Chp 1.6 Modern Industrial Practises 1.20

Question 1

Give me some examples of products made in one off/job production?

Answer 1

A luxury custom chair, personalised wedding cake

Question 2

Give me some examples of products made in batch production?

Answer 2

Wooden furniture and jet engines

Question 3

Give me examples of products made in mass production?

Answer 3

Clothings, bicycles, cameras, TVs, ready made meals

Question 4

What will they use in batch production to aid their production process as a whole?

Answer 4

The uses of jugs and fixtures will help them in production + CNC machines in the manufacturing of a product in large quantities

Question 5

Advantages of using Vertical in -house production? And disadvantages?

Answer 5

Reduction is the unexpected rise of pricing to increase for components
Less susceptible to suppliers going out of business
Easier implementation of quality assurance strategies

Reduction in flexibility
Increase in administration
Reduction in specialisation

Question 6

When manufacturers are considering the right uses of materials what must they think about i order to reduce costs?

Answer 6

Rather than sing expensive materials we could opt out for cheaper ones which may cost less to buy in bulk needed for our project however we also have to consider that they have different durability, weight and bending properties compared to the originally sought out for materials which was expensive

Picking the amount f material to use as well is also important for waste and storage costs if needed

Question 7

How do manufacturers plan out and use effectively the correct amount of material to reduce waste?

Answer 7

Woodworker may use a special software to plan out and cut boards of MDF into pieces, so that they don’t produce a large no. Of unused board pieces as well.and helps them economically as well

In general planning with or without the software and using standardised stock boards avoids wasting and additional machining - time

Question 8

What is one example of how a product is being made now to reduce waste produced and save on materials?

Answer 8

Children toys are no being made hollow in the inside to reduce the amount for material being made via rotational and blow moulding - ensuring the overall product is strong due to coherent.

compared to injection moulding with requires it to be made in parts and assembled at high set up costs would waste time and material as a whole

Question 9

How do companies save on the production of glass bottles?

Answer 9

They are becoming thinner due to advances in blow moulding 3% lighter than in 1980. A drop of material is needed now for production of these bottles so energy and material costs go down.

With the help of FEA and computer analysis this was made possible reducing the amount used

Question 10

How do manufacturers increase accuracy and reduce waste?

Answer 10

Te use of automation in manufacturing once human input during manufacturing would take too long and make it rather expensive. E.g. using cams and levers rather than screwing making machines reduces time and waste of production and increase accuracy

The use of CNC increases accuracy as well + time to and is becoming a widely used process in manufacturing

Question 11

What are the main differences between one off production and batch production?

Answer 11

One off Production requires high proportions of manual labour and hand crafting skills whereas batch production on a line can make use of automation and jigs + templates to make production of the products in large quantities quicker + materials for them are also bought in cheaper than for one off production

Question 12

What are Barcodes and RFID tags used in manufacturing?

Answer 12

To fascinate the transfer of information relating to components and stock and can be used to identify time until production is complete etc

Question 13

What does cell production make use of?

Answer 13

Uses robotic arms, agvs and forklifts to transfer materials and components from one cell to another line to the other reducing the time wasted if it was done with people

Question 14

What is an advantage using jIT compared to normal methods

Answer 14

Storage requirements done exists, material costs and damage + redundancy of stock is no longer a story for manufacturers

Question 15

Instead of predicting the clients order Toyota had waited for clients to purchase their product and then go to suppliers to attain all the possible parts needed to produce the machine in a given time- which helped reduce waste and random errors in In the production line

Question 16

Examples of products made under JIT production ?

Answer 16

Cars and computers

Question 17

Name some of the Japanese words and English phrases that they use in JIT production

Answer 17

Muda - reduction of waste and stock
Kaizen - regular feedback meetings and continuous improvement
Kanbans - use of RFID tags and barcodes to track stock when on the mov

Increased consultation with manufacturers and workers
Optimisation of machinery

Question 18

Name some of the disadvantages of using JIT production?

