D-Industry, Requirements and Standards Flashcards
Scales of production-One-off production?
Used for hand-crafted furniture, custom jewellery, cakes and bespoke interior design.
They are more expensive and difficult to produce:
-Individual client consultation required.
-More skilled workers required for the manufacture.
-Each manufacturing process has to be set up individually for each of the unique components.
-Greater time required for manufacture.
Scale of production-Batch production?
Used for pottery, wooden furniture and jet engines.
Batch production summary:
-Workers require less skill than in one-off and can work on a production line.
-Medium set-up cost as more specialist equipment can be used compared to one-off.
-Low cost per product as the volume increased from one-off production.
Scale of production-Mass production?
Used for clothing, bicycles, mobile phones and televisions.
Mass production summary:
-Workers carry out a single process in a production line that is often heavily automated.
-High set-up cost as lots of machinery and tools are required.
-Low cost per product, as large volume of products produced at once, which makes each individual product very cheap.
Scale of production-Quick response manufacturing?
-A strategy to reduce the lead time on products, to bring the product to market more quickly.
-Used for products that can be upgraded on a regular basis.
Scale of production-Vertical in-house production?
-Company owns its supply chain, which minimises dependancy on external suppliers. Their factories manufacture all the components required.
Advantages:
-Reduces risk of component price increases.
-Less impacted if suppliers go out of business.
-Protections of their brand/Security of their intellectual property.
-Easy to implement quality assurance.
Disadvantages:
-Reduces flexibility.
-Increase in administration
The use of computer systems-Modular cell production?
-CNC machines can be grouped to carry out a sequence of operations to perform a task.
-Robotic arms can load the material at the stat of the process, transferring the work piece between machines and removing the finished parts.
-If longer distances are required, automatic guide vehicles (AGVs) are.
Just-In-Time manufacture?
-Products are made to order rather than being made in the hope of being sold.
JiT strategies:
-Regular feedback to ensure continuous improvements.
-Selection of suppliers in close proximity to the factory where assembly takes place.
-Reduction of waste and unused stock.
-Optimised configuration and layout of machinery.
Advantages:
-Saves on storage costs.
-Customers can chose various options before manufacture.
Disadvantages:
-Longer wait times after order.
-Dependance on reliable suppliers.
Flexible manufacturing systems?
-Makes use of modular production that transfers from the production of one part to another to respond quickly to changes in demand.
-Uses single-minute exchange dies (SMED), that facilitate the changing of dies or moulds very quickly in response to demand for a new part.
Computer controlled systems in production, distribution and storage?
-Computer intergrated manufacture-the use of computer systems to control all stages of bringing a product to manufacture (CAD and CAM).
-Use of AGVs, forklifts and narrow aisle stacking machines to reduce manual handling and this uses space more efficiently.
Standardised components?
-They must be able to fit other elements of a design, so are made to a common standard to ensure interchangeability.
-Less skills required by staff, less specialist equipment needed to produce specialised components and they can reduce costs.
Bought-in components?
-Used where it would not be suitable to manufacture the components themselves, due to their specialist nature or high volumes are required.
-Components bought in bulk to reduce unit cost.
-Don’t need their own manufacturing facility, which reduces the need for specialist equipment, which can be expensive.
-Time will be saved.
-A greater level of consistency in the components.
Sub-assembly?
-Pre-assembled parts are bought in and added to the final product.
-It reduces manufacturing times and costs.
-Ordering has to be efficient and dependent on the quality and reliability of suppliers.
Advantages and disadvantages of CAD?
Advantages:
-Speeds up the product design and development process, they can edit and develop existing drawings, which will be faster than redrawing items by hand.
-Makes it easier for teams of designers to work collaboratively in different countries and reduces the need for travel.
-CAD drawings can be downloaded to CAM equipment easily.
Disadvantages:
-The initial set-up can be expensive, especially if staff have to be trained to use the software.
-Software has to be updated on a regular basis, which can be expensive.
-CAD software is not easy to use for quick sketches.
Virtual modelling-Computational fluid dynamics?
-Used to stimulate the flow of fluids or gases around a product.
-Using CFD can save designers time and money, which would be needed to produce physical models and prototypes and the expenses of using specialist equipment like wind tunnels or wave tanks.
Virtual modelling-Finite element analysis?
-Used to carry out component stress analysis, is used to stimulate vibrations or shock loads on products.
-Can save time and money that would be needed to prototypes for physical testing.
What is rapid prototyping?
-Using CAD files and downloading them to a machine to produce a 3D model of the drawing.
-A fast way to make a realistic model, would of have to been done by hand, which is a highly skilled and time consuming process.
-It reduces cost and time for product development.
What is fused deposition modelling?
-The machine 3D prints a model from 3D drawings by using a processing software, which slices the drawing up to guide the extruder in paths to build the model from the bottom up.
-It softens a thermoplastic filament and extrudes it to build the model.
-Can use a support material that can act like a scaffold, which is then broken away when the model is finished.
-Allows the prototype to be modelled quickly, accurately and cheaply.
-Can be used to show clients what the product will look like to obtain feedback.
-Models can be made full size and used to make moulds for casting and making dies.
What is electronic point of sales (EPOS)?
-Items are labelled with barcodes and when they are scanned at purchase the details of the sale are recorded.
-It is used to control stock levels, limits can be set so that replacement stock can be reordered when stock levels are low.
-Used to monitor how many items are being sold, which can be used to target their marketing to help improve sales or know when a new product need to be launched to replace one that reaches the end of its life cycle.
-Can ask the consumer for an Email address to advertise additional products to the consumer.
What is a master production schedule (MPS)?
-A plan to determine how many products will be made in a given time.
-Uses software that will network with all parts of the business to determine the amount and availability of labour and network with suppliers to order materials and control stock.
Specification criteria-Pugh’s plates?
-Environment, consider the impact of the product on the environment during production, use and disposal.
-Testing, consider how the product will be tested to ensure it fulfils the claims made by the manufacturer.
-Safety, Consider all relevant safety standards and legislations.
-Life span, how long should the product last for before replacement required.
-Materials, consider key material properties required.
-Ergonomics, how will the products be interacted with and how will the design assist this.
-Aesthetics, consider the appearance.
-Cost, cost restrictions on the design.
-Size and weight, consider the restrictions on the product including anthropometric data.
Critical analysis?
Current products and analysed to help develop new ideas for new and improved products:
-Product analysis, completed on a product you have direct access to, so you can interact with it and see how it performs its perceived function.
-Function, analyse the function, you must use the product and assess its success.
-Task analysis, break a task down into specific steps to look more closely at how the product is suited to its function.
-Ergonomics, analyse how the user would interact with the product.
-Aesthetics, should be a factual analysis and avoid anything subjective.
-Materials, do they perform their key properties, the material used could also be influenced by the method of manufacture and scale of production.
-Manufacture, assess each process and how it was assembled.
-Scale of production, it impacts the manufacture and materials.
-Environmental impacts, evaluate its impact, extraction of raw materials and the end of the products life.
User-centred design (UCD)?
-All products we design should focus on the end user and the end user should be involved at all stages of the design.
-Products concepts and models should be tested in the real world situations with the user to gain an opinion on the products functions.
What is concept modelling?
-Essential to model concepts, it can be done using many materials but the selection is done on the purpose of the material.
-All modelling should be done to make decisions or prove/disprove predictions.
Initial concept generation?
-Used to gain feedback from clients prior to investment of physical prototypes.
-The feedback is restricted to form/aesthetics.
