Part 5 - Design for Manufacutre Flashcards
Why are tolerances required?
Machine misalignments
Tool Wear
Material Property Variations
What can cause asymmetric distributions around the mean?
Tool wear. E.g. on a lathe if the tool wear it becomes shorter but the reference position stays the same. Avoided by regularly checking the tool.
Why are Cp and Cpk used industry
Ensures more products are produced closer to target value.
If Cp- Cpk > 0.5 then Cpk must be used
Describe house of quality table
Used to convert customer requirements into engineering requirements. Whilst subjective it still improves product quality.
What must be considered when devising a manufacturing strategy for a new product?
What is the best product footprint? - How is the brand defined.
Is the product part of a family? e.g. Audi A1 A2 A3 etc…
Should the product be a service? - Manufacture to reduce maintenance costs?
Is the product intended to be first to market or a fast follower?
When should the product be retired from market?
Are any parts to be outsourced?
Should sub assemblies be multi functional?
Should there be mass customisation?
State 5 scales of production for a given product?
Engineer to order - Built to customer spec- F1 cars
Make to Order - Based on standard design but made to order E.g. Rolls Royce
Assemble to Order- Built to customer spec from existing components. E.g. Ferrari
Made to stock - Product built against sales forecast. E.g. Low end cars
Ship to Stock - Same as made to stock but inventory is held by the retailer. E.g. gears
Advantages/ Disadvantages of Modularity
Advantages: Ease of maintenance Quality control over assembly. Sealed for life Aids testing Enables new technologies to be easily integrated.
Disadvantages:
Difficult to repair small defects
Requires HVM
Advantages of Platform Design
Easier inventory management Lower development costs Increased quality Global standardisation Greater product variety
How to minimise mass and volume of a product?
Integrated product within minimal interfaces.
Minimise assembly complexity?
Modular designs with standard interfaces.
How does modularity impact recycling?
Makes high level disassembly easier but sub level disassembly harder. It can make remanufacture easier;
Why is quality management important?
Ensures quality of design and manufacture. Adequate paper trails, design reviews, material/component sourcing.
Describe main stages of BS 7000 Design Management Systems.
1 - Managing Innovation 2- Managing design of manufactured products. 3- Managing service design 4- Managing design in construction 5- Managing inclusive design
Key aspects of ISO 9000
International standards to help companies effectively document the quality system elements. Specifically Requirements, Fundamentals and Vocab, Managing for sustained success and guidelines for auditing management systems.
What is Total Quality Management
Emphasis on: prevention rather than inspection, right first time, continuous quality improvement.