Answer 18

Potential fires could burn a suppliers stock
They could go bust in business
Theft and robbery

Question 19

Explain the JIT production process:

Answer 19

A customer uses the manufacturer’s interactive car configuration website to select all appropriate options for the vehicle they require, such as engine type/size, wheels, colour, trim, audio and accessories.

The information is digitally transferred to the car manufacturer’s planning and control software that generates the order, organises the necessary parts and places the manufacturing process in an available time slot.

The lead time that is generated by the software will enable the dealer to give the customer an anticipated delivery date, which may be longer if the car is being assembled abroad or if there are any particular issues with the supply of parts.

Manufacture of the vehicle commences, with an RFID tag being used as an electronic Kamban td ensure that the correct parts are available and appropriately assembled as the vehicle proceeds along the assembly line

Once completed, the car can be delivered to the customer’s local deal on a transporter that has been loaded in accordance with the computer software’s optimum schedule for economical delivery.
Manufacturing vehicles in this way can result in potentially millions of different option combinations, so it is sometimes referred to as mass customisation.

Question 20

What does QRM make use of? Give an example of a product that is made via this?

Answer 20

Uses rapid prototyping and flexible manufacturing cells and multi-skilled workers to reduce lead time

Packaging for food

Question 21

FMS:

Answer 21

Makes it easier to respond to quick changes in demand and demand in general for parts of a product being made

SMED : changing the die within ten minutes due to changes of demand and or for making a different part - e.g. a car radiator remember dies are a fancy word for moulds/shapes

SMEd reduce the idle time- time waiting, downtime for machines

Offers finical advantages keeping expensive machines running effectively

Question 22

What does EPOS do (electronic point of sale)

Answer 22

Used to record sales and feed information through to a warehouse for re-stockings

Question 23

What is the term used to describe the management of and control of stages bringing a product to the market from design

Answer 23

CIM - computer integrated manufacturer

Which includes: CAD. CAM Qc checks , warehouse organisation etc, employing avgs and forklifts as well using space efficiently

Question 24

What is the use of RFID and barcodes for

Answer 24

To make an efficient flow of parts for the production line, and can be monitored but a computer in relation to storage and distributions.

Question 25

What is the ISO (international Standards organisation)

Answer 25

A metric which has been adopted and used for stock products and materials to make things standard globally and easy to use everywhere except America and Canada.

Question 26

Give some examples of standardised components:

Answer 26

Tyres, door locks, fuses, biro refills, memory cards, batteries, plumbing fittings

Question 27

Gove some examples of bough in components?

Answer 27

Electric motors, screws bolts and rivets

Question 28

By using bought-in components, companies can make major financial savings because..?

Answer 28

• the components can be bought in bulk.
Which reduces the unit cost
• they do not have to set up their own manufacturing facility, reducing the need for specialist equipment and expertise which can be very expensive
• there will be a greater level of consistency in the components
• time will be saved

Question 29

Give some examples of sub assembly products? Of a Bicycle

Answer 29

Braking systems, lighting systems, saddle, chain, frame, mudguards ,

Sub-assemblies can also speed up the manicuring process in industries where its normal for practise for all parts to be made in the same factory

Question 30

Changing standards
When standards used by manufacturers change, it can cause major problems to customers who use their products, as it can sometimes make the products or the ancillaries used with them obsolete. It is, however, sometimes necessary for companies to make major changes to their products to ensure that they stay competitive, and it is in this situation that brand loyalty is paramount. Some changes are adopted universally as a result of technological advancement. Examples of changing standard elements of products that have caused consumers compatibility problems include:
• Apple lightning connector replacing 30-pin type and the removal of the 3.5 mm headphone socket from smart phones
• introduction of HDMI connectors instead of SCART to facilitate HD TV
• Windows 10 installation causing software compatibility issues
• camera manufacturers changing the type of battery used in new models so older batteries and chargers can no longer be used
• removal of optical disc capability from some new models of laptop, making it difficult to use DVDs, etc.
• new printers that will not accept earlier types of cartridge, so they may have to be discarded.