Production systems Flashcards
1
Q
What is general terms that describes manufacturing?
A
Than an input as well as control and mechanism transform to an output.
2
Q
What are the five fundamentally different transformations?
A
They are:
- Separating
- Putting together
- Detaching
- Forming
- Quality adaption
3
Q
Describe what a production process is
A
A chain of specific transformations for each specific product and variant
4
Q
What are the different types of production system?
A
They are:
- Fixed position
- Functional layout
- Batch flow
- Line flow
- Continuous process
5
Q
Describe what a fixed position production system is
A
- The production system is special for each project and produce few products (one piece).
- It has generic and flexible equipment.
- An example where this is used is construction and power- and shipbuilding.
6
Q
Describe what a functional layout production system is
A
- A functional layout is machine oriented in such a way that the machines is organised in groups based on what type of machine it is.
- It has sequence flexibility.
- It can produce many different products in small volumes.
7
Q
Describe what a batch flow production system is
A
- The batch flow production system is product oriented with few products and few variants produce in higher volumes.
- High value added in the group.
8
Q
Describe what a line flow production system is
A
- A line flow production system is product oriented.
- It used to mass produce and have a even and high demand.
- It’s machine or operator controlled
- It has dedicated equipment and low flexibility.
9
Q
Describe what a continuous flow production system is
A
- A continuous flow production system produce a limited product range measured in tons, liters, meters, etc.
- It has a high level of automation and physically linked units.
10
Q
What influence the choice of production system?
A
- Product
- Volumes and number of variants
- Available space
- Existing production/system
- Customer order decoupling point
- Manufacturing strategy
11
Q
Draw the product-process relation
A
See figure in lecture Manufacturing Strategy
12
Q
Draw the volume-variety graph
A
See figure in lecture Manufacturing Strategy
13
Q
What is the customer order decoupling point (CODP)?
A
The customer order decoupling point is the point which splits the flow into two parts:
- what is produced on expectation i.e on forecast
- what is produced for a specific customer order
14
Q
Describe the P/D ratio
A
The P/D ratio is the ratio between Production Lead Time and Delivery Lead time.
The production lead time covers from the production is initiated to that the customer order is delivered.
The Delivery lead time is from the that the customer order is received to the customer order is delivered. The start of this is the decoupling point.
15
Q
Describe the common COPDs
A
Make to Stock: Long forecast short commitment
Assembly to order: A bit shorter forecast and a longer commitment
Make to order: Pretty short forecast and long commitment
Engineer to order: Short forecast and very long commitment.
See figure in lecture Manufacturing Strategy
16
Q
What WIP?
A
Work in Process
17
Q
How does the tie-up of assets depend on the customer order decoupling point?
A
It depends on the stock level and the time it takes to reach a finished product.
18
Q
What is a strategic advantage as a manufacturing strategy?
A
- Unique manufacturing technology
2. Better performance using common technology
19
Q
Describe what a manufacturing strategy is
A
Manufacturing strategies comprise a series of decisions concerning process and infrastructure investments, which over time provide the necessary support for the relevant order-winners and qualifiers of the different market segments of a company
20
Q
What are the performance objectives?
A
- Quality
- Speed
- Dependability
- Flexibility
- Cost
21
Q
What are the decision areas?
A
- Capacity
- Supply network
- Process technology
- Development and organisation
22
Q
Draw the operations strategy matrix
A
Draw the matrix of performance objectives and decision areas
23
Q
Describe the sand cone model
A
The sand cone model is a way to describe the competitive priorities. You have to have the bottom layer/layers because otherwise the sand cone collapse.
The order is:
- Quality
- Deliverability
- Cost efficiency
- Flexibility
24
Q
What are some if the common KPIs?
A
- Quality
- Cost
- Speed
- Dependability
- Safety
- Sales
25
What is the hierarchy of manufacturing systems?
1. Manufacturing system
2. Production system
3. Production process
4. Production technology
26
Describe production technology
The resources are:
- workers
- manual machinery
- automated machinery
- robots
The equipment:
- tooling
- tools
27
Describe the life-cycle of a production system
Research, Engineering, Design
--> Acquisition, Deployment, Installation
- -> Operation
- -> Maintenance
- -> Replacement, Retirement, Disposal
28
What can be used to design/analyzing products?
