Unit 10 - Product Manufacture complete Flashcards
When were product lines introduced?
1900s
coincided with the introduction of standardised components
Bespoke production (one-off)
‘Tailor-made’ to specific user needs
Made by highly skilled people
Made predominantly ‘by hand’
Of high-quality using quality materials
Time-consuming to produce
Batch production
for more than one but less than a thousand units
may use CAD/CAM
used for
Mass production
Uses a production/assembly line
High-level of automation
High initial set-up costs
food packaging and containers
One-off production profile
A small company or crafts person with
a limited number of staff
Close communication with the client
High-quality materials are used
Highly skilled labour is required
for handcrafted elements
Unique and high-quality products
are produced in low volumes
High unit cost
Batch production profile
A simple production line
Some level of automation
Skilled and semi-skilled workers
Flexibility to adapt their product line
Produce limited product runs
Lower unit costs
Mass production profile
High set-up costs and capital investment
Shift work is used to facilitate 24/7 production
Both skilled and unskilled labour are required
Expensive purpose-made tooling and machinery required
High-level of automation
Low unit cost
Less flexibility for product diversity and slow to respond to change
Lean production
Overproduction
Waiting
Transportation
Over-processing
Excessive inventory
Unnecessary motion
Defects
Finite element analysis
simulates real-life materials and can test them through non-destructive virtual testing
meaning materials do not need to be wasted
FEA can be used to simulate stresses on components and measure how they react under real-life simulations
can help to identify weaknesses in materials
Computational fluid dynamics
simulates the movement of liquids and gases
tests can mimic real-life weather conditions and product performance
can run scenarios and accurately record data that would be more difficult to run in real-life
Fused deposition modelling
melted filament is extruded through a nozzle, run by a CAD program and built up in layers
time-consuming but doesn’t require much manual work as the process is predominantly automated
requires knowledge of CAD and correct equipment
JIT manufacturing
JIT (just in time) focuses on producing exactly the amount you need at exactly the time your customers need it, which saves on storage, excess unused materials and transportation of products. Resulting in a streamlined manufacturing process as manufacturers can respond quickly to demand.
However, JIT manufacturing can be risky, as disruptions to the supply chain can greatly impact the production
Vertical in house production
integrates parts of the supply chain into the company, which increases productivity and profit
provides a reliable source of components since they are sourced internally
these components are also set at a fixed price that will not fluctuate, unlike externally supplied products
high capital outlay (cost)
more complicated management structure
Quick response manufacture (QRM)
reduces time in response to demand
production is triggered by demand rather than traditional trend forecasting
increased flexibility in manufacturing
improved internal and external communication
time-based competition (good time management) can be used to beat the competition
increased reliance on suppliers
Unit production systems (UPS)
UPS use overhead tracks to move and organise components
- increases workflow control
- streamline and speeds up production
- reduces labour costs
- stages of production are logged
What are the 6Rs ?
Reduce, reuse, recycle, refuse, repair, rethink
Flexible manufacturing systems
allows manufacturers to adapt and change products, and materials and alternate between scales of production, depending on demand
uses multi-functional tools and easily adaptable dies to allow for easy adaptability with limited downtime
Modular/ cell production
divides work into individual work teams
teams focus on achieving quality and reducing waste
each ‘cell’ is linked through computer controls
robotic arms help to transport components alongside automated guided vehicles (AGV)
RFID - tags and barcodes
can be used to track products and scanning products can help to update inventory and collect sales information
reduces risks of human error
expensive setup and repairs
Computer integrated manufacture (CIM)
Uses computers to aid with planning, and can help with research, planning and inventory control
requires regular monitoring and data feedback
can be used in all management stages (production, distribution and storage)
Electronic data interchange (EDI) & Electronic point of sale (EPOS)
EDI - exchange of data within a company
allows for flexibility within businesses as all data is collated together
EPOS - allows sales data to be collected, sales can trigger reordering of stock, which reduces downtime and increases productivity
Computed aided quality control (CAQC)
Reduces human error
Enables efficient inspection and testing
Generates feedback data
Standardisation
Manufacturers comply with universal norms, so parts integrate seamlessly
components use the same measurements
Standards are set by bodies like the British Standards Institute (BSI) and the International Standards Organisation (ISO)
Bought in components
bought in components may be sub-assembled (particularly more complex components)
CAD files of components can be provided to virtually test the final product before purchasing physical versions
