Example
Beam Transfer Robot

Question 6

There are three main configurations of robots used in industry today:
Second Generation

Answer 6

These robots do utilise sensors to perform more complicated tasks where It has to check a part is there, pick it up, sense there is no obstacles when moving it and presenting it to the machine for working.

Example
Robotic Arm

Question 7

There are three main configurations of robots used in industry today:
Third Generation

Answer 7

These are the AI – artificial intelligence robots that change what they are doing automatically based on changes to their environment.
Example
Automated Guided Vehicle (AGV)

Question 8

Robotics in Production
Advantages
disadvantages

Answer 8

Advantages
Carry out mundane boring tasks
Carry out physically demanding work
Work in hazardous areas such as welding or spraying
Work to high levels of accuracy, consistently and quickly
Work for long periods of time with no breaks (with the exception for maintenance)

Disadvantages
Poor mobility and flexibility, humans can move to different task easily but robots require retooling and reprograming
Limited degrees of freedom; humans are more effective at some tasks like fitting interiors
High set up costs; cost of purchasing, setting up, training staff and maintaining robots
Employment issues; some loss of jobs which can lead to labour issues with work force

Question 9

Materials Handling Systems

Answer 9

Material handling is the movement, protection, storage and control of materials and products throughout manufacturing, warehousing, distribution, consumption and disposal. As a process, material handling incorporates a wide range of manual, semi-automated and automated equipment

Question 10

Material handling systems

Their application helps with:

Answer 10

Forecasting
Resource allocation
Production planning
Flow and process management
Inventory management and control
Customer delivery
After-sales support and service

Question 11

Material handling systems are used in every industry, including:

Answer 11

Aerospace, Appliance, Automotive, Beverage, Chemicals, Construction, Consumer goods, E-Commerce, Food,

Question 12

Materials Handling Systems - Principles

Answer 12

Planning

Standardization

Work: Material handling processes should be simplified by reducing, combining, shortening or eliminating unnecessary movement that will impede productivity

Ergonomics

Unit load

Space utilization

System

Environment

Automation

Life cycle cost

Question 13

Flexible manufacturing systems (FMS)

Answer 13

A form of flexible automation by which several machines are linked together by a material-handling system, with all aspects of the system controlled by a central computer.

Question 14

The two main features of FMS are:

Answer 14

Machine flexibility; the system’s ability to be changed to produce new product types, and to change the order of operations on a part.

Routing flexibility; the system’s ability to perform the same operation on a part as well as absorb large-scale changes in volume, capacity or capability.

Question 15

Flexible manufacturing systems (FMS)

Advantages and disadvantages

Answer 15

Advantages:
Integrated system means reduction in errors.
Flexibility allows for changes.
Automation increases productivity and removes human error.
Shorter lead times.
Consistent quality.
Integrates with JIT which reduces storage.
Machine/routing flexibility.

Disadvantages: 
Expensive to set-up. 
Substantial planning required. 
Complex manufacturing systems. 
Productivity can decrease due to down time of machines. 
Loss of manual skilled workers.

Question 16

Just In Time (JIT)

Answer 16

Computerised stock control ensures that the part needed for a product comes from its supplier just in time for its assembly.

Question 17

Just In Time (JIT)

examples

Answer 17

Car manufacturers on a production line. Seasonal or limited edition fashion items.
On demand publishing, for example, photographs and greeting cards; Moonpig.

Question 18

Electronic Point of Sale (EPS) - JIT

Answer 18

Barcodes or data communication tags are not just used at the point of sale, they are also an essential part of QRM. They allow the JIT (just in time) ordering of components and products and also allow us to restock warehouses and supermarket shelves when the goods are needed.

Question 19

Just in Time (JIT)
Advantages
disadvantages

Answer 19

Advantages:
Just in Time production can increase efficiency and reduce wastage, as parts are only ordered when needed.
Companies can react quickly to customer demands.
Resources are in the right place at the right time.
No warehouse storage costs for products.
There is less money tied up in materials that are not being used by the company.
Higher levels of quality control and quality assurance.

Disadvantages:
A break in the supply chain can hold up production.
Higher cost of more frequent deliveries.
Fewer bulk-buying discounts.

Question 20

Lean Manufacturing – Just in Time (JIT)

Advantages and disadvantages

Answer 20

Advantages
Parts are ordered when needed.
Resources are in the right place at the right time.
Eliminates overproduction.
Minimises defects.
Reduces storage, movement or processing of parts or products.
Multi-skilled teams are responsible for one part of the production process.
Improves efficiency as workers share their skills & expertise.

Disadvantages
Requires time consuming data analysis.
Requires disruptive changes to existing processes.

Question 21

Quick Response Manufacturing (QRM)

Advantages and disadvantages

Answer 21

Advantages:
Reduction of manufacturing time means the customer receives the product quicker.
Company can react to changes in trends, making the system more flexible.
Use of automation/robots makes the system more efficient and better quality.
Uses a skilled workforce that require little training.

Disadvantages:
High set-up costs.
Can be a reduced production rate when compared to a dedicated production line.
Increased reliance on suppliers to react to demand.

Question 22

Data Integration

Answer 22

Data integration is the combination of technical and business processes used to combine data from disparate sources into meaningful and valuable information. A complete data integration solution delivers trusted data from various sources.

Question 23

Concurrent Manufacturing

Answer 23

Concurrent design and manufacturing involves simultaneously completing design and manufacturing stages of production. By completing the design and manufacturing stages at the same time, products are produced in less time while lowering cost.