- CAD
- BoM (Bill of Materials)
- EBoM (Engineering Bill of Materials)
29
What are some examples of innovation driven by technological evolution?
- Physically smaller components fulfill the same function
- Components become more integrated
- Overall products become more complex
30
What is innovation?
The conversion of new knowledge into economic and social benefits.
31
Describe product innovation
Product innovation involves the introduction of new goods or services that are substantially improved. this might include improvements in functional characteristics, technical abilities, ease of use or any other dimension.
32
Describe process innovation
Involves the implementation of a new or significantly improved production or delivery method
33
Describe product-production systems
When a improvements is beneficial from a product and production stand point for example modularisation both easier to produce standard parts as well as giving more product variants.
34
Describe what product-service system (PSS) is
The physical product isn't necessarily the product the company sell instead it sells the service of that product.
For example Sunfleet
35
What is remanufacturing?
A used product is industrially renovated in order to assure quality
36
What can support remanufacturing?
1. Pave the way for easy remanufacturing of systems and components that have a low pace of development
2. Pave the way for easy updrading/replacement of componenets that have a high pace of development
3. Pave the way for easy repair/replacement of components that often break or deteriorate
4. Pave the way for easy re-configuration of systems and components whose context-of-use differ much during their life cycle
5. But, one should not remanufacture good that inherently have a short service life
37
What is sustainable consumption about?
Sustainable consumption is related to the process of purchasing, consuming and disposing of products.
38
What are the sustainable consumption target in developing countries?
If there is insufficient accessible resources to meet basic need
Target
- Effectively expanding the resource based to meet human needs
- Increasing access to energy through renewable or clean energy technologies
- Use of forest for energy. food and construction in a way that avoids irreversiable damage
39
What are the sustainable consumption target in developed countries?
Resources are more extensive, wasteful and inefficient
Target
- Altering consumption patterns to achieve reduced material and energy
- Reduce intensity per unit of functional utility
Organic produce?
40
What is sustainable production?
The creation of goods and services using processes and systems that are:
- non-polluting
- conserving of energy and natural resources
- economically viable
- safe and healthful for workers, communities and consumers
- socially and creatively rewarding for all working people
41
What is the Triple Bottom Line and what is a challenge with it?
It is to evaluate the company from a broader perspective than just finances.
Ecological sustainability
- To preserve the earth's production capacity and to reduce harmful environmental impact in the long term
Social sustainability
- That ethical rules are applied and that basic human needs are met in the present and for the future
Financial sustainability
- To maintain long-term human and material resources
A challenge is the relevance and weighting of each factor. What is more important for an organisation?
42
Who and how decides if a system is sustainable or not?
Stakeholders
Through the use of tools on particular measurement points that allow them to have more objective judgement they can decide if a system is sustainable enough or not. For example, LCC, LCA & SLCA.
43
What are indicators?
Indicators are typically numerical measures that provide key information about a physical, social or economic system.
Its objective is to compress large amounts of information from different sources intro format easier to under, compare and manipulate.
44
How can indicators contribute to a more sustainable production?
Enable identification of more sustainable options.
By:
- Comparison of similar products made by different companies
- Comparison of different processes producing the same product
- Benchmarking of units within corporations
- Rating of a company against other companies in the sector
- Assessing progress towards the sustainable development of a sector
45
What are the challenges in the use of indicators?
- Indicators that are not so relevant
- Wrong set of people deciding the indicators
- Generalizing indicators across industries
- Keep indicator number small and manageable
- Use the indicators objectively in the decision making process
46
Explain LCCA
Life-cycle cost analysis (LCCA) is a method for assessing the total cost of facility ownership. It takes into account all costs of acquiring, owning and disposing of a building or building system.
It's especially useful when project alternatives that fulfill the same performance requirements, but differ with respect to initial costs and operations cost, have to be compared in order to select the one that maximizes net savings.
47
How can we ensure sustainability in the economic aspects?
Business models
48
Explain some business models
Business model is in which way the enterprise delivers value to customers
Sustainable business model
- Go beyond delivering economic value and create competitive advantage through superior customer value while contributing to sustainable development of the company and society.
