Unit 10 Scale of Production Flashcards
What is laser cutting?
A versatile and rapid process for etching or cutting sheet material.
How does a laser cutter operate?
A machine head moves across t while mirrors reflect a laser beam from the tube into the machine head and onto the material.
What is the primary effect of laser beams on materials?
They vaporize or ‘cut’ materials with extreme precision.
What is kerf in laser cutting?
The narrow cut path created by the laser beam.
What types of materials can school laser cutters typically cut?
Papers, boards, timber, polymers, and some fabrics such as felt or leather.
What types of materials are suitable for cutting with industrial laser cutters?
Metals
What are some limitations of laser cutting?
Limited by the thickness and type of material; cannot cut 3D shapes.
What is CNC routing?
A process that uses rotating cutting tools to waste away materials.
What materials can CNC routers work with?
Timbers, composite sheet materials, polymers, foams, and in some cases, certain metals.
How do CNC routers differ from laser cutters?
CNC routers use rotating cutting tools and are more labor-intensive to set up.
What is essential during CNC routing and laser cutting?
Extraction to prevent the build-up of waste material.
What is CNC milling?
A process that cuts materials using a range of different spinning cutting tools.
How many axes can CNC milling machines operate on?
3-5 axes.
What is the purpose of coolants in CNC milling?
To flood the workpiece and lubricate for a perfect finish.
What is CNC turning?
A process where the workpiece spins/moves while cutting tools are used to waste or cut materials.
What functions do CNC lathes perform?
Parallel turning, facing off, knurling, etc.
Are CNC lathes are controlled manually.
No
What is the benefit of using pneumatic vacuum beds in CNC routers?
They hold materials in place with little bother.
What is a key safety feature in CNC milling processes?
Enclosed screens to increase safety.
What are NB Lathe attachments used for?
increase functionality of CNC routers and enable CNC turning of wooden parts
NB Lathe attachments enhance the capabilities of CNC routers.
What does a plotter enable?
Cutting, drawing, and scoring based on a 2D CAD file
Plotters use a pen or blade to manipulate materials.
How does a plotter operate?
Moves a pen or blade across the surface of a material using CNC G-code
Rollers clamp and pass the material back and forth during operation.
What can be adjusted on a plotter to suit different materials?
The pressure applied by the machine head
This customization helps differentiate between cutting and scoring materials.
Which types of materials are used on plotters?
Rolls and sheets
Rolls offer greater efficiency and reduced waste from off-cuts.
What are some industrial applications for plotter cutting?
Sign making and manufacture of stickers for branding of vehicles
Plotter cutting is crucial for precise branding materials.
What can self-adhesive vinyl be printed and cut to?
Extremely accurate tolerances
This allows the vinyl top layer to be cut without going through the backing paper.
What was the traditional use of plotters?
To produce full-size engineering and architectural drawings
Interchangeable pens allowed for different line thickness and colors.
What does Scale refer to?
Type of product
Demand (long and short)
Unit Cost
Set-up Cost
What significant technological advancement occurred around 1780?
The invention of steam powered machines and early automation
This marked the beginning of the Industrial Revolution.
What type of change did the Industrial Revolution initiate?
A social and economic change that began to improve living standards for the masses
This change was driven by various factors including employment opportunities.
How did the Industrial Revolution improve living standards?
Through employment, movement of people and goods, mills, mines, and agriculture
These factors contributed to economic growth and social mobility.
Fill in the blank: The late 1700s saw the invention of _______.
[steam powered machines and early automation]
True or False: The Industrial Revolution led to a decline in living standards for the masses.
False
What was one of the primary effects of steam powered machines?
Improvement in employment opportunities
This led to increased movement of people and goods.
What is a bespoke product?
A bespoke product is often seen as an investment as each product is unique.
What are examples of bespoke products?
Examples include suits and dresses, artwork, ceramics and jewellery, architecture, and furniture.
What is batch production?
Batch production is used when a greater number of products are required.
What is the range of product quantities in batch production?
From more than one to thousands of units.
What tools are commonly used in batch production for accuracy?
Jigs, moulds, formers and templates.
How does CAD/CAM relate to batch production?
CAD/CAM may be used in batch production.
What type of products is batch production suited for?
Seasonal products with limited demand.
Name some types of products produced through batch production.
- Printed items such as newspapers, magazines, and books
- Most clothing
- Perishable food products
- Seasonal goods
What is mass or line production?
Mass or line production is used when a high number of products need to be produced quickly and consistently.
What are the characteristics of mass or line production?
