Lesson 4 Flashcards
is how a company builds or creates a product. It can be a complex activity that involves a range of machinery, tools and equipment with many levels of automation using computers, robots and cloud-based technology.
Manufacturing process
Six Types of Manufacturing Processes
Job Shop Manufacturing
Repetitive Manufacturing
Discrete manufacturing
Batch process manufacturing
Continuous process manufacturing
3D printing
uses production areas instead of an assembly line and is most often used for small-batch, custom products that are made-to-order for certain clients or customers. These workstations might focus on one particular product or a handful of them, like a custom shoemaker or commercial printing press, and easily offer the ability to customize the final product.
Job Shop Manufacturing
is appropriate when making repeat production at a committed production rate. This manufacturing process has dedicated production lines all working on the same product or component all day, every day year-round. Because there is such little changeover and setup, you can match operation speeds to customer demand or client requirements to make more or fewer items.
Repetitive Manufacturing
uses an assembly or production line, though it is much more diverse than repetitive manufacturing and allows for more frequent changeover and variation. A company can have multiple styles, sizes or modifications for a product with discrete manufacturing, though it often means production can take longer because of extra setup or removal as necessary.
Discrete Manufacturing
___________ shares similarities with discrete and job shop manufacturing processes, driven by customer demand or the availability of ingredients and raw materials. One manufacturing run might produce a batch enough to fill client needs, so you finish production, clean the equipment, and resume when you need another batch.
*Food production, newspaper printing, bookbinding, and pharmaceuticals often rely on batch process manufacturing.
Batch process manufacturing
_______________ runs all the time like repetitive manufacturing. The difference is this process focuses on raw materials that are often gases, powders, liquids or slurry.
*Oil refining, metal smelting, paper production and some food products like tomato sauce, juice and peanut butter use continuous process manufacturing.
Continuous process manufacturing
Many in the industry now recognize ____ printing as a sixth manufacturing process with widespread use. Developed in the 1980s,_____printing uses various composites and materials like plastics and metals to make three-dimensional goods layer by layer based on a digital model, rather than using physical labor or mechanization. There has been an enormous expansion in this field, with dozens of equipment manufacturers and hundreds of thousands of _____-printed items already on the market.
•While _____printing can be expensive, it also offers the potential to reduce financial capital, raw materials and waste and lets companies create and test products before committing to them on a larger scale. This growing manufacturing process is already being used for products such as:
3D printing
Other types of manufacturing processes
Machining
Joining
Forming
Casting
uses power-driven tools to shape solid materials and metals by removing extra materials from the piece, usually by trimming. _________ is the foundation of the industry and includes things such as presses, chip-making tools and modern machinery.
Machining
Metal forming bends, spins or stretches using a metal press, die or punching tools. Forming is expensive, though you can reuse equipment by changing the dies.
Forming
involves a solid dissolving into a liquid when heated and poured into a mold or cavity. ______ can create complex or simple shapes from any kind of meltable metal with a wide option for designs.
Casting
is a collection of resources and processes that transform raw materials into finished goods. It aims to produce goods efficiently with high quality. Additionally, it can improve production processes by increasing regulations, reducing waste, and improving product quality and consistency.
Manufacturing System
is a combination of tools and procedures used to turn raw materials into completed products. Its objective is to create products and services profitably, effectively, and by client requests.
manufacturing system
raw materials or parts that will be used in the manufacturing process
Inputs
the methods and techniques used to transform the inputs into the desired output
Processes
the products or services that are created as a result of the manufacturing process
Outputs
The process of such a system typically involves several stages, including:
Planning
Design
Procurement
Production
Quality Control
Distribution
Maintenance
Continuous Improvement
Components of a manufacturing system can include:
Equipment and machinery
Raw materials and components
Labor
Methods and procedures
Software and control systems
Workflow and production planning
Maintenance and repair
Quality Control
Types of Manufacturing Systems
Mass Customization
Custom Manufacturing System
Flexible Manufacturing System
Continuous Manufacturing System
Intermittent Manufacturing System
involves determining the type of products, resources, and production process
Planning
involves designing the products, tools, and equipment used in manufacturing. It may include creating detailed drawings, specifications, and blueprints.
Designing
involves obtaining theraw materialsand components to create the finished products. It may include purchasing materials from suppliers or sourcing them from internalinventory.
Procurement
Transformation of raw materials intofinished goodsthrough various manufacturing processes such as assembly, fabrication, and inspection. It may involve the use of multiple types of machinery and equipment, as well as manual labor.
Production
involves inspecting and testing the finished products to ensure they meet the required quality standards.
Quality Control
involves delivering the finished products to customers or storing them in inventory for future use.
Distribution
involves maintaining the manufacturing equipment and tools to ensure they are in good working condition and can operate at optimal performance.
Maintenance
involves continuous monitoring, which will increase efficiency, reduce waste, improve quality and reduce costs.
Continuous improvement
can constitute the tools and machines used to transform raw materials into finished goods. It can consist of everything from essential hand tools to highly automated and computer-controlled machinery.
Equipment and machinery
are used to create the finished goods. It can include raw materials, such as metal and plastics, to purchased ingredients, such as motors and sensors.
Raw materials and components
includes the human resources needed to operate the equipment and perform tasks such as assembly and inspection.
Labor
include the systems that transform raw materials into finished goods. It includes assembly instructions, fabrication techniques, and quality control procedures.
Methods and procedures
used to manage and control the manufacturing process. It can have everything from simple manual controls to sophisticated computer-controlled systems that monitor and adjust production in real-time.
Software and control systems
include the manufacturing process layout, the flow of materials and information, and the production schedule.
Workflow and production planning
include the __________ of the equipment and facilities to ensure that the manufacturing process runs efficiently.
Maintenance and repair
includes inspecting and testing the finished products to ensure they meet the required quality standards.
Quality Control
This is the most efficient type of manufacturing system, as it uses assembly lines to produce large quantities of products quickly and cheaply. However, ____ production is not well suited for products that require customization or have a lot of variation.
Mass Customization
is designed to produce a specific product or set of products. This type of system is usually used when products are not mass-produced and require special attention during production. One good example of these is handmade furniture and wedding cakes.
Custom Manufacturing System
is a type of manufacturing system that is able to quickly change between different product types or sizes. This type of system is characterized by its use of automated equipment and computer-controlled robots
Flexible Manufacturing System (FMS)
is also known as mass manufacture. It is a process of manufacturing in which processes and assembly are continuously performed during an operation at one station instead of stopping and starting the process.
In this ____________________ , there is no storehouse (raw material) needed. The material would come from one place or another process and go into the next phase immediately without being stored between steps.
Continuous Manufacturing System
Also known asbatch processing, an I__________________ is a type of manufacturing process where products are produced in small batches. This type of process is characterized by its ability to produce a variety of products, its reliance on human workers, and its limited level of automation. A perfect example for this is clothing production.
Intermittent Manufacturing System
