Manufacturing systems Flashcards
Define - flexible manufacturing system
A flexible manufacturing system (FMS) is a manufacturing system in which there is some amount of flexibility that allows the system to react in case of changes, whether predicted or unpredicted. This flexibility is generally considered to fall into two categories, which both contain numerous subcategories.
Advantages of flexible manufacturing systems
- fast response to market changes, shorter lead times
- products can be customised for individual consumers
- allows for quick changes in product production
- increased productivity due to automation
- lower labour costs due to automation
- reduced risk of error due to automation
- consistant quality due to automation
- creates higher skilled technical jobs
- production systems can respond to market demand
Disadvantages of flexible manufacturing systems
- high initial set up cost
- production rate could reduce on large batches due to CNC machines being slower
- staff would need retraining
- substancial planning is required
- complex manufacturing systems required
- loss of manual skilled work
- maintenance down time interrupts production
- high skilled technical jobs are a cost to the company
What is Just in time production (JIT)?
The purpose of JIT production is to avoid the waste associated with overproduction, waiting and excess inventory
Advantages of Just in time manufacturing
- no wasted storage of materials
- no wasted time as production delays are eliminated
- no waste energy as movement of materials is minimalizied
- minimilized faulty products as quality assurance systems are established
- no wasted labour due to careful planning
- no wasted equipment as machinery used efficiently
What is concurrent manufacturing?
Concurrent engineering, also known as simultaneous engineering, is a method of designing and developing products, in which the different stages run simultaneously, rather than consecutively. It decreases product development time and also the time to market, leading to improved productivity and reduced costs.
advantages of concurrent manufacturing
- quick to respond to demand/trends
- high quality product leads to customer satisfaction
- increasing quality of products
- multi-skilled workforce gives flexibility
how does concurrent manufacturing enable quick response?
- key teams from all departments work together at each stage of the design reducing product development time
- by overlapping the development process lead times are reduced
- helps overcome production delays
- enables first time designs to be correct
- teamwork leads to product quality improvements
- reduces demand to market time
advantages of automated stock control
- reduces the need for large costly storage areas
- production lines can be balanced efficiently
- resources are in the right place at the right time
- reduces the transportation of materials
- enables quick response manufacturing
- reduces labour costs
- no human error in record keeping
- never run out of stock
- less waste
- stock only arrives when it is required
disadvantages of automated stock control
- high set up costs
- staff training has cost implications
- the system is dependent on efficient delivery times
- increased unemployment
Moving manufacture offshore to a different country
advantages to the developing country
- increased employment opportunities
- increased training for workers
- increased wealth/standard of living
- local infrastructure improved
- develops local economy
- brings increased levels of technology to the country
Moving manufacture offshore to a different country
advantages for the company moving there
- can use cheap labour
- less legal restrictions e.g. waste disposal
- being a large employer they can gain political influence
Implications of CIM (computer integrated Manufacturing)
- reduced need for manual skills
- increased unemployment as many skills become automated
- some jobs reduced to machine minding / repetitive / boring
- improved safely levels as workers removed from hazards
- workers need CADCAM skills / able to work with computers
- workers need to be retrained
- workers need to be flexible to fulfil a number of roles
- increased literacy and numeracy are required in order to access ICT based systems
Advantages of CAM (computer aided manufacture)
- repetitive accuracy
- the ability to save and reload the CAD drawings to suit demands
- the ability to machine complex shapes
- the speed of production
- reduced labour cost
- increased safety
- continuous 24/7 production
- reduced human error, less waste
disadvantages of CNC machinery compared to Manual
- more expensive to buy
- loss of skilled workers
- highly skilled workers required for set up
- poor job satisfaction, boring
- does not recognise errors
- CAM lacks flexibility
- computer systems can become corrupted leading to lost work.