It uses a production/assembly line, has a high level of automation, and involves high initial set-up costs.
What types of products is mass or line production suited for?
It is suited to high and continuous product runs including packaging and containers, many food products, materials like steel and timber stock, and paper stock and paper products.
How Does the cost of materials relate to the quality of the product?
Global financial markets can cause raw materials costs to fluctuate which can lead to company only affording the bad quality
What factors should be considered when selecting materials for a product?
Material properties, manufacturing processes, form and standard sizes, cost and availability, sustainability.
How does scaling up production affect material and process suitability?
The suitability of materials and processes changes with the scale of production.
What is a benefit of handmade products?
Handmade products celebrate the skills of artisans and avoid high set-up costs.
What processes are ideal for flexible manufacturing while maintaining accuracy?
CNC and CAD/CAM processes.
What does mass production favour?
Mass production favours automation with fewer labour-intensive processes.
What can careful layout of parts using nesting or tessellation reduce?
Waste
What technology allows parts to be laid out to make optimal use of materials?
CAD/CAM
How can the shape or size of a design be modified?
To make best use of materials
What do manufacturers aim to capitalise on?
The standard shapes and sizes of the materials they use
What are designs developed to maximise?
Output from standard sheet size/thickness
What can a product with a strong structure economise on?
Materials
How can key pressure points be reinforced?
With ridges and fins
What can be reduced by reinforcing key pressure points?
Overall wall thickness and weight
What are older materials often substituted for?
Those offering superior properties
What is a key consideration in many designs regarding waste?
Their own waste streams
What can waste materials and faulty parts be?
Recycled and reprocessed in-house
What type of products can be developed to encourage reuse?
Bags for life and printer cartridges
What can manufacturing processes increase?
Manufacturing processes can increase accuracy and reduce waste for maximum efficiency.
How do accuracy and waste reduction impact profits?
Accuracy and the reduction of waste increases profits and ensures efficient use of resources, including time and labour.
What do manufacturers work to?
Manufacturers work to strict tolerances which allow parts and products to function and integrate reliably.
What are the two physical states of materials?
Materials exist in one of two physical states: solid state and liquid state.
What happens in the solid state of materials?
In the solid state, materials are cut, formed, and fabricated.
What happens in the liquid state of materials?
In the liquid state, materials can be injected and cast.
Is waste inevitable in manufacturing?
Yes, waste in the form of off-cuts or overflow is inevitable.
What are companies moving towards in manufacturing?
Companies are moving away from linear manufacturing systems to create a more circular economy.
What should companies rethink in manufacturing?
Companies should rethink materials and processes, focus on sustainability, look for additional revenues, and consider social responsibility.
What percentage of waste is mentioned?
93%.
What have rapid technological developments reduced?
Rapid technological developments have worked to reduce human error.
What did the Industrial Revolution transform?
The Industrial Revolution transformed manufacturing, replacing people with machines to increase productivity, consistency, and accuracy.
What do automatic processes and CNC processes offer?
Both automatic processes and CNC processes offer high levels of accuracy and waste reduction.
What developed as modern manufacturing processes advanced?
As modern manufacturing processes advanced, management systems developed too.
What are the economic advantages of bulk production?
Bulk production has various economic advantages, including the ability to negotiate discounts on raw materials and reduced logistics and transport costs.
How does bulk production affect processing costs?
Bulk production makes automatic processing financially viable, saving time and labour costs.
What can manufacturers do with waste streams in bulk production?
Manufacturers can capitalise on waste streams by reusing waste or selling it on for reprocessing.
What is the Just In Time (JIT) method?
The Just In Time (JIT) method streamlines manufacturing to make products on demand.
What costs does JIT reduce?
JIT reduces costs associated with storing surplus inventory, such as real estate and energy costs.
How does JIT help manufacturers respond to market demands?
Manufacturers can respond quickly to market demands through the JIT method.
What is a benefit of lower production costs in JIT?
Lower production costs can be passed on to consumers, allowing companies to undercut competitors.
What data is collected when a customer places an order?
Details of the product and quantity required, payment information, delivery destination, and so on.
What happens if a product is in stock after an order is placed?
The packing and distribution process may begin instantaneously.
What additional details are required for products made to order?
Specification of the product (styling, aesthetics, design features), details of any customization, and so on.
What is a lead-time in manufacturing?
A lead-time is generated depending on the complexity of the product required and production schedules.
What is the role of software in manufacturing?
Software follows algorithms to manage tasks, plan and manage manufacture on complex and adaptable production lines.
How are products, parts, and orders tracked in manufacturing?