Circular business model
- Sustainable business models that extend the value of products and processes within their life cycle .
- Cradle to cradle approach
- Example: Closer customer relationship through service agreement or by the seller owning the product
49
What are the five requirements of a sustainable business model?
1. Diversity
Diverse set of resources, people and investments
2. Modularity
Less interdependent organisations that can be insulated from shocks
3. Openness
Sense horizon beyond their boundaries. React to potential futures and help shape them.
4. Slack resources
Innovation and adaption requires both financial and creative investments.
5. Matching cycles
Understand rhythms of business and the environment to synchronize and not overreact.
50
Explain LCA
Life cycle assessment (LCA) is a multi-step procedure for calculating the lifetime environmental impact of a product or service.
The complete process of LCA includes goals and scope definition, inventory analysis, impact assessment and interpretation. The process is naturally iterative as the quality and completeness of information and its plausibility is constantly being tested.
51
What is Cradle-to-Grave?
- Raw material extraction
- Manufacturing
- Transportation
- Usage
- Disposal
52
What environmental impacts are there?
- Greenhouse gases
- Particulates
- Water withdrawal
- Toxics
- Land use
53
What application of LCA for production systems are there?
To support decision for production, procurement, logistics, waste management options for more efficient and environmentally sounder operation by identifying the hotpots within the processes.
Therefore:
- To detect sources of inefficiencies and/or where environmental efforts are mostly needed
- To show companies possibilities for economy and environment win-wins
54
Explain SLCA
Social Life Cycle Assessment (SLCA) is a method that can be used to address the social and sociological aspects of products and potential positive as well as negative impacts along the life cycle.
It can be used to promote improvement of social condition and of the overall socio-economic performance of a product throughout its life cycle for all of its stakeholders.
55
What methods for control and measure for a sustainable production are there?
- LCA
- LCCA
- SLCA
56
How can companies influence a more sustainable society?
- Big companies have a great opportunity to influence and set standards
- Put pressure on subcontractors
Reduce your own resource utilization
- Training
- More durable products
- Lifespan
- Recycling
- Alternative business models
57
What is life cycle thinking?
A way of thinking that includes the economic, environmental and social consequences of a product or process over its entire life
58
Draw the Industrial Revolutions Curve
See figure in introduction lecture
59
What are the four stages of industrial revolutions?
Industry 1.0 - 1750
Steam
Industry 2.0 - 1900
Electricity
Industry 3.0 - 1960
Electronics
Industrie 4.0 - 2000
Internet
60
What is Scientific Management?
The principal object of management should be to secure the maximum prosperity for the employer, coupled with maximum prosperity for each employee. Around the year 1910
61
Explain mass production
- Started with Ford 1908
- Interchangeable parts
- Division of labour
- Time-motion study
- Dedicated equipment
- User-friendly: owner-driven/repair
62
Explain a bit about industry 3.0
A time where a lot of changes happening from what is smart production in the 50's with assembly lines to smart production in 1992 with robotcells/CIM. A fear from the public that machines would "take over" production, lights-out factories.
63
Explain four dimensions of Industrie 4.0
1. Horizontal integration across value networks
2. Vertical integration and networked production systems
3. Digital consistency of the engineering across value chain
4. Man as conductor of value creation
64
What is the difference between occupation, jobs and tasks?
Occupations describe the complete role of a person in a work situation.
An occupation contains many tasks and sub-tasks that people perform in a work situation.
Jobs describe the number of people in a specific role/occupations that are needed for the company to fulfil the customers requirements.
65
What will the impact on automation on "jobs"?
Automation will not take jobs but tasks.
There is also a difference between physical automation and cognitive automation. Automation and AI will change the skills needed in the workforce.
66
What is Product Life Cycle?
It refers to the consecutive and interlinked stages of a product system from the acquisition of raw materials to end-of-life disposal
67
What is raw material?
The materials or substances used in the primary production or manufacturing of a good.
68
What are the stages of the life cycle?
Beginning of Life: Design and manufacturing
Middle of Life: Usage phase, maintenance
- Usage phase includes all the time when the products are used for the function they have been required. This may require resources such as electrify and may cause pollution or other emissions.
