Manufacturing Practices & Materials Components And Fabrication Flashcards
(140 cards)
1
Q
What are the different types of scales of production?
A
-One-off/Jobbing production
-Batch Production
-Mass production
-Continuous production
2
Q
What is one off/jobbing production?
A
Making a single product to the specific requirements of the consumer. So every item will be made differently
3
Q
What are the disadvantages of one off/jobbing production?
A
-Requires a highly skilled workforce
-Very labour intensive
4
Q
What are some examples of one-off productions?
A
-Bridges
-Statues
-Personalised jewellery
5
Q
What is batch production?
A
Where a specific quantity of products are made, between 2 and 100 units.
6
Q
How does batch production work?
A
A production line is set up where each worker completes a task and passes it along the production line to the next worker.
7
Q
What are the advantages of batch production?
A
-Workers are only semi-skilled or unskilled
-Flexible workforce
8
Q
Why does the production line need to be easily and quickly changed in batch production?
A
So different products can be made
9
Q
What are examples of batch production?
A
-Sport shoes
-Clothes
-Books
10
Q
What is mass production?
A
High volume production of products, usually over 100 units made
11
Q
What is the main disadvantage and advantage of mass production?
A
D: Initial set up cost is high for machinery
A: Since high costs are spread across large number of units the cost per unit is reduced greatly allowing more profit
12
Q
What are the examples of mass production?
A
-Electrical goods
-Cars
13
Q
What is continuous production?
A
Uninterrupted 24/7 mass production of tens of thousands of identical products.
14
Q
How does continuous production work?
A
A semi-automated production line is set up using computer control and a combination of skilled and unskilled workers.
15
Q
What are the advantages of continuous production?
A
-Has unskilled workers
-Workers less flexible than batch manufacturers
16
Q
What are the disadvantages of continuous production?
A
-Training needed for new equipment or new staff
-Quality control occurs at every stage if production.
-High level of investment in machinery needed
17
Q
What are examples of continuous production?
A
-Petrol & oil products
-Cars
-Bricks
18
Q
What is in-line assembly?
A
Used for mass production, most of production line is automated.
19
Q
What is the used of unskilled labour and semi skilled workers in In-line assembly
A
-Unskilled labour used for assembly
-Semi-skilled workers make sure there is continuous flow along production line
20
Q
What are the advantages of in-line assembly?
A
-Human error reduced due to machinery
-Company produced larger quantity of one product
-Labour costs reduced and production increases
21
Q
What are the disadvantages to in-line assembly?
A
-System is inflexible as production process cannot be changed
-Lack of variety in system as all products are all produced on one production line
22
Q
What are flexible manufacturing systems?
A
Where semi-skilled workers are able to do a variety of jobs
23
Q
What is the approach to the idea of flexible manufacturing systems?
A
A flexible workforce and flexible machinery is key to successful manufacturing
24
Q
What are the advantages of flexible manufacturing systems?
A
-Useful for batch manufacturing where change and flexibility needed
-Manufacturing time reduced per product
-Cost per unit reduced
25
What is the disadvantage to flexible manufacturing systems?
Requires alot of pre planning and organisation prior to starting production
26
What does just-in-time manufacture require?
Requires high level of forward planning as materials and components only bought when needed
27
What are the advantages to just in time assembly?
-Resources not stockpiled which saves warehouse space and money
-Reduces chance of stock going out of date
-Avoids build up of unfinished products as demand changes
28
What are the disadvantages to just-in-time assembly?
-Little room for mistakes as minimal stock kept
-Very reliant on suppliers
-No excess finished products to meet unexpected orders
29
What are the two types of industrial practices?
1. Standardised components, assemblies and bought in components
2. Sub-contracting
30
What are standardised components, assemblies and bought in components?
Building of blocks of much more complex products
31
What are the advantages of standardised components, assemblies and bought in components?
-Speed up manufacturing and reduces maintenance and manufacturing costs
-Means manufacturers do not have to create everything from scratch
32
What is the disadvantage of standardised components, assemblies and bought in components?
-Manufacturer depends on other manufacturers to supply them
33
What is subcontracting?
When a part of a job or manufacturing process is contracted out to another source or company to compete.
34
When does sub-contracting occur?
When machines and operators are working to full capacity and production is at its full efficiency but orders are still being placed
35
What are the advantages of sub-contracting?
-Provides relief to manufacturer
-Prevents manufacturing plant from becoming overburdened
-Improves efficiency
-Helps manufacturers meet delivery dates
36
What are the disadvantages to sub-contracting?
-Time consuming
-Difficult to ensure quality
-Tracking parts can be an issue
37
What should improved quality and improved reputation of company return in?
-Greater demand for products
-Increase in production volumes
-Unit costs being reduced
-Higher selling prices
-Customer satisfaction
38
What is quality assurance?
