Acronyms

Question 1

What is UPS

Answer 1

Unit Production system - UPS

The use of overhead transporter devices to improve factory efficiency

Question 2

How and why is UPS used

Answer 2

● UPS is worked in textile production.
● Employs an efficient, organised and synchronised, computer-controlled overhead transporter system.
● Incorporates appropriate hanging carriers to convey the garment components between workstations.
● Reduces handling operations, optimises labour and equipment use, and improved quality.

Question 3

What is QRM

Answer 3

Quick response manufacturing - QRM

The use of mainly computer-based technologies to make low-volume, customised products efficiently and competitively.

Question 4

How and why is QRM used

Answer 4

● QRM is a manufacturing strategy for reducing lead-times.
● A system for low-volume, customisable production.
● Lead-times (the time taken to respond to orders) must be as short as possible to complete
successfully.
● Rapid completion of the product design and development process is vital to minimise delays.
● Creativity, quality and customer needs are given high priority throughout the process.

Question 5

Example of QRM being used

Answer 5

Designing and manufacturing a machine for packaging food.

Question 6

What is FMS

Answer 6

Flexible manufacturing systems - FMS

Production mainly using CNC and robot-based cells to carry out bespoke and batch production to suit demand.

It also includes the the organisation of manufacturing to facilitate easily switching from one product to another as demand dictates.

Question 7

What are two main features of FMS

Answer 7

1. Modular/cell production:
   Manufacturing cells combine CNC machines (lathes, milling machines, grinders) in a group. The cell is programmed to carry out a sequence of operations to make parts such as car engine components.
2. Single minute exchange dies (SMED):
   SMED means changing dies/mould in machines in a target time to under 10 minutes. Examples: Pressed sheet metal car radiators and various injection-moulded parts.

Question 8

What is CFD

Answer 8

Computational fluid dynamics (CFD)

CFD is virtual testing of products in liquid or gases, using CAD-based software.

Question 9

How and Why is CFD used

Answer 9

software.
● 3D CAD simulation tool for fluid or gas flow in or around a product.
● Vehicle drag (wind resistance) can be tested in a simulated wind tunnel.
● Test results can then inform aerodynamic improvements.
● Marine craft designers use a simulated wave tank for similar purposes.
● Designers save time and money that is normally required for physical testing.

Question 10

What is FEA

Answer 10

Finite element analysis (FEA)

FEA involves virtual testing of components and products to identify stress or weak points.

Question 11

How and Why is FEA used

Answer 11

● FEA is the analysis of stress elements of a CAD Design.
● It allows designers to simulate forces, vibration or shock loads on products or components.
● Weak points are highlighted usually using an easily identified colour- coded scale.
● Money and time can be saved as designs can be optimised by modifying and re-testing.
● Static and dynamic testing is useful for many products, such as bicycle frames and cars.

Question 12

What is EPOS

Answer 12

Electronic point of sale EPOS

Computer system using barcodes and other devices to monitor product sales.

Question 13

How and why is EPOS used

Answer 13

● Computer-based barcode system for capturing data when consumers purchase goods.
● Stock levels and the triggering of stock reordering are facilitated in retail and wholesale.
● System collect sales data and customer details for use by marketing departments.
● The product life cycle status of a products can be established to indicate when extension strategies or replacements might be appropriate.
● Customers email addresses and loyalty cards facilitate additional marketing opportunities.

Question 14

What is PPC

Answer 14

Product, planning and control - (PPC)

It’s where computers are used to:
● Plan and control production
● Organise the availability of materials and components
● Co-ordinate suppliers and customers

Question 15

What are examples of PPC (Product, Planning, and Control)

Answer 15

• MPS (Master Production Schedule)
• Kanban
• RFID (Radio Frequency Identification)

Question 16

What is MPS

Answer 16

Master production schedule (MPS)

MPS is a software-based system to organise and schedule product Manufacture.

Question 17

How and why is MPS used

Answer 17

Software that arrives out several co-ordinated PPC functions in a JiT environment including the following:

• Availability of materials.
• Scheduling of machines and people.
• Co-ordinating suppliers and customers.

Question 18

What is Kanban

Answer 18

Factory materials and components monitoring and re-ordering system central to JiT Production.

Question 19

How and why is Kanban used

Answer 19

To facilitate a JiT system the flow of materials and components through a factory must be carefully controlled using a Kanban (signal card) system for re-ordering components.

Question 20

What is RFID

Answer 20

Radio Frequency identification (RFID)

Scannable electronic devices used to track parts and products.

Question 21

How and why is RFID used

Answer 21

Many of the Kanban cards that were once used have now been replaced by barcode labels. RFID tags and scanners linked to MPS software

Question 22

What is TQM

Answer 22

Total quality management (TQM)

TQM is a system used to improve QC by harnessing workforce expertise.

Question 23

What are the aims of TQM

Answer 23

● TQM aims to remove waste and make products right first time by continuous improvement.
● Workforce’s views, feedback, teamwork and communication are highly prioritised

Question 24

What is SCRUM

Answer 24

SCRUM - agile manufacturing

The use of workforce teams to respond quickly to issues in product design and manufacture.

Question 25

What are the aims of SCRUM

Answer 25

● Main focus is working in a team to reach goals in short time scale ‘sprints’.
● Team goals and specified and individuals feedback progress at daily update meetings.
● Regularity of feedback meetings facilitates quick response to issues that arise.

Question 26

What is Six Sigma and what are its aims

Answer 26

● In the 1980s Motorola introduced the system.
● It is a set of techniques and tools for process improvement which is designed to minimise defects.
● Aim: reduce the number of defect products to less than 3.4 in every million.
● The system requires the implementation of DMAIC procedure to access and improve each stage of the design and manufacture.

❏ Define
❏ Measure
❏ Analyse
❏ Improve
❏ Control

Question 27

What are the aims of Lean Six Sigma

Answer 27

● Aimed at reducing the number of defective products through Monitoring.
● Systematic approach to production that aims to eliminate all waste from the product production.

Question 28

What is Six Sigma

Answer 28

Six Sigma

A system for process improvement to reduce defects to fewer than 3.4 in every million.

Question 29

What are the aims of Six Sigma

Answer 29

● Procedure monitors, assesses and improves each stage of design and manufacture.
● DMAIC - the five key stages of Six Sigma:

1. Define the issue requiring improvement.
2. Measure the extent of the issue.
3. Analyse where the measured issues occur.
4. Improve by introducing rectification procedures.
5. Control the modified procedures through effective QA.

Question 30

What is CPA

Answer 30

Critical path analysis (CPA)

CPA is the analysis of stages in a project to ensure time-efficient completion.

Question 31

What are the aims of CPA

Answer 31

● Project management method used to schedule efficient completion of process stages:
● A sequence order of tasks is established for a project or process.
● Unnecessary waiting time can be identified.
● Parallel processing opportunities can then be exploited for maximum efficiency.