End of Life: Reuse, Remanufacturing, Recycle and Disposal
- When a product or material has no or marginal value for the owner and which the owner wants to discard.
69
What are the four stages of a LCA?
1. Scope and goal definition
2. Life Cycle Inventory
3. Life Cycle Impact Assessment
4. Life Cycle Interpretation
70
What do you do in the first step of an LCA?
Goal and Scope
Goal
- Why, reason for the study?
- Who, is the audience?
- What, product/system?
Scope
Functional unit
System boundaries
How far upstream, downstream and sidestream the analysis goes
71
What is attributional and consequential LCA?
Consequential
- LCA compares product/alternatives with each others. For decisions upon waste management options and recycling schemes, product development, process choices.
Attributional
- Analyzes the total life cycle of a product with the purpose to assess its own environmental impact for: eco-labeling, finding the hot spots within processes
72
What is a functional unit?
A functional unit is determined for the scope of the LCA.
The quantified performance of a product system for use as a reference unit.
73
What five qualities should have functional unit have?
1. Verb!
2. What?
3. How much?
4. How well?
5. For how long?
74
What are the steps of an LCI?
Data collection:
- raw materials and energy
- products, direct and indirect
- emissions
How the allocations keys are decided gives different LCI results.
75
Explain LCI
LC Inventory includes:
Data collection, detailed flow chart, and calculations to get the quantities of resources required and emissions and waste generated per functional unit
76
Explain LCIA
LC impact assessment is the evaluation of potential human health and environmental impacts from the resources and releases identified during the LCI
77
What is eco-efficiency?
Do more with less
78
What are the steps in the improvement hierarchy?
Starting from the top:
1. Prevent
2. Reduce Waste
3. Reduce resource use
4. Reuse waste as resource
5. Substitute, upgrade, replace
79
What is automation?
Automation is the automatically controlled operation of an apparatus, a process, or a system by mechanical or electronic devices that the place of human organs of observation, decision and effort.
80
Why automate?
- Increase capacity
- Increase productivity
- Reduce personnel needs
- Decrease monotonous and repetitive tasks for humans
- Introduce a more even and increased product quality
81
What are some of the challenges with automation?
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DEMANDS
Internal
- Reduce cost/time
External
- Sustainable "eco-friendly"
```
```
RESOURCES
Effective
- "Doing the right thing"
Efficient
- "Doing the thing right"
Allocation
- "Man or machine"
```
```
MEASURES
Direct
- Cost, time quality, LoA
Indirect
- Flexibility, productivity
```
82
What are some example of operator 4.0?
- Virtual operator
- Super-strength operator
- Collaborative operator
83
What are for key parts for maturity for industry 4.0?
- Resources
- Information systems
- Organizational structure
- Culture
84
Explain physical automation
- Mechanical automation
- More common
- Tools, robots, etc.
85
Explain cognitive automation
- Information and control
- Less common
- Instructions, pick-to-light
86
Explain Level of Automation
1. There are 7x7 Levels of Automation = 49 possible solutions
2. To suggest solutions a current state analysis of flows, LoA, information system, competence levels and perceived complexity is useful.
3. The humans and the organisation are critical for a successful implementation.
87
Draw the Level of Automation Matrix
See figure in Lecture 'Automation Strategies and Level of Automation'
88
What is remanufacturing?
The process of rebuilding a product, during which the product is cleaned, inspected and disassembled; defective components are replaced; and the product s reassembled, tested and inspected again to ensure it meets or exceeds newly manufactured product standards.
89
What are the steps of remanufacturing?
1. Inspection
2. Clean
3. Disassembly
4. Storage
5. Reprocess
6. Reassembly
7. Testing
90
Explain three company incentives of remanufacturing?
Profit
- Cost reductions
- Customer demands
- New product sales
Environment
- Legislation
- Moral and ethical issues
Policy
- Protecting aftermarket
- Protecting brand
- Providing additional aftermarket solution
91
In what way is remanufacturing good for the environment?
- Most environmental calculations show that re-manufacturing is preferable option in comparison with new manufacturing and other end-of-life options
- Reduction of Global Warming Potential
- Chances to close the loop for safer handling of toxic materials
92
What are the challenges for remanufacturing?