Setting standards and meeting them.
39
What is quality control?
How you check standards of product.
40
What does quality control ensure?
-Does job it was designed to do
-Conforms to design specifications
-Gives customer satisfaction
41
What are the 3 types of sample testing?
1. Measuring
2. Non-destructive testing
3. Destructive testing
42
What happens in measuring in sample testing?
Where measuring can be completed using a limiting gauge, micrometer, vernier gauge. Very time consuming and costly
43
What is non-destructive testing in sample testing?
Testing where the sample isn’t damaged, as testing is visual it used x-rays or dyes to find defects.
44
What is destructive testing in sample testing?
Testing that is physical and destroys product to see how product would collapse or how fractures develop
45
What is tolerance in testing a sample?
The amount of error allowed.
46
What is manufacturing cost?
The sum of all costs of resources needed in process of making a product
47
What are the 3 categories of manufacturing cost?
•Direct costs
•Overhead costs
•Manufacturing overheads
48
What are the 2 types of direct costs?
1. Human
2. Material costs
49
What are the 4 types of overhead costs?
1. Management
2. Administration
3. Research and development
4. Marketing and sales
50
What are the 3 types of manufacturing overheads?
1. Manufacturing equipment
2. Manufacturing plant
3. General overhead costs
51
What are the direct labours cost?
The cost of paying employees directly involved in production process.
52
How to calculate direct labour costs?
Multiply production time period by hourly cost of paying each worker
53
What are the direct materials cost?
The raw materials that become a part of the finished product
54
What are the manufacturing overhead costs?
Any costs which are not the direct labour or direct materials, e.g equipment
55
What is the total cost of manufacturing a product?
The direct costs + the indirect costs
56
What is reforming?
When plastics or metals are liquefied with heat pressure, then shaped with a mould
57
What is deforming?
When the shape of a material is changed
58
What are methods of reforming
-Extrusion
-Die casting
-Injection moulding
59
What are methods of deforming?
-Blow moulding
-laminating
-press/compression moulding
60
What materials and what is extrusion used for?
Used on Thermoplastics and some metals.
Used to make sheets of plastic for fabrication, pipes, tubes etc… And to mould copper for pipes, wires etc…
61
What are the advantages of extrusion?
•High production rates are achievable
•Many materials can be extruded
•Products have very good surface finish
62
What are the disadvantages of extrusion?
•Complex parts can’t be produced
•Only shapes with uniform cross sections can be produced
63
What is injection moulding used for?
To produce bottles, sand buckets, electrical components etc
64
How does injection moulding work?
By forcing the molten material into a closed mould
65
What are the advantages of injection moulding?
•High production rates are achievable
•Products have good surface finish
66
What is the disadvantageof injection moulding?
Very expensive
67
What is die casting used for?
Kitchen equipment and castings for car industry
68
How does die casting work?
Material is melted and poured into a mould that is the required shape of product
69
What are the advantages of die casting
•Fast
•Produces durable parts
•Parts have good surface finish
70
What are the disadvantages of die casting?
•Initial cost setups are high
•Large production volume is required
•Only non-ferrous metals can be used
71
What is made with blow moulding?
drink bottles, cosmetics, plastic pipes
72
What are the advantages of blow moulding?
•Less expensive
•Fast production
•Need for adhesives is reduced
73
What is the disadvantage of blow moulding?
Can only be used to manufacture hollow products
74
What is laminating?
Process of constructing a material with two or more layers together
75
What is made with laminating?
Table, chair legs, roof beams
76
What is press moulding and how does it work?
A mould is made in two halves and sheet plastic is placed between them, they’re heated and pressurised forcing plastics to form the shape
77
What are circular saws used for?
Cutting woods into size
78
What are band saws used for?
To cut wood and other materials for straight or curved cuts
79
What are jigsaws?
A power tool with a thin blade that reciprocates
80
What are jigsaws used for?
Cutting curves and custom shapes into wood and other materials
81
What is a planer used for?
To remove shavings of wood. Used to reduce material to its required size
82
What is a sander used for?
To sand or smooth wood
83
What are the tools used in manufacturing processes?
-Circular saw
-Band saw
-Jigsaw
-Sander
-Planer
84
What is computerised production?
When manufacturing process becomes automated by using computer aided design
85
What are the advantages of CAD systems?
•Produces high quality and consistent drawings
•Changes to drawings are easily made
•Drawings can be emailed
86
What are the disadvantages of using CAD systems?
•Not a substitute to freehand sketching
•Initial set up cost is high
87
What is computer aided manufacture?
The process that converts drawings produced by CAD into actual products
88
What are the advantages to using CAM?
•High production speed
•Flexible as they can be reprogrammed
•Ensures products are produced accurately
89
What are the disadvantages to using CAM?
