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manufacturing Flashcards

1
Q

what are the …… of manufacturing scales of production

A

high volume production
batch production
one off production

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2
Q

what is high volume production

A

involves the continuous production of standard items over a long period of time

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3
Q

what type of industry should not use high volume production

A

industries that undergo rapid changes (fashion and technology)

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4
Q

what is the aim of high volume production

A
  • make as many production in the most efficient manner possible
  • make products as consistent and identical as possible
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5
Q

what makes high volume production possible

A
  • economic of scale
  • buying large quantities of parts and materials allows them to be brought at a lower cost
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6
Q

what are the wages like for high volume production

A

unskilled workers
- robots
- automated process

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7
Q

what is the production timing like for high volume production

A
  • fast, efficient production
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8
Q

why is there a large investment in captial required to set up high volume production

A

build equipment
developing automated systems to improve efficiency

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9
Q

what processes are suitable for High volume production

A

fast and efficient
create consistent and identical parts and products

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10
Q

what are the processes used in high volume production

A

injection moulding
blow moulding
high pressure die casting
press die casting
press forming operations

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11
Q

what can high volume production be

A

continuous flow
repetitive flow

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12
Q

what is continuous flow

A

products are made on a production line, one process after the other
- usually highly fully automated

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13
Q

repetitive flow

A

production is broken down into sub- assemblies, which are assembled together at the end of the process

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14
Q

what is batch production used for

A

where change occurs fairly and frequently - type of product remains similar, but the exact natural of product changes frequently
(fashionable products)

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15
Q

what does batch production mean

A

different versions of the similar type of product can be made

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16
Q

what must the equipment be in order for it to be used in batch production

A

flexible

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17
Q

what is the labour like in batch production

A

intense - requires more skill than those employed in hv

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18
Q

what i the difference between batch production and High volume production

A

batch production is more labour intense whereas high volume production labour is easy

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19
Q

what are processes frequently used in batch production

A
  • vacume forming
  • sand casting
  • steam bending
  • sewing
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20
Q

what workers are used in batch production

A

skilled or semi skilled
- need to be switched rapidly and respond quickly and efficiently to needs of clients