They are tracked with barcodes and radio frequency identification (RFID) tags.
What type of data does software produce in manufacturing?
Spreadsheets and visual data on sales, buying habits, inventory, distribution, and so on, updated in real-time.
What is Computer Integrated Manufacture (CIM)?
CIM enables seamless progression from product development to manufacture, allowing employees to do higher value jobs.
What are the benefits of a multi-skilled workforce?
Better trained staff gain greater job satisfaction, which enhances productivity.
What does CIM usually involve?
A high level of automation and relies on feedback from sensors during production.
What are some advantages of CIM?
Reduced set-up and lead times, easier set-up and control with CAD, CAM, and CNC compatibility, and JIT delivery of materials.
What is the purpose of analyzing data from CIM?
To improve efficiency and avoid errors, such as monitoring machine performance to reduce downtime.
How can production be triggered in manufacturing?
By orders or data from electronic points of sale (EPOS).
What is the role of EPOS in retail environments?
EPOS activates repeat orders to keep shelves stocked without a large inventory.
How do loyalty and rewards cards help in marketing?
They help profile individual customers for targeted marketing.
What technologies are used to track products during manufacture?
Barcodes, QR codes, or RFID tags.
How do algorithms improve distribution systems?
They produce realistic work schedules and lead times for the production of products.
What is the benefit of integrating packaging into the production line?
It speeds up distribution and can reduce waste.
How do storage facilities use computer software?
To facilitate optimum use of space in storage facilities and freighters for transporting goods.
What are Automatic Guided Vehicles (AGVs) used for?
To arrange and collect products in warehouses and storage facilities, reducing labor costs and human error.
What is the function of scanning in manufacturing?
To identify products/parts and accurately calculate quantities of materials needed for production runs.
How does integrating scanning reduce errors?
It allows data to be fed back to computer systems, reducing human error and incorporating the use of Kanbans.
What is the purpose of digital tags in inventory management?
Digital tags make stock and order data visible throughout the process in real-time and reduce the need for storage of raw materials, saving money.
What is Kanban?
Kanban is a system that uses cards (visual or digital tags) to track inventory and details of customer orders, triggering re-orders to maintain low inventory levels.
How do barcodes and QR codes differ?
Barcodes and QR codes can be scanned to identify parts/products; QR codes can store larger amounts of data as they hold data vertically and horizontally.
What are RFID tags?
RFID tags are identification and tracking devices using radio waves, containing an integrated circuit (IC), and can be either active or passive.
What is the difference between passive and active RFID tags?
Passive RFID tags are powered by electromagnetic energy from the reader and can be read from 25m, while active RFID tags have their own power source for two-way data transfer up to 100m.
How does data analysis benefit production?
Data collected from computer systems is analyzed to optimize future production, respond to customer feedback, and enhance customer service.
What methods are used to collect customer feedback?
Online surveys and focused questionnaires allow researchers to quickly collect and assimilate feedback.
What is the significance of detailed customer profiling?
Detailed customer profiling informs product development and marketing by providing a better understanding of consumer needs.
What concerns arise from sharing personal data?
Sharing personal data raises concerns about targeted advertising influencing user behavior and potentially undermining democratic systems.
What is GDPR?
The General Data Protection Regulation (GDPR) protects personal data, requiring manufacturers to have consent systems and declare cookies.
What is Computer Aided Quality Control (CAQC)?
CAQC makes quality control more efficient by integrating testing into the production line and identifying problems immediately.
How does CAQC improve manufacturing?
CAQC uses feedback data to ensure efficiency and consistency, preventing issues like product recalls and diagnosing problems early.
How is packaging integrated into the production process?
Packaging materials are ordered as needed, and codes are scanned to ensure correct delivery, reducing waste.
What advantage does integrating distribution into manufacturing provide?
Integrating distribution allows for tracking orders, enhancing security, and providing customers with accurate delivery updates.
What is Computer Integrated Manufacture (CIM)?
CIM uses computers to enable planning and control of the production process.
What aspects do computer systems integrate in manufacturing?
Computer systems integrate planning, research, design, testing, development, purchasing, accounting, inventory control, and distribution.
What is a key characteristic of Computer Integrated Manufacture?
It involves a high level of automation and relies on feedback from sensors and data streams.
What is the benefit of regular checks in an integrated manufacturing system?
Regular checks provide constant data feedback.
What is one purpose of monitoring performance in manufacturing?
To eliminate downtime.
How does data analysis contribute to productivity?
It helps in increasing productivity.
What can data analysis lead to in a manufacturing context?
