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Unit 10: Modern Industrial and Commercial Practice - Coggle Diagram
Unit 10: Modern Industrial and Commercial Practice
Scales of Production
UPS: Unit Production System
Use
overhead tracks
to move component parts on hanging carriers. Benefits include
H+S
,
reduced costs
,
lead times
, more
effective QA and QC
QRM: Quick Response Manufacturing
Reduces
lead times
in response to demand. Production is triggered by
consumer demand
, not traditional methods e.g. trend forecasting
TBC: Time-Based Competition
Strategy used to get ahead of the competition. It is a
feature of QRM
Vertical Production:
In-house
production, increases
productivity + profits
by
integrating parts
of the supply chain within the main company
Mass/Line Production Profile:
High setup costs
,
Shift work for 24/7 production
,
Skilled + Unskilled labour
,
High level of automation
,
Low unit costs
,
Less flexibility for product diversity
Batch Production Profile:
Simple production line
,
Some automation
,
Skilled + Semi-Skilled work
,
Flexibility to adapt production
,
Limited product runs
,
Lower unit costs
(than one off)
One-Off Production Profile:
Small company with
limited staff
,
Close client communication
,
High quality materials
used,
Highly skilled labour
,
Unique products
,
High unit costs
Kaizen:
Japanese term meaning '
Change good
' / '
Making Constant Improvements
'
Lean Production:
Strives to
reduce waste
. Stems from Japanese philosophy originating at TOYOTA
7 distinct areas for waste reduction:
Over Processing
Excessive Inventory
Transportation
Unnecessary Motion
Waiting
Defects
Overproduction
Efficient use of Materials
JIT: Just In Time
Streamlines manufacturing to make products on demand
Considerations when selecting materials:
Material properties, Manufacturing processes, Standard sizes/Forms, Costs, Availability, Sustainability
Cost/Quality: Higher cost materials usually mean higher quality products
Scaling up production:
Suitability of materials/processes changes with the scale of production
General trends: Larger scale = higher setup costs, lower unit costs, more automation, less flexibility
Global Supply Chains:
Global financial markets cause raw material costs to
fluctuate
.
Higher costs are
absorbed
by manufactures or passed on to consumers (increased prices)
Makes forecasting
problematic
Any resources linked to
extraction of the raw material
can affect costs
Economic use of materials:
Marking/Cutting:
Careful layout of parts via
nesting or tessellation
can
reduce waste
.
CAD/CAM
can be used to make
optimal use
of material.
Standard sizes and stock forms:
Designs are developed to maximise output from standard sheet size/thickness & profile shape/length
Structural integrity:
Strong structure can reduce material usage. Key pressure/force points can be reinforced so wall thickness/weight can be reduced.
Older materials can be substituted for newer materials with better properties
Miniaturise & Dematerialise:
Developments in
microelectronics
enable products to be smaller. Smaller components = less material
Reuse & Recycle:
Waste materials/Faulty parts can be recycled/reprocessed
in-house
Products can be developed to
encourage reuse
. Design for disassembly makes products easier to
repair
and
recycle
Efficient Processing:
Increased accuracy
can
reduce waste
for
maximum efficiency
=
increased profits
, efficient use of
resources, time and labour
Strict tolerances are used to allow parts/products to function and
integrate reliably
Material waste
: Materials are processed either in
solid or liquid state
. Liquid reduces
waste
& gives a c
leaner manufacture
with
higher accuracy
Automation vs CNC
Both offer high levels of accuracy and waste reduction
Automation offers accuracy whereas CNC offers accuracy AND flexibility
CNC/CAM is best suited for batch production as it allows for easy modifications + virtual testing
QA and QC assurance:
Ensure efficiency, accuracy and consistency in manufacture. Builds reputation & reduces waste
QA: prevents inaccuracies & defects
QC: checks accuracy of final product
Rethinking Waste:
Companies are moving away from
linear manufacturing
systems to create a more
circular economy
'
Cradle to Cradle
': All materials considered as either
technical
or
biological
nutrients.
