Problem Sheets

Question 1

Typical steps for one product

Answer 1

• Shaping of the part — usually a multi-step process
• Surface finish
• Painting
• Joining/assembly
• Quality control — not all components go through this
  Average is 10 operations per component

Question 2

The percentage contribution of Manufacturing to global GDP has been dropping since
records started a few decades ago. What is replacing that value?

Answer 2

Other sectors of the economy are experiencing an inverse trend. For example services
(tertiary industries) are becoming more prominent. At the same time, expenditure in
Science and Research, which do inform manufacturing, is experiencing massive growth.

Question 3

The historical trend has been for products to be made with an increasing number of components (compare a Ford focus with the Ford Model T). At the same time, design for
manufacturing principles encourage product designers to reduce the number of components. How can you explain these opposing trends?

Answer 3

The drivers for increasing number of components may include: increasing complexity
of products, more use of standardized components, reuse in design and the drivers for
reducing the number of components would be: ease of assembly and disassembly and
requirement for a smaller skilled workforce.

Question 4

Problems encountered while machining

Answer 4

• The location of the hole is likely not to be accessible.
• Thin walls will deform under the large forces during machining.
• The curved surface prevents gripping of the part.
• Sharp corners can be a challenge.
• Surface finish on curved base will be of low quality.

Question 5

Explain how economies and diseconomies of scale may work in a coffee shop.

Answer 5

Economies of scale occur when existing coffee machines and resources are used more efficiently, reducing costs. Diseconomies of scale happen when expanding capacity requires purchasing more expensive machines and providing additional training, which increases costs.

Question 6

An online retailer of cycling accessories has a 30-day, no-questions-asked return policy and relies on its reputation for quality service for word-of-mouth marketing. A customer ordered a pair of pedals but received two left pedals causing damage to their crank threading during installation. Identify and explain the different gaps in expectations and perceptions that are demonstrated in this scenario.

Answer 6

Although the organization delivered the wrong product, it is unlikely that it satisfies their internal specifications to make such blatant errors. In other words, this is unlikely to be a gap between management concept and organization specification (Gap 2). It is more likely a mistake in implementation, i.e. a deviation between (packaging) specifications and the actual product (Gap 3). At the same time, the actual product does not match the customer’s expectation, hence Gap 4 is also present. In order for the customer expectations to match the organizations internal standards, the response to the problem has to be substantial, if Gap 1 is to be avoided.