Making improvements.
How can machine performance data be utilized?
To reduce downtime.
What is traditionally used to model and test products?
Physical prototypes.
What is a characteristic of making models by hand?
It is a highly-skilled and labour-intensive process.
What are some materials used to create handmade models?
Various materials can be used, including wood, clay, and plastic.
What is destructive testing?
A testing method that involves destroying the model to assess its performance.
What are the disadvantages of doing destructive tests on physical models?
Destructive tests can result in the loss of the model and may require additional time and resources to create new models.
What is an advantage of CAD models over handcrafted models?
CAD models offer a more versatile alternative.
What can virtual modelling software do?
It can define the properties of materials and match the real-life, full-size product.
What is a benefit of CAD files?
They are easy to edit and output using CAM.
What is the purpose of software testing in manufacturing?
Software offers a huge range of simulations and tests that can be carried out prior to manufacture.
What is meant by ‘products tested to destruction’?
Products can be tested to destruction with little cost, and numerous tests can be repeated rapidly.
How do digital simulations benefit engineers?
Digital simulations allow engineers to spot errors, gather precise data, and work to tight tolerances.
What is Finite Element Analysis (FEA)?
FEA simulates specific loads and stresses on parts and components.
What can FEA measure?
FEA can measure exactly how well products will perform under real-world forces.
What types of mechanical stresses can be analyzed with FEA?
Mechanical stresses like vibrations, heat, torsion, and compression can be analyzed.
What can be identified and resolved through FEA?
Weaknesses in the design can be identified and resolved to improve performance.
What does Computational Fluid Dynamics (CFD) simulate?
CFD simulates the flow of gases and liquids.
What can tests using CFD mimic?
Tests can mimic extreme weather conditions with virtual wind tunnels and wave tanks.
How can products be developed using CFD?
Products can be developed to optimize the flow of gases and fluids, e.g., vehicle engines.
What is Fused Deposition Modelling?
Fused Deposition Modelling (FDM) is a 3D printing process that extrudes melted filament through a nozzle to build objects in layers.
What materials are commonly used in Fused Deposition Modelling?
A variety of materials can be used, often thermoplastics.
What is rapid prototyping?
Rapid prototyping is a CAM method that produces physical prototypes from CAD files.
How are 3D shapes built in rapid prototyping?
3D shapes are built up from 2D layers.
What is sintering in 3D printing?
Sintering uses a laser to fuse layers in a bath of powder.
What is stereolithography?
Stereolithography uses a laser to cure a bath of resin, solidifying it layer by layer.
What should you consider when listing advantages of rapid prototyping?
Consider versatility, time, and cost as guiding keywords.
What are traditional methods of collecting data from market research?
Traditional methods include paper-based surveys, interviews, and focus groups. These methods are time-consuming and require manual data-entry.
How do digital tools improve data collection?
Digital tools speed up data collection and collation, making it cheap and efficient. Online surveys collect and collate data automatically, and video conferencing makes interviewing more flexible.
What is Electronic Data Interchange (EDI)?
EDI is the exchange of digital data within a corporation, which increases efficiency and flexibility, reduces costs, and enables cloud-based file sharing.
What is an Electronic Point of Sale (EPOS) system?
EPOS is a holistic system that allows a company to monitor sales, stock, and gain insight into customer behaviour. Sales data is gathered and analysed for future business plans.
How can EPOS systems assist in customer profiling?
EPOS systems collect data on specific customers for marketing purposes, using loyalty card schemes to provide valuable data for targeted advertising.
What does Production, Planning and Control (PPC) coordinate?
PPC coordinates various manufacturing activities to meet market demand as effectively as possible.
What data is used in PPC to streamline manufacturing?
Data from logistics and labour, materials, and machinery is used to streamline manufacturing.
What is the goal of PPC?
The goal of PPC is efficient and economic operation.
What does a Master Production Schedule (MPS) allocate?
An MPS allocates labour, materials, and time to a job.
How can planning software assist in production?
Planning software can prioritise and schedule tasks to avoid delays in production caused by downtime and bottlenecks.
What does PPC enable companies to monitor and deploy?
PPC enables companies to monitor and deploy materials and employees strategically.
What are the benefits of using PPC?
PPC ensures time and resources are used wisely and reduces costs.
What does PPC efficiently control?
PPC efficiently controls orders and deliveries.
How do suppliers and distributors relate to PPC?
Suppliers and distributors are coordinated to reduce transport costs and revenue tied up in inventory.
What is the impact of improved logistics on customer experience?
Improved logistics enhances the customer experience.