•Initial setup costs are high
•Training required for the operation
90
What materials are laser cutters used for?
-Plastic
-Wood
-Card
91
What materials are lathes used for?
-Wood
-Metal
-Nylon
92
What materials are routers used for?
-Foam
-Wood
-Metal
93
What materials are milling machines used for?
-Wood
-Metal
-Plastic
94
What materials are milling machines used for?
-Wood
-Metal
-Plastic
95
What is computer integrated manufacture? (CIM)
Central computer system used to link together all stages of design and manufacturing process
96
What are the advantages to using CIM?
•Lower costs
•Human error is reduced
97
What are the disadvantages to using CIM?
•Initial setup cost are high for machinery and training
•Fast special purpose machines cheaper to run for large scale production
98
What is the intended uses for selection of materials?
-What will it be used for?
-Where will the product be used?
-How long will it last?
99
What are the properties for the selection of materials?
-Strength
-Hardness
-Durability
-Malleability
-Heat, electrical conductivity
100
What are the functions of its finish for selection of materials?
-Does product need aesthetically pleasing finish?
-Does it need a protection finish?
101
What are the shape and cross sections of materials?
Sheet, bar, tube, angled, u-shapes channel, i-shaped section
102
What shapes and cross sections can metals be?
-Flat sheet
-Solid bar
-Tubes
-Angled u-shaped channel
-I-Shaped sections
103
What shapes and cross sections can plastics be?
-Rods
-Sheets
-Extruded mouldings
104
What shapes are metals in stock form available in?
-Sheet
-Bar
-Rod
-Tube
105
What shapes are plastics in stock form available as?
-Sheet
-Rod
-Bar
-Granules
106
What is different groups of woods?
-Hardwoods
-Softwoods
-Manufactured boards
107
What is the appropriate use of hardwoods?
-For furniture as very aesthetically pleasing.
-Building beams and flooring as very strong
108
What is the appropriate use of softwoods?
-Furniture, ceilings, doors as it is aesthetically pleasing and easily cut
-Staircases as it also cheaper
109
What can be done to improve the aesthetic of manufactured boards?
They can have a thin layer of wood covering them to improve appearance.
110
What are the different types of manufacturing boards?
-MDF
-Chipboard
-Plywood
-Blockboard
111
What is the issues with using wood?
Shrinkage
Expansion
112
What is the difference between ferrous and non-ferrous metals?
Ferrous contains metal
Non-ferrous don’t contain metal
113
What is an alloy?
A mixture of two or more metals
114
What are the appropriate uses for metals such as brass?
-Malleable and machines well
-Doesn’t tarnish and resist corrosion
-Has good acoustic properties which makes it ideal for musical instruments
115
What is the difference between thermosetting plastics and thermoplastics?
Thermosetting can’t be reheated and reshaped.
Thermoplastics can be reheated to be shaped and moulded
116
What is an advantage and a disadvantage of thermosetting plastics?
A: Resists heat and fire well
D: Cannot be recycled
117
What is an advantage and a disadvantage to thermoplastics?
A: Can be recycled
D: Doesn’t resist heat well
118
Where can butt joints be used?
-Basic boxes or cabinets,
-Building frames
119
Where can dowel joints be used?
-Chair and table legs
-Table tops
-Cabinets
120
Where can comb or finger joints be used?
-Tables and chairs
-Floor boards
-Roof and door construction
121
Where can dovetail joints be used?
-Drawers
-Jewellery boxes
-Cabinets
122
Where can half-lap joints be used?
Framing
123
Where can mitre joints be used?
-Picture frames
-Pipes
-Moulding
124
Where can housing joints be used?
-Bookcases
-Cabinets
125
Where can mortise and tenon joints be used?
-Table and chair legs
126
Where can bridle joints be used?
-Legs or stiles to rails
-Frames
127
Where can corner halving joints be used?
Frames
128
Where can cross-halving joints be used?
-Strengthening rails for tables and chairs
-Trellis
129
Where can biscuit joints be used?
Table tops
130
What are the smart materials?
Shape memory alloy (nithinol) and polymorph
131
What are shape memory alloys?
Alloys that change to their original shape when heated
132
What are shape memory alloys used for?
Glasses frames
133
What is nithinol?
An alloy that when cool is easily shaped but if heated to certain temperature it will return to remembered shape
134
What is nithinol used for?
Glasses frames, wires of teeth braces, equipment for medical industry
135
What is polymorph?
A new type of plastic smart material ideal for model making
136
What is polymorph used for?
One off moulds, orthopaedic splints and specialised prototyping
137
What are the types of composites?
-Fibre based
-Particle based
-Sheet based
138
What are fibre based composites?
Composites reinforced with fibres
139
What is glass reinforced plastic (GRP) made from?
Glass fibres and resin
140
What is carbon reinforced plastic made from?
Carbon fibre and resin
