Manufacturing Processes (Mass Production)

1. Manufacturing Processes(Mass Production) Mr. Pottkotter Ohio Academic Content Standards Technology: Standard 7, Benchmark C

2. Definitions • Manufacturing: • the mechanical, physical, or chemical transformation of materials or substances into new products • Mass-Production: • the production or manufacture of goods in large quantities, esp. by machinery. • Production: • the act or process of producing something

3. Where can manufacturing processes be found? • Anywhere an item is made or produced? • Examples: • Factories • Retail factories- clothing, personal items • Automobile factories • What are some others? • Fast Food Restaurants • Ridgedale’s Technology Lab

4. How is everything made? • Every product that is produced goes through some sort of manufacturing process, whether it is mass-production manufacturing or production manufacturing.

5.  Mass Production • Is large scale production and is carried out by a number of workers on a production line each doing one part of the manufacturing process. The product is then passed on to the next person in the line. Identical products are made very quickly and sometimes the same style is repeated for months on end.

6. The view above is taken from inside the Coats Viyella Factory. It shows Assembly line Mass Production of Boxer Shorts.

7. Mass Production • Disadvantages: • Production halts if there is a problem. • Changing the line to making a different product or style can take a long time. • Advantages: • Identical products made quickly • Reduction in costs • Interchangeable parts 7.C.10.4

8. Mass Production/ Cost Effective • The first industrialist to make full use of this system was Henry Ford and as a result it became known as Fordism. • This has been described as "the mass production of standardized goods, using dedicated machines and moving assembly lines, employing unskilled and semi-skilled labor in fragmented jobs, with tight labor discipline, in large factories." 7.C.10.4

9. Model T • Initially it took 14 hours to assemble a Model T car. By improving his mass production methods, Ford reduced this to 1 hour 33 minutes. This lowered the overall cost of each car and enabled Ford to undercut the price of other cars on the market. Between 1908 and 1916 the selling price of the Model T fell from $1,000 to $360. Following the success of Ford's low-price cars, other companies began introducing mass production methods to produce cheaper goods. 7.C.10.4

10. CAD/CAM CAD- Computer-Aided-Design CAM- Computer-Aided-Manufacturing 7.C.9.7 7.C.12.2

11. Types of Manufacturing Processes • Batch Production • Lean Manufacturing • Just-In-Time • Others 7.C.9.2; 7.C.10.3

12. Batch Production • This type of production is used when a number of identical items are produced by a team. It is cost effective because it takes less time for the team to make a garment than it would for one person working alone. The team share the responsibility of the different tasks and equipment. The members of the team are usually skilled in more than one particular task. This flexibility allows the team to be able to respond quickly to changes in market demand by being able to switch from one design to another. For instance they may be making a batch of 1,000 sweatshirts of one design one week and be able to switch to another design making 2,000 items the next. 7.C.9.2

13. Batch Production Cont. • Advantages: • Allows for flexibility of the workforce • Quick response to changes in the market place • Disadvantages: • More training required for workers to be mutli-skilled 7.C.9.2

14. Lean Manufacturing • Lean is reducing the time from customer order to manufacturing and delivering products by eliminating non-value added waste in the production stream. The ideal of a lean system is a one-piece flow. 7.C.9.2

15. JIT is a philosophy of continuous improvement in which non-value-adding activities (or wastes) are identified and removed for the purposes of: -Reducing Cost -Improving Quality -Improving Performance -Improving Delivery -Adding Flexibility -Increase innovativeness Just-In-Time Manufacturing JIT is not about automation.  JIT eliminates waste by providing the environment to perfect and simplify the processes.  JIT is a collection of techniques used to improve operations  It can also be a new production system that is used to produce goods or services. 7.C.9.2

16. JIT: Elimination of Waste • JIT usually identifies seven prominent types of waste to be eliminated: • Waste from Overproduction • Waste of waiting/idle time • Transportation Waste • Inventory Waste • Processing Waste • Waste of Motion • Waste from Product Defects

17. JIT Principles • When the JIT principles are implemented successfully, significant competitive advantages are realized.  JIT principles can be applied to all parts of an organization:  • Order taking • Purchasing • Operations • Distribution • Sales • Accounting • Design • Etc.