1. Lack of control
2. Lack of economic motivation
3. Lack of knowledge
93
Why is PSS a driver for remanufacturing?
- PSS reduce the uncertainty of when and how many cores that arrive to remanufacturing.
- PSS give possibilities of condition monitoring that can provide useful data for remanufacturing.
- PSS facilitate OEM (Original Equipment Manufacturer) remanufacturing with much product data knowledge from remanufactuing and good feedback loop to product design
PSS and full core knowledge is an approach to overcome tough remanufacturing challenges
94
What is productivity?
Productivity is a ratio of outputs to inputs
95
What is the point of line balancing?
To get a efficient production line the work loads on the stations shall be as equal as possible. Which is done by in an even way as possible distribute the work tasks to the work stations on the line.
96
What is a work task?
A sequence small operations that can not be or inconvenient to change the order of.
97
What is a work station?
A physical defined place on the assembly line where at least one task is performed.
98
What is cycle time?
The time it takes for one station to perform the tasks assigned to a station
99
What is takt time?
The maximum time the production line has available before the product goes forward
100
What is disturbance in a production flow?
Any breakdown or problem in one or more stations resulting i a stop or higher cycle time.
101
What is a buffer?
A temporary storage products in a production flow
102
What are the two scenarios in line balancing?
1. Fixed stations
Know number of stations, therefore minimize the takt time as mush as possible
2. Fixed takt time
In order to reach the takt time, minimize the amount of work stations and resources used
103
What is balance loss?
Balancing loss is the proportion of time allocated for processing but not used
It's the difference between takt time and that cycle time.
B=((Number of stations*Highest Cycle Time)-Total Time)/(Number of stations*Highest Cycle Time)
104
Explain what a Precedence Relations is
The work tasks to the performed are related to the other tasks. Therefore, some tasks have to be performed before the other are made.
105
Explain the Theory of Constraints
In order to reduce the system losses:
1. Identify the systems constraints
2. Decide how to exploit the systems constraints
3. Subordinate the other resources to the constraints
4. Elevate the systems constraints
5. If in any of the previous steps a constrain is broken, go back to step 1
106
What are the steps of developing a production system?
If there is an existing product the steps are:
Designing/analyzing products
- CAD
- Bill of Materials, BoM
- Engineering Bill of Materials, EBoM
From EBoM to Process Design which requires information about
- Material
- Resources, such as equipment, machines and workers
- Activities
Create MBOM for the resources.
From the MBOM the next step is the technological aspects
och något mer bla bla bla.
107
What are the five working principles of Theory of Constrains?
1. Identify constraint
2. Exploit constraint
3. Subordinate all resources to global decision
3. Elevate constraint
5. Overcome inertia
108
Draw the graph of "competing through production"
See lecture Manufacturing Strategy
109
What is reactive maintenance?
Reative maintenance:
- Run-to-failure
- Repair
110
What is preventive maintenance?
- Time-based maintenance (or periodic maintenance)
- Lubrication
- Cleaning of equipment
111
What maintenance strategies are there?
Connect maintenance strategy with business strategy
Preventive maintenance
- Predictuve maintenance
Conditon-based maintenance (CBM)
- Condition monitoring
Autonomous maintenance
- Production operator maintenance
112
What are the maintenance concepts?
1. Preventive maintenance
- Productive maintanence
2. Maintainability
3. Reliability - RCM
4. TPM
- TQM
- JIT
5. CMMS
113
Explain maintenance management
Measure
- Maintenance KPIs
- Tools used in maintenance
Plan & Perform
- Maintenance planning and scheduling
114
Describe some maintenance KPIs
1. Measures of equipment performance
- Availability
- Reliability
- MTTR
- MTBF
- OEE
2. Measure of cost performance
- Maintenance cost
- Labour cost
- Inventory cost
. Material cost
3. Measures of process performance
- The ratio of planned and unplanned work
- Scheduled compliance
115
What are some maintenance tools?
- What-if
- Root cause analysis
- Fault tree analysis
- Hazop
- FMEA
116
Describe maintenance planning
The objective of the maintenance planning function is to effectively utilize the maintenance staff and minimise the impact of ...
