A2 Technology

1. DT4 - Exam A2 Technology Product Design Systems and Control Notes

2. 7 Organising the Manufacturing

3. Coming up in this unit: • Principles of industrial manufacturing systems which will include: • mass, • batch, • one off; • staffing needs, • allocation of costs, • JIT manufacture and commercial liability; • bought-in, standardized part assembly, • sub-contracting

4. Mass Production • Mass production (also called flow production, repetitive flow production, series production, or serial production) is the production of large amounts of standardized products on production lines.

5. Batch Production • The primary characteristic of batch production is that all components are completed at a workstation before they move to the next one. Batch production is popular in bakeries and in the manufacture of sports shoes, pharmaceutical ingredients, inks, paints and adhesives.

6. Manufacturing station or CELL. Standard components Products in Products out Power Testing Workers seat Batch Production

7. Workers need : Training Paying (even when sick) Incentives Contracts of employment To be flexible Respond to market demands Respond to company priorities Job security Companies are aware that Skilled labour costs more Machines replace work force and are cheaper in the long run. Other countries offer a cheaper labour Employment law exists to protect workers’ rights They can make workers redundant Staffing needs

8. A Prices are calculated by … Materials Equipment Labour Profit Overheads Transportation Marketing 4Ps Cost Allocation

9. Just In Time • The philosophy of JIT manufacturing is to meet consumer orders with a quality product with minimal delay and effective use of resources. The JIT system is sometimes referred to a ‘lean manufacturing’ as it focuses on giving customers value for money by reducing wastage.

10. Implementing a JIT • 1) F Design FLOW process • F low Redesign or re-layout for flow – • L Reduce lot sizes (quantities of item) • O Link operations – • W Balance workstation capacity • M Preventative maintenance. • S Reduce Setup Times.

11. Implementing a JIT • 2) Q Total quality control • C worker compliance • I Automatic inspection • M quality measures • M fail-safe methods • W Worker participation (suggestion box)

12. Implementing a JIT • 3) S Stabilize Schedule • S Level Schedule • W establish freeze windows • UCUnderutilize Capacity • Keep the orders constant and do not try to over produce, similarly leave space for one high demand.

13. Implementing a JIT • 4) KKanban Pull System • DDemand pull • BBackflush • L Reduce lot sizes • Backflush costing is a method of costing a product after manufacturing has been carried out. Then costs are backflushed through the system to calculate an overall cost for manufacture.

14. Kanban pull to keep stock up When red zone reached new products are needed to re-stock a zone. A card (or any other visual e.g. computer method) is used to identify the items

15. Implementing a JIT • 5) V Work with vendors • L Reduce lead time • D Frequent deliveries • U Project usage requirements • QQuality Expectations • Lead time is the time it takes from design conception to retail sale.

16. Implementing a JIT • 6) I Further reduce inventory in other areas • SStores • TTransit • C Implement Carrousel to reduce motion waste • C Implement Conveyor belts to reduce motion waste

17. Implementing a JIT • 7) P Improve Product Design • P Standard Production Configuration • P Standardize and reduce the number of parts • PProcess design with product design • QQuality Expectations

18. Implementing a JIT • In summary • Just in time reduces waste by making to order • Lead times need to be reduced • Emphasis on Lean production • Involvement of all people workers and vendors • FLOW

19. Lead times • In Semiconductor Industry • In very complex manufacturing environment, like the manufacture of microprocessors, a usual Lead Time may be between 5-7 weeks. This is due to the sequence of operations, where there are multiple very similar steps repeated, and none can be skipped. If a manufacture of a CPU requires 35 exposure masks, that translates approximately into 35 x (photoresist coating, exposure, development, main process step (like etching, diffusion, metal filling), photoresist stripping and/or polishing + other possible steps ) plus additional steps before and after all processing. There are wait times not only associated with scheduling a product into production, since the product lines are busy, but also a beginning run of production goes to scrap (plus tool change and alignment takes time), and there are possible wait times of batches being processed during the production. (Not all machinery works at the same speed, or requires maintenance steps, tool change, plus there is the time it takes to physically transport the silicon wafers from one processing machinery to another in small transport batches.)

20. Lean Manufacturing • Lean manufacturing or lean production, which is often known simply as "Lean", is the practice of a theory of production that considers the expenditure of resources for any means other than the creation of value for the presumed customer to be wasteful, and thus a target for elimination. In a more basic term, Morevaluewithless work. • Lean manufacturing is a generic process management philosophy derived mostly from the Toyota Production System (TPS) and identified as "Lean" only in the 1990s. It is renowned for its focus on reduction of the original Toyota seven wastes in order to improve overall customer value, but there are varying perspectives on how this is best achieved. • The steady growth of Toyota, from a small company to the world's largest automaker, has focused attention on how it has achieved this.

21. Stages in Production

22. Stages of production.

23. Stages of Production

24. Stages of production • Sourcing of materials, where, expense, sustainability • the buying cycle, when, how often, reliability of supply, • forward ordering, reduction of lead times, good supplies, reliability of supplier • storage, where, wasted space, • processing, what method to use? • assembly, how, best method? • finishing, how best method? • packaging, why? Security? Marketability? • Labeling, bar coding, kanban • Transportation, plane, train automobile?

25. (iv) Detailed manufacturing methods, when preparing, combining, manipulating or processing materials. • Comparison of hand and commercial methods of • preparing, • shaping, • cutting / wasting, • joining materials, • circuit board production, • population and soldering; • the influence of the above on the time taken to produce the product, its quality and final cost.

26. (v) Management systems for production, quality assurance, organisation of equipment and people. • Internal Quality Control (QC) and external Quality Assurance (QA) requirements; • project management systems including flow charts, Gantt charts and critical path analysis; • modern methods of labour organisation to include single craft, progressive bundle and cell.

27. (vi) Safe working practices, including identifying hazards and making risk assessments. • Commercial working practices and responsibilities and their application to project work; • five-step risk assessment. • Identify hazard, • who might be harmed & how, • evaluate potential for risk, • record, • review if details change; • provision of equipment, signage etc.; • the safe operation of electrical, mechanical and pneumatic systems.

28. Past paper questions