Recycle technical
output,
biological output degrades
Bulk Production:
Provides various economic advantages, such as potential discounts when buying raw material and with transport costs, Allows automatic processing, Can capitalise on waste streams to reduce waste
Computer Systems in Manufacturing
Manufacture vs Management:
Computers are used in planning, research, purchasing, accounting, sales, production storage and distribution processes
CIM: Computer Integrated Manufacture
Uses computers to enable planning and control of the production process. Integrates parts of the production line, and requires a large amount of automation whilst relying on feedback from sensors
RFID: Radio Frequency Identification
QRM: Quick Response Manufacture
Data Analysis:
Regular checks within an integrated manufacturing system provide constant data feedback to:
Monitor performance
Eliminate downtime
Increase productivity
Make improvements
Catch errors/mistakes early
Computers in Manufacturing:
EPOS
: Used to trigger orders to keep stocked, activates repeats orders, loyalty cards can profile customers to target marketing
AVG: Automatic Guided Vehicles
, used in warehouses & are controlled by a computer. Use of these can reduce labour, costs, error, and increase safety & allow 24/7 operation
RFID tags & barcodes
: scanning products at the point of sale updates inventory, collects sales info & can trigger repeat orders
Packaging & Distribution are often integrated into the production process. Computers add codes to ensure successful delivery and tracking
Research:
GDPR: General Data Protection management introduced to protect personal data
Data analysis allows companies to forecast & market products more strategically
Online surveys, sales analysis, & buying habits feed into product development
CAQC: Computer Aided Quality Control
Integrates QC and QA strategies throughout production, reducing human error, generating feedback data, & enabling efficient inspections/testing
Systems That Control Manufacture:
Modular/Cell Production:
Divides work into teams called cells or modules. Each cell works to achieve quality, efficiency and to reduce waste
Robotic arms are used to change parts, and AGV's transport parts from one cell to the next
Often used to manufacture cars/electronics. Computer control is used to link several cells seamlessly.
JIT: Just In Time
As the order is processed, scheduling software assigns time for the job which gives accurate lead times. Orders specific parts to arrive on time
Relies on computer systems to track/manage orders and inventory. Suited to made-to-order items with multiple design features/customisation
Kanban's used to ensure parts arrive at a specific time/location depending on the order
QRM: Quick Response Manufacturing
Developed as an addition to JIT, and to respond rapidly to consumer demands. Design/manufacture is compressed to beat competitors & gain a larger market share
Suited to industries with short life cycles/rapidly changing trends
Rapid prototyping generates accurate models
FMS: Flexible Manufacturing Systems
Can adapt to changes in a product, material and scale of production to quickly respond to market demands
Use of CNC machines allows quick switching between products via multi-functional tools
Sub-Assembly: A form of bought-in parts
Reduce
waste
Allow
faster assembly
Take advantage of
specialist skills/facilities
Can increase overall
quality
Can be
bought in bulk
= reduced costs
Fewer workstations
required in-house
Sub-contractors provide CAD files so designs can be tested virtually with all bought-in parts in place
Manufacturers comply to standards set by the
ISO
to ensure
consistency
through supply chains
Bought In Parts:
Manufactures buy in fixtures/fittings such as fastenings and electronic components
Can save
time/money
, allows manufacturers to
specialise
& achieve good
QC
and
waste reduction
Relies on parts being
high quality
,
delivered on time
, and
storage
is needed if
bought in bulk
Standardisation:
BSI: British Standards Institute
ISO: International Standards Organisation
Provide global standards that companies must conform too. Provides customers with reassurance and a wide range of places to buy from
Manufacturers comply to universal standards so parts integrate seamlessly
Standards cover everything from H&S protocols to paper sizes
Digital Design and Manufacture
CAD/CAM:
Streamlined design
,
development
and
presentation
,
Flexible manufacturing
and
24/7 production
Increases
speed
and
accuracy
Entire production systems can be
integrated
(CIM)
Digital files are
easily shared
between designers, customers, and manufacturers
Skilled operatives
needed to upkeep machinery,
expensive staff training/initial setup
, easier for designs to be
copied
Replace the need for
manual labour
Shifting to CAD/CAM is
risky/expensive
CAD: Computer Aided Design
CAD files can be
easily shared
and
edited
during design and manufacture to generate
high-quality market feedback
Allows 2D and 3D drawings to be made, and
virtual testing
can be carried out on these designs
VR
can be used to present ideas in areas like architecture to save huge amounts of
money
and to ensure the
design is right
Working Drawings:
Include vital information and details for manufacture such as:
Dimensions, Elevations, Sectional views, and notes explaining details
Can show
different perspectives
of the object, hidden and internal features, and all small details can be shown
Hand made drawings require
high skill
, and are very
time consuming
and
fragile
(can be easily lost/damaged)
2D CAD can be used for
technical artwork
and to
export files for CAM software
such as laser cutting or CNC routers.