117
What is the purpose of maintenance management?
Effects on productivity
Maintenance task prioritization and workforce allocation.
- Good equipment maintenance will improve the productivity of that equipment
- Maintenance should be the focus on critical equipment
- Prioritization of maintenance will not only improve the productivity of that equipment but also the entire system
- Maintenace workforce need to continuously updated on the critical equipment to effectively plan and schedule maintenance
118
How is the division of types of maintenance in industry today?
70 % Reactive maintenance
30 % Preventive maintenace
Starting with maybe some with predictive maintenance
119
Why is maintenance important?
Utilization efficiency during stable production. A big part of what causing down time losses is maintenance related.
The cost of maintenance has increased and a large part of the total production cost goes to maintenance activities.
Poor maintenance can cause social, economical and ecological sustainability losses.
- production inefficiency
- Equipment failures can cause blockage and idle times
- It is often safety critical
- Consumes more energy to repair than produce
120
Give a brief introduction to the history of maintenance
Has underw
121
Give a brief introduction to the history of maintenance
Has underwent much transformation and went form "nothing" to major industrial strategy.
122
Explain the first generation of maintenance
This was pre 1950s. It was mostly manual work with simple machines and low downtime. As such only form of maintenance was repairs and it was the start of reactive maintenance.
It was seen as necessary evil and "firefighters" increased in industry.
123
Explain the second generation of maintenance
It took place during the 1950s.
Industries become more dependent on equipment that also became more complex. There was a need to stop the equipment from failure so a more scientific approach to maintenance took place and it was the start of preventive maintenance.
Maintenance department was first introduced in industries.
Finns förklaring fram till 1970 but fuck this shit.
124
What was the problems faced during the second generation of maintenance 1950?
Problems faces was:
- Caused inefficiency
- Scheduled PM caused downtime
- Non-value adding PM activity was hard to find
- Questions raised on equipment reliability and maintenance cost
125
What is reliability-centered maintenance?
RCM is a process used to determine what must be done to ensure that any physical asset continues to what its it to do its present operation context.
The tools are:
FMEA, Failure mode and effect analysis
126
What are three components of TPM?
The three components of total productive maintenance are:
1. Maintenance prevention
- Prevent by simple machine design and eliminate parts which requires high maintenance.
2. Preventive maintenance
3. Autonomous maintenance
- Major contribution of TPM
- Production and maintenance department work together
- Major maintenance work done by maintenance
- Production operator maintenance
127
Explain the third generation of maintenance
It's from 1980 to 2000.
- TPM and RCM continued to grown (and is at work today)
- Started with computerized maintenance management system.
- Database tracked and recorded every maintenance work orders and downtime.
View of maintenance changed from technical matter to profit contributor.
128
Explain maintenance since 2000
The product and the equipment has become more complex along with an increased demand, quality and speed of products. Industries are still working with the same concepts.
The scope of maintenance is expanding and new technology such as industry 4.0, RFIDs and IoT means the field of maintenance management is currently even more challenging and going changes more than ever in its brief history.
129
Explain dependability
Dependability of production systems includes:
- Reliability
- Maintainability
- Maintenance support
130
What are the parts of mainteance managaement?
- KPIs
- Tools
- Planning and scheduling
- Decision support system for maintenance operation
131
What is maintenance planning?
The objective of the maintenance planning function is to effectively utilise the maintenance staff and minimise maintenance downtime on the production capacity of the plant.
132
What is maintenance scheduling?
Scheduling a maintenance work order requires maintenance planning, allocation of time, and availability of equipment.
133
Effective maintenance planning and scheduling will?
- Increase availability
- reduce product quality problems
- Increase production capacity
134
Explain effective maintenance planning
Data is important
- needs to gather and maintain data
Data on, for example
- MTTR
- MTBF
- Repair history
Maintenance plan contains
- Scope and location of job
- Job priority
- Materials and tools required
- Safety procedures
135
Explain maintenance decision support
It must include:
- Bottleneck detection
- Maintenance task prioritisation
- Maintenance staff allocation
- Maintenance opportunity windows
- Joint production and maintenance scheduling systems
