design for manufacture and project managament

Question 1

planning for accuracy and efficiency

Answer 1

clear list of the clients essential and desirable requirements
needs to be tested against specification
evaluated for suitability and the achievable level of accuracy
clear schedule with deadlines and clear QC

Question 2

ensuring accuracy of prototype designs

Answer 2

heavily on a UCD approach with client feedback
pre production
- cad simulations, client feedback, peer review
production
- visual aesthetic checks, manufactured finish

Question 3

ensuring accuracy jn small medium and large scale production

Answer 3

• CAD like simulation
• sample prototypes
• templates
• visual aesthetic checks
• machine maintenance and tool replacement

Question 4

quality assurance

Answer 4

procedure and policies to reduce waste produced accurately within set acceptable tolerances
‘right first time and every time’
QC issues will decrease
CAD modelled to make sure they fit
FEA analyse the stresses in the working life
MFA check flow materials within moulding machinery

Question 5

project management systems
total quality management

Answer 5

remove waste and produce products right first time
for continual improvement
communicate procedures and understanding is essential

Question 6

project management systems
scrum

Answer 6

first used within software development
work in a team
achieve goals in short sprints
individuals feedback progress and issues

Question 7

project management systems
six sigma

Answer 7

process improvement
minimise defects
reduce the number of defective products to less than 3.4 every million
define
measure
analyse
improve
control

Question 8

project management systems
lean manufacture

Answer 8

reducing number of defective products through monitoring
systematic approach
elimante all waste
transport- reduce distance
inventory- reduce raw materials on site
movement- minimise movement
waiting- split evenly
over production- don’t over buy materials
over processing- don’t produce too many
defects- remove

Question 9

critical path analysis

Answer 9

analyse all individual stages within a project
in time order
reoragamise ofer dependencies and structure the order
longest and shortest time path

Question 10

quality control

Answer 10

monitoring testing checking materials
throughout the production process
- material checks- visual, chemical testing, colour matching
- dimensional accuracy- fit within set limits
- digital measuring devices- calliper +_ 0.02mm, interval sample testing
- go/no go gauge- fits within tolerance
- coordinate measuring machinery- range of pre defined measurements on finished components high accuracy

Question 11

non destructive testing

Answer 11

internal structure of materials after joining processes
x-ray and ultrasound waves

Question 12

monitoring checking and testing throughout production
case study

Answer 12

allied glass is a world producer of high quality glass containers
facilitate a wide range of varying designs
600 million containers per year

Question 13

monitoring checking and testing throughout production
stage 1 customer specifications

Answer 13

developed closely with customer
specific criteria

Question 14

monitoring checking and testing throughout production
stage 2 concept development

Answer 14

design devleopment is done in house
concurrent approach
guiding customer through production limititsiodn
modelling in solid form using 3D CAD
2 rapid prototyping machines

Question 15

monitoring checking and testing throughout production
stage 3 mould design and sampling

Answer 15

mould of container is developed to fit the existing production equipment
design must conform
- working drawings with tolerances
- sample prototypes
- sample dimension checks
- visual aesthetic checks
- machine alignment
- machine maintenance
- destructive testing
- template and jigs