Design for Manufacture

Question 1

For a symmetrical distribution what is the tolerance range

Answer 1

2tolerance (=2ztheta)

Question 2

What range should the value for z fall in

Answer 2

4 - 7.5 theta (1 in 63ppm to 0 ppm)

Question 3

How does asymmetrical distribution occur

Answer 3

tool wear can give consistent bias

Question 4

What is a house of quality

Answer 4

it helps to convert customer requirements into engineering requirements

Question 5

What is a product footprint

Answer 5

Product footprint defines the brand

Question 6

What is the difference between ‘first-to-market’ and ‘fast follower’

Answer 6

first-to-marker seek the ‘first mover advantage’ through premium prices. Other companies may prefer to be ‘fast followers’ to learn from the mistakes of the first-to-market

Question 7

What kind of order can products be made for

Answer 7

Engineering to order (ETO)
Make to order (MTO)
Assemble to order (ATO)
Make to stock (MTS)
Ship to stock (STS)

Question 8

What is mass customization

Answer 8

Its a marketing technique that combines the flexibility and personalization of custom-made products with the low unit costs associated with mass production

Question 9

What is product architecture

Answer 9

The scheme by which the function of the product is allocated to physical components and the specification of interactions between physical components

Question 10

What are the advantages of modular units

Answer 10

Ease of maintenance, quality control over assembly, sealed for life

Question 11

What are the disadvantages of modular units

Answer 11

Small defects cant be easily repaired, requires high volumes to make feasible

Question 12

What are the advantages of platform design

Answer 12

Easier inventory management/smaller number of parts
Lower development costs
Increased quality
Global standardization
Greater product variety

Question 13

What is the best way to achieve low mass and volume

Answer 13

have integrated products with minimal interfaces

Question 14

What is the best way to minimise complexity

Answer 14

best to have a modular design with sub-assemblies and standard interfaces

Question 15

What is the purpose of quality management

Answer 15

it ensures adequate paper trails for design reviews, materials sourcing, component sourcing, product testing and company decision making

Question 16

Name 2 quality standards

Answer 16

BS7000 Design Management Systems

ISO 9000 Quality Assurance

Question 17

What is the 6 sigma rule

Answer 17

If manufactured parts have a normal distribution such that six sigma falls within the tolerance limits then there will be very few failures

Question 18

What is lean manufacturing

Answer 18

Lean manufacturing is a method for minimizing waste within a manufacturing system without sacrificing productivity

Question 19

What is a poka yoke

Answer 19

any mechanism in a lean manufacturing process that

helps an equipment operator avoid mistakes

Question 20

For an asymmetrical distribution around the mean, what is the equation for the worst case scenario

Answer 20

z_2 = | x_m - L_2 | / sigma

Question 21

What are Cp and Cpk

Answer 21

Process capability numbers (for symmetrical and asymmetrical respectively)

Question 22

What is Cp equal to

Answer 22

t/3*sigma

Question 23

What is Cpk equal to

Answer 23

x_m – L_n | / (3*sigma)

Question 24

What does a house of quality table look like?

Answer 24

Customer requirements (column list); customer priority (1-5); Engineering requirements (row list)
Correlation denoted by 1, 3 or 9

Question 25

What is house of quality used for

Answer 25

Converting customer requirements into engineering requirements

Question 26

What does Total quality management (TQM) embody?

Answer 26

TQM emphasizes right first time, continuous quality improvement and prevention over inspection

Question 27

What must be considered when defining product architecture?

Answer 27

What is the sales volume? What is the desired performance? Should the product be adaptable or upgradeable (modular)