3D CAD Presentation Drawings:
Offer virtual
360°
views and walk-throughs of products
Virtual lighting/rendering can provide a
realistic idea
of the final product, and can quickly and easily
compare
materials or colours
Saves
time/resources
, and can be exported to
rapid prototyping
CAD to CAM:
CAD allows a variety of methods for outputting a digital file, making it very attractive to manufacturers
CAM machines are operated by CNC coding, which controls the movement along each axis
Laser Cutting:
Converts 2D CAD designs to CNC code to move a machine head along the
X and Y axes
Versatile
,
fast
,
extremely precise
,
narrow kerf
(cutting path),
less waste
Can
cut or engrave
materials, the cut depth is affected by the
speed
and
power
of the laser
The workpiece
does not require clamping
, and is
self-finished
. Extraction required as
toxic
fumes produced
when cutting some materials
Limited by the
thickness
and
type of material
, and can
only cut 2D
shapes
CNC Routing:
Offer versatility both in terms of movement and materials. Operate along the
X, Y and Z axes
Can
waste
thick materials with a variety of cutting tools which can be
changed automatically
Less clean
than laser cutting, more
complex setup
, but more
versatile
.
Requires extraction
, and for the workpiece to be
clamped
. (Workpiece is usually vacuumed to the bed)
Can make complex
3D
prototypes and shapes
CNC Milling
Used to cut complex
3D forms
. Machines operate on
3-5 axes
with a variety of cutting tools allowing for much more complexity
Cooling liquids
flood the piece to provide
lubrication
for a perfect finish, and to
prolong the life
of the tools when cutting metals
CNC Turning:
Workpiece spins
instead of the cutting tool. Used to manufacture
symmetrical shapes
Completes operations such as
cutting, boring, knurling, and thread cutting
. Swarf is created by both milling and turning
Similar to standard lathes, but
operated by CNC automatically
Plotter Cutting
Plotters read
2D CAD files
and cut materials such as vinyl, paper and lightweight card
A machine holding a
blade/pen
passes from left to right simultaneously with
rollers
moving the material back and forth
Plotters can incorporate printing functions so graphics can be
printed, cut and scored
at the same time.
Use
rolls
of material to reduce downtime and waste
CAM in a nutshell:
Increased
precision
and
consistency
Greater
control
and
accountability
Increased
output
Waste reduction
Increased
efficiency
Skilled machine operators
no longer required
Reduced human input =
less jobs
Modelling, Testing, Marketing and Scheduling
FEA: Finite Element Analysis
Simulates specific loads/stresses on parts and components. Measures exactly how well products will perform under real-world forces and to identify weaknesses
CFD: Computational Fluid Dynamics
Simulates the flow of gases/liquids on or through a product. Can mimic extreme weather conditions and be used to optimise flow in products e.g. engines
Rapid Prototyping:
FDM: Fused Deposition Modelling
A type of 3D printing, extrudes melted filament through a nozzle, often thermoplastics
A CAM method which produces physical prototypes from CAD files. It is used to quickly produce scale models of products/parts for evaluation
3D shapes built up from 2D layers.
Sintering
uses a laser to fuse layers
Stereolithography
uses a laser to cure a bath of resin
EDI: Electronic Data Interchange
The exchange of digital data within a corporation. Increases efficiency & flexibility within a business, Reduces costs & enables cloud-based file sharing
EPOS: Electronic Point of Sale
A holistic system that allows a company to monitor sales, stock and to gain insight into customer behaviour. Sales data is gathered & analysed to inform future plans/development
PPC: Production, Planning and Control
Coordinates various manufacturing activities to meet market demand as effectively as possible. Data from logistics/labour/materials/machinery is used to streamline manufacture.
MPS: Master Production Schedule
Allocates labour, materials & time to a job. Increases flexibility & workforce satisfaction, ensures time/resources are used wisely
Model making:
Traditionally, products are modelled/tested with physical prototypes, which is a high skill, time consuming & expensive process
Destructive tests: Causes damage to the prototype to assess safety and performance standards
CAD models offer a more versatile alternative to physical models, such as full-scale designs, strength/stress tests, and ease of outputting to CAM software
Virtual Testing:
Can save time & money on large jobs by testing at the start. Data/simulations can be collected to inform decisions. Reduces need for physical prototypes = costs/errors/waste reduced
Digital Market Research:
Traditional methods of data collection (e.g. paper surveys, interviews) are time consuming
Digital tools speed up data collection & collation, making it cheaper and more efficient
Customer profiling:
EPOS systems can collect data on specific customers for marketing purposes.
Loyalty card schemes/cookies provide sales/marketing teams buying habits for targeted marketing