18. Health and Safety in the Workplace • Designers and manufacturers must ensure that new products will be safe to use and safe to make. • The designer must ensure that the product conforms to all the relevant safety standards.  There are many laws in existence which help to ensure that products are safe to use. 7.C.9.3 7.C.11.3

19. Lab Safety • Lab safety will be covered once again this year, before we enter the lab. • We will review each of the tools in the lab, including one new one. 7.C.9.3 7.C.11.3

20. The four main areas to consider in order to avoid potential accidents in a factory are as follows:  • The layout of the factory work area must be safe • The workforce must be trained in safety precautions. • The design of machinery and tools being used in the manufacturing process must be safe. 7.C.9.3 7.C.11.3

21. Safety devices and procedures must be set up in order that the workers are in a safe environment. • An example of this is if a machinist breaks a needle, then the broken needle must be found at all costs. If the needle is not found the machinist may have to take the machine apart in order to find it. If it is still missing the garment may have to be destroyed. 7.C.9.3 7.C.11.3

22. Possible Jobs • Degree in Manufacturing- (MFG) • Floor Supervisor • Shipping Supervisor • Line Engineer • Solves problems • Line Worker • Quality Control • Supplier (Honda has many suppliers) 7.C.9.1 7.C.9.5

23. Management We will set this class up like a factory. • What are the major components of a factory that influence cost of production? • Materials • Labor • Energy • Time • Location 7.C.11.2

24. Management of Product & System • All factories continuously look for ways to improve their production system. • Look for ways to lower cost by: • Changing processes • Introducing Robots & New Technology • Changing materials • Cheaper materials • Changing suppliers • May offer more options/ or are willing to work with you • Preventing/ Fixing Problems • Trouble shooting, diagnosing, recalling, maintaining, repairing, altering, & upgrading 7.C.11.5

25. Durable We want our game to be well built so it will last a long time. Examples Steel Furniture Washing machines Nondurable We do not want a game that fall apart Examples Food Batteries Paper The Product 7.C.11.6

26. Flow Chart Process Symbols • The flow chart process symbols are recognized internationally and have been standardized so they have only one meaning. This permits easier communication between all personnel who may need to use the flow process chart. The symbols and their definitions are as follows: 7.C.11.1

27. OPERATION • Something which takes place or happens in one place. Object is intentionally changed physically or chemically, assembled or disassembled. • Examples: casting & molding, forming, separating, conditioning, assembling, finishing, drilling, sawing, mixing, sewing, typing, putting together, or taking apart.  7.C.10.1 7.C.11.1

28. TRANSPORTATION • Something is moved from one place to another, except where the movement is considered to be a part of the operation. • Examples: • moved from typing desk to filing desk • moved from machine to an assembly bench • moved from finishing room to drying area.  7.C.11.1

29. INSPECTION • Verification. Objects are examined for quality, quantity, or identification. • Examples: checking for correct size, color, number, or shape.  7.C.11.1

30. DELAY • Delay or interference. Object is held up for a short period of time before it can move into the operational sequence. • Example: drying time for paint or varnish to dry. D 7.C.11.1

31. STORAGE • Retention of object in a location in which it is protected against unauthorized removal for a relatively long period of time. • Example: in warehouse waiting to be shipped.  7.C.11.1

32. Jigs & Fixtures • What is a jig: • A device used to guide a tool to a precise spot on a part or piece of material. • Used when an operation must be repeated numerous times. (a stop block on a miter saw) • What is a fixture: • A device used to hold material in place while it is being worked on. • Usually some sort of clamping device 7.C.9.6

33. Questions ?

34. Mass-Production Paperwork • Process Flow Chart • List of machines and tools used • Safety Precautions • Jigs/ Fixtures Used- pictures with explanations • Special Setups • Time Sheet- figure our effectiveness 7.C.11.1

35. 7.C.11.1

36. Possible Example Cornhole Games

37. Types of Materials Natural Synthetic Mixed What types of materials will we be using? Wood Screws Cloth Corn Nails Glue Cornhole Game Materials 7.C.9.4

38. What types of tools or equipment will we need? Table saw Radial-Arm Saw Compound Miter Saw Nail Gun Drill Drill Bits Cornhole Game Tools/ Equipment 7.C.9.6

39. Cornhole Jigs & Fixtures • Jigs • Stop block on miter saw & radial arm saw • Placement of 6” hole • Fixtures • Assembly fixture

40. Space Storing Materials/ Finished Product We will need to develop a plan or system that will be effective for our class, along with other classes that use the lab. What’s going to be our biggest problem? 7.C.10.2

41. Examples • Sliding DVD Holder • Birdhouse • Windmill