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21
Q

what is one off production also known as

A

bespoke / custom made

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22
Q

bespoke meaning

A

custom made

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23
Q

what is the production like for one off items

A

slow
- work carefully and methodically and with great deal of care and attention

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24
Q

what type of materials are used in one off production

A

high quality

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25
what equipment is used in one off items
hand tools - saws - files -lathes - sewing machines
26
what is the advantage of one off
equipment comes at a far lower cost - capital outlay is low
27
what is modular / cell production system use
use a number of production cells grouped together to manufacture a component / sub-assembly
28
what does modular / cell production usually consist of
group of machines assembly inspection point
29
what workers are required in order to to modular / cell production systems
multi skilled - can be automated
30
how is modular / cell manufacture laid out
workstations are arranged in a logical manner to produce one complete item at a time
31
how is rate of production decided in modular / cell manufacture
customer demands
32
why should cell / modules be accurately scheduled
to ensure that the correct number of components / sub-assemblies is produced in time for the final assembly of the product
33
how are cell / team manufacture laid out
workstations are carefully positioned in a logical manner to ensure minimal and quick movements from one operations to the next
34
who is responsible for production and quality of products in cell / team manufacture
the team
35
what is the job satisfaction like for cell / team manufacture
high level job satisfaction
36
sub-assemblies
elements of the finished product are brought together before the main assembly - drawer in a desk
37
standard parts
parts brought in from other companies - buts bolrs and zips
38
what are the benefits of buying in parts
reduce the amount of processes needed on a production line
39
what are the benefits of a car company of buying in sub-assemblies such as air conditioning units
- many cars have the same or similar air conditioning units - there is no need for the equipment and space required to make the ac units - the company that make the ac units will have a specialist equipment and employees with specialist knowledge and experience - the car company may have a choice on suppliers - using JIT, storage can be kept minimum
40
what are the drawbacks of a car company of buying in sub-assemblies such as air conditioning units
- suppliers need to be reliable - time may be needed to allow for ordering and supplying - the car company has no control over the quality of the ac unit
41
one-off
- high cost products - made by skilled craftspeople who are paid well - production is slow and not efficient - simple slow cost equipment means capital outlay is low
42
high volume production
- 24/7 production of identical objects - very fast and efficient - high automated / low workforce - low cost products - capital outlay is huge
43
batch production
- any quantity between 2 and several thousand - semi-skilled / skilled workforce - flexibility - ability to produce a wide range of different products - important that it is easy to switch from one product to the next with minimum down time / to adapt quickly to changes in demand - often operated as a modular / cell production system
44
modular / cell production
- use a number of production cells grouped together to manufacture a component / a sub-assembly - usually consist of - group of machines - assembly - inspection point - multi skilled workers - can be automated
45
cell / team manufacturing
- work stations are carefully positioned in a logical manner to ensure minimal and quick movements from one operation to the next - team is responsible for the production of their output - high job satisfaction
46
what is the aim of lean production
get to the right place at the right time, in the right quantity to achieve perfect workforce
47
what are the three groups of stock / inventory
- materials and components - work in progress - finished products
48
materials and components
- brought in from suppliers to be used in manufacturing
49
work in progress
incomplete products currently being manufactured
50
finished products
assembled and ready for distribution
51
what is the aim of just in time
reduce stock to smallest level possible
52
what needs to happen in just in time for it to work
goods needs to be manufactured as they are required
53
benefits of just in time
less space reduce cost less risk of damage sue to less transport goods are made to order nothing manufactured that isnt required less waste
54
disadvantages of just in time
reliant on suppliers to deliver material and products no buffer stock to fall back on miss out on 'economic of scale' that might make bulk orders less expensive suppliers need to be close to manufacturing plant frequent transport of suppliers has environmental impact
55
what has a massive effect on just in time
Brexit
56
what are the four management methods
gantt charts scrum six sigma critical path analysis
57
what does gantt chart provide
clear schedule to help plan and track specific tasks against a time frame
58
what happens in scrum
a team work towards a goal by dividing tasks into short timescale sprints
59
what does the team do in scrum
attend daily scrum updates / stand up meetings where individuals feedback their progress towards the team goal
60
what is six sigma designed to do
minimise defects
61
what is the aim of six sigma
reduce defective products to less that 3.4 in every million
62
what does six sigma use
DMAIC
63
what does DMAIC mean in six sigma
define - what is the issue with the purpose measure - takes steps to measure the extent of the issue analyse - determine where the issues occur improve - introduce measures to rectify the issues control - ensure modified procedures are implement and maintained through effective Q&A
64
what is a critical path analysis
method to plan the most effective and time sequence in which to complete a task
65
how does a critical path analysis work
the project is split down into smaller tasks which are arranged in the correct order - dependencies are analysed and a sequence is planned which has the least and possible amount of waiting time
66
what does quality control mean
monitoring, checking and testing of materials and components throughout the production process to ensure they conform to acceptable standards and tolerance specified within the quality assurance policies set by the company
67
where does quality control take place
take place throughout the production process and are performed in conjunction with strict guidance documentation produced by the company and the client
68
raw materials should be checked for
dimension defects warps damage from transport
69
types of quality control tests
size of dimensional accuracy tests on electronics circuits tests to check parts have been welded together properly visual inspection to check quality of finish tests to check colour tests to check strength of parts chemical analysis
70
what can a product be tested by
human or robot
71
how are dimensional checks made
tools and equipment can be tested to check that materials, parts and products are the correct size
72
dimensional check equipment
vernier callipers micrometer screw gauge co-ordinate measuring machines GONOGO gauge
73
what measuring devices are used during quality checks
venier caliprs micrometer screw gauge tolerance GONOGO gauges
74
what does the measuring device tolerance specialise in
minimum and maximum measurements
75
what is a GONOGO gauge used for
check that specific parts are within tolerance
76
how can you ensure consistency when making a product
jigs jigs and fixtures former's moulds
77
when are jigs and fixtures helpful
when welding or brazing
78
what are former's used for
bend around so that a chape can be cut
79
what are moulds used for
casting
80
what are critical control points
stages of the project that are identified at which QC checks are performed
81
what does quality assurance involve
putting into place all the actions which are required to ensure quality - a series of planned actions and procedures are set up to check the product before, during and after manufacture
82
what is total quality management
philosophy designed to ensure the products being manufactured are all conistant and of good quality
83
what principles are used in total quality management
continuous improvement in every part of manufacturing process
84
what does total quality management rely on
every employee to be responsible for thair quality standards

junk (pd) (5 decks)

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