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Systems and Control (Computer - Integrated Manufacture (Lean Manufacturing…

- - - - Example cust info is entered to the ERP and all info is accessible. Employees of different departments use the info to fulfill the request; Admin, stock, logistics.
  - - - Pull Tools - Kanban
        
        Uses cards and containers as simple visual signals to indicate when to 'pull' mats, comp, or products through the production system
        
        System relies on simple rule of only producing or delivering when card or empty container is passed to a workstation or manu cell
        
        Production and Trans Kanban work in a integrated system
        
        Production includes details of ops that need to be carried out at manu cell
        
        Trans only has info on where material, comp have come from and where they need to be delivered to
        
        Main benefit: reduces the amount of work in progress and finished goods in stock; Restricts need for supply of materials until they are needed, provides effective JIT system
    - - Perfection Tools - Kaizen
        
        Also known as a continuous improvement process
        
        Changes are made to the process resulting in small improvements being made
        
        Tends to be carried out on a regular basis; changes are low cost and improvement tend to be small
    - - Manu. Cells allow manufactures, provide customers with the right product at the right time
      - Allows flexibility within for a Manufacturer
      - Achieved by grouping similar products into families that are processed on same equip and sequence
      - A manu. cell is a group of workstations,arrange so a product can be processed progressively from one station to anther; no need to wait for a batch to be completed, removes additional handling
      - Ads and Dis
        
        Ads
        
        Greater control of the production process enabling fully automated production
        
        Safer working environments due to removal of risks to humans
        
        Scale of prod. is directly linked with customer demand, responding quickly to demand
        
        Dis
        
        Extremely high set-up costs, as expensive machinery and installation are required
        
        Negative effects on employment as CAM requires less human involvement in ts operation
        
        Worker morale may be affected due to 'machine minding' job roles
        
        More on Pg 106
    - - CAQ can be achieved within a manu. cell using a coordinate - measuring machine (CMM)
        
        This is designed to move a meas. probe to determine the coords of points of a piece of work; this accuratly measures distances
      - Provides data that can be immediately be fed back into the production process;analyse in small tolerances and control the quality of the product
      - Laser Scanning Tech rapidly being used. Can be used to check sizes and positioning but also creating 3D images in CAD
      - Automatic ID such as OCR and barcode readers used to scan special codes on products very quickly and without any problems
    - - Automated materials-handling systems
        
        Is a device that takes materials from one place to another, trucks conveyor. Start from unloading, storage, machining, assembly, testing, packaging and finally back on truck for distribution
        
        Includes manual and automatic
        
        Manual: Forklifts and lorries
        
        CIM systems; fully automated ensures that materials are delivered to the production line without manual intervention
    - - ASRS Robotic system for, storing, sorting and retrieving from warehouses; all tasks controlled by computer using CIM
      - Necassary for companies to use them:
        
        Manual methods up to 4x slower
        
        Increased efficiency of storage and retrieval
        
        reduces labour costs
        Employees technical skills are developed
    - - AGV is a materials-handling device to move things between machines and work-centres; controlled from instructions by central computer or onboard comp
      - Guided by Radio Frequency wires buried under floor, or optical sensors in a laser-guided nav-system
      - Types of AGV:
        
        Towing Vehicles: very pop to pull all trailer types
        
        Unit Load Vehicles Equipped with decks to transport . Decks: lift, lower; powered, non-powered, chain or belt or custom decks
        
        Pallet Trucks: palletised loads from floor level
        
        Fork truck: services loads from floor and stands. Can be used for stacking
        
        Light load: transport small parts, used in light manu. area; can be used in small areas
        
        Assembly line vehicles: apapted from light load. Apps involving serial assembly such as manu. cells
- - - - QFD, is a method that incorporates customer satisfaction into the development of a product.
      - Main features are:
        
        focus on customer requirements
        
        multi-disciplinary team work
        
        Comprehensive 'House of Quality' Matrix
        
        Matrix is used to translate customer requirements into targets and requirements used for a new product
        
        Components of 'House of Quality' matrix
        
        Customer Requirements
        
        Technical Requirements
        
        Planning Matrix
        
        Interrelationship matrix
        
        technical correlation
        
        Technical Priorities, benchmarks and targets
        
        Ads of QFD in concurrent manu.
        
        Reduced time to market
        
        reduction in design modifications
        
        decreased design and manufacturing costs
        
        improved product quality
        
        enhanced customer satisfaction