UNIT 15 L4 PLANNING FOR ACCURACY Flashcards
What is vital to planning for accuracy and efficiency?
A detailed product design specification (PDS) is vital to give a clear list of the clients essential and desirable requirements.
List some pre-production quality assurance procedures
- CAD simulations
- Working drawings with tolerances
- Mock-up models and mechanical systems
- Client feedback
- Peer review
What do control checks include?
Visual aesthetic checks
Appropriately accurate dimension checks, using flexible measuring equipment, (e.g. vernier calliper) of:
- individual parts
- the overall product
Machine tooling and alignment checks
Assembly checks of multiple components
Quality checks of the manufactured finish
What are the benefits to business of increased accuracy and efficiency?
- Reduced time to market
- Competitve advantage
- Increased market share
- Satisfied customers
What economic advanatages does increased accuracy and efficiency bring?
- Reducing expenditure on energy and materials
- Reducing manufacturing and labour costs
- Reducing the cost of waste processing and disposal
What are the environmental implications of increased accuracy and efficiency in manufacturing?
- Fewer resources used
- Less energy used
- Lower levels of pollution
- Less waste created
What does a product design specification include?
- Development
- Prototyping
- Testing
- Product planning
- Production
What are working drawings
Working drawings are used to show technical detail to enable accurate modelling and manufacture, at all scales of production
What is the purpose of modelling and prototyping?
3D CAD modelling and physical prototyping allow designers to realise designs prior to the product and test them against the PDS including:
- Anthroprometrics
- Function and usability
- Form and aesthetics
- Tolerances
What type of research is used in the pre-production stage?
Market research methods are used in the pre-production stage to gain objective insight into prototype products, these include:
- In-home studies and surveys
- Consumer consulting boards
- Focus groups
What does accurate measuring lead to?
Vital for functionality but also increases efficiency, leading to reduced:
- Waste
- Material costs
- Disposal and recycling costs
- Time required
What does computer-aided manufacturing (CAM) help do?
Enables greater repetitive accuracy and is used in batch, mass and continous production methods
Examples of CAM machinery
- laser cutters
- CNC router
- lathes
- milling machines
How do CAM machines work?
Machines read code generated from CAD software which can plot efficient tool paths, these can be optimised for speed
How can you cut parts to reduce waste?
Cutting parts or components from the edge of a piece of material saves space and reduces wastage
Give two methods of reducing wastage when cutting out parts
Nesting shapes limits the amount of waste material by closely grouping them
Tessellation revises the layout, including more shapes, increasing efficiency and reducing waste, however, this is not always possible and depends on the cutting process used
Explain what patterns are
Can be full sized guides on paper, card or hardboard and include accurate information for drilling, cutting, etc., but pattern is also the term for a wooden shape used for casting
Explain what templates are
Can be more permanent than a pattern; this will often be a piece of board material cut from a pattern
Explain what jigs and fixtures do
are used to hold materials to be cut, drilled or machined accurately and safely
What different processes are used in cosmetic products so that the production line can be completed?
- forming and molding
- application of labels
- insertion of product
- application of lids and caps
Why might sub-assembly be important to incorporate?
This allows manufacturers to outsource parts, make use of specialist skilled labour and increases efficiency and quality
In a car for example, what sub-assembled parts could be included?
- engines and gear boxes
- seats and upholstery
- dashboards, entertainment and navigation equipment
