MANUFACTURE Flashcards
What are the four scales of production
One off/bespoke
Batch prodcution
Mass/line production
Continuos production
One off production
- single item produced
- often specific requirements from customer/client
- higher cost (more wastage, workshop costs, more time taken)
- high skill level/craftsman
Batch production
- 2-5000 products
- use moulds, formers or templates
- limited number
- production line can be decreased or increased on demand
- unit cost is reduced as more are made
- use of computer aided manufacture/design
- usually lower skilled workforce than bespoke
Mass/line production
- large amounts of items in large volumes
- greater use of automation (machinery, cells)
- 1000-100,000 products
- higher volume therfore lower costs
- introduction of assembly lines
- high initial set up = machinery
- need large amounts of storage space
- large usage of programming
- low skilled workforce
Continuos production
- runs 24 hours a day, 7 days a week
- there is always a need for the product eg. milk, water, bread, oil, newspapers
- very expensive set up costs
- requires lots of energy to maintain machinery
- low individual product costs
What are unit production systems
UPS
- used extensively in the production of textile products
- overhead transporter systems incorporating hanging carriers to carry components between workstations
- reduces the number of handling operations and optimises the use of manual labour while improving qulaity of goods
What is vertical in house production
(vertical integration)
- The supply chain of that company is owned by the same company
- when a company require external parts this is known as outsourcing
Benefits
= reduced risk of unexpected price rises for components
= less susceptible to suppliers going out of buisness
= protection of their brand and IP rights
= easier implementation of quality assurance strategies
Just in time
JIT
- the product is produced upon demand, at the right time on the production line
- high efficiency
- extensive planning is needed to ensure effectiveness
- relies on carefully controlled systems and management
- common in the car industry
- relies on delivery of parts from suppliers
- good transport systems and networks
- are essential for the assembly line
- heavy financial effect if delivery of parts is missed
- warehousing and storage costs are reduced
- quicker financial return on investments
In-line production
- product is assembled along a production line
- parts are added in sequence as it moves continuosly along the line
- worker/machine responsible for single/small number of processes
- eg. cars, dishwashers and TVs
- very expensive to set up
- very large quantities of products
Automated production
- assmebly/process carried out by pre-programmed machines and work within set paremeteres
- overseen by an observer to check correct quality and performance
- samples of product are taken at intervals to check quality
Robotics
- computer controlled devices are used to carry out lifting, handling and placing components
- they also can carry out production tasks such as welding and spray painting
- repetitive tasks are carried out that humans find tedious
- carry out tasks that are damaging or dangerous to humans eg. fumes, radiation
- accurate
- consistent
- expensive
- adaptable
- employment concerns
- reduced labour costs
- no human error
- 24/7
Modular/cell production
- combined number of CNC machines in a group = (CNC module or cell)
- the job of loading the material at the start of the process is often done by a robotic arm which can carry out a range of tasks
What are the types of robotics
1st generation
- respond to a pre-set program and will carry on regardless of any external changes
- eg. packing eggs, if one egg broke it would carry on
- these are slowly becoming obselete
2nd geneartion
- fitted with sensors which feedback information to a computer
- the most common feedback method being used is a digitial camera
3rd generation
- use sophisticated sensors and AI
- this type of robot is able to not only detect changes in the environemnt but also modify its working program.
CAD, benefits, disadvantages
= an online desiging tool
- can model
- can make simulation of different materials
- surface model = singular shape
- solid model = assembled shape
- wire frame view = shows connections and parts
- orthographic projection = contains measurements
Advantages
- can be fully automated
- saves time and labour costs
- designs can be communicated electronically
- products can be tested before produced = reduced waste
- material simulations can be done to change aesthetic
- multi-use easy access
Disadvantages
- need skilled people = training costs
- high costs of machihery and software
- not intuitive
- puts labourers out of work
List some CAM machines
Laser cutter
CNC router
CNC miller
CNC lathe
3D printer
3D plotter
(CNC = computer numerical control)
Rapid prototype
= 3D prtotype
FDM = fused deposition modelling
