Introduction to Manufacturing

1. Introduction to Manufacturing Written by Roland Williams

2. GPS Standard • ENGR-EET-5: Students will analyze the designed world of engineering, electronics, manufacturing, and energy systems.

3. Critical Knowledge/Elements • Examine Manufacturing

4. Essential Question How are assembly lines used to used in the manufacturing of products?

5. Word Wall Manufacturing Separating Forming Combining Conditioning Durable Goods Non-Durable Goods Manufacturing Process Push Production Pull Production

6. “What’s up in Manufacturing?” The History of Manufacturing http://www.aptv.org/APTPLUS/Digitalibrary/digitalmediadetail.asp?ConVidID=15 Click on link or picture to watch video.

7. Manufacturing a Product Split the class into two groups.

8. The Problem You and your team are assembly-line workers in Company XYZ. Your line manager has given you a new product to assemble. You will assemble the product according to the manager’s instructions. Then you will brainstorm ways to improve the overall production. The product is a bolt with three washers and a nut that holds the washers firmly in place. The diagram shows how the product should be assembled and what the finished product looks like.

9. Bolt Object Project

10. Assemble the bolts.Record total time to assemble bolts.

11. Discussion • Is there a better way of distributing materials? • Is there a better way of arranging the line to make the flow of work smoother? • Is there a better way of assembling the item? • Is there a way of cutting down on the number of people involved? • How can you improve the quality of the item in order to make an inspector and rework team unnecessary?

12. Each team member should choose one of the jobs below. Task 1: Place small washer on bolt and pass to position 2. Task 2: Place large washer on bolt and pass to position 3. Task 3: Place lock washer on bolt and pass to position 4. Task 4: Tighten washers onto bolt with a nut. Task 5: Check the quality of each product. Any piece that does not meet the standards shown in the illustration should be sent to position 6. Task 6: Rework any defective products to bring them up to acceptable standards. Task 7: Oversee the line production to make sure the assembly process runs smoothly. Task 8: Supply each position on the line with needed parts.

13. Bolt Object Project

14. Assemble 10 bolts with washers and nuts. Time how long it takes you.

15. Discussion • Is there a better way of distributing materials? • Is there a better way of arranging the line to make the flow of work smoother? • Is there a better way of assembling the item? • Is there a way of cutting down on the number of people involved? • How can you improve the quality of the item in order to make an inspector and rework team unnecessary?

16. “What’s up in Manufacturing?” New Trends in Manufacturing http://www.aptv.org/APTPLUS/Digitalibrary/digitalmediadetail.asp?ConVidID=16 Click on link or picture to watch video. Worksheet: New Trends in Manufacturing”

17. “Push” and “Pull” • Push Production : Each person is to do their individual task, and when it is complete, they are to give the product to the next person. (It is pushed to the next person.) • Pull Production: Each person is only to do their task when there is one product waiting to be assembled. (It is pulled from them.)

18. Assemble the bolts.Record total time to assemble bolts.

19. Compare “Push” and “Pull” • Push Production • Pull Production

20. “Push” and “Pull” • Push Production • Faster production. • Increased chance of error-less quality. • Pull Production • Increased quality. • Slower production.

21. The Assembly Line Challenge

22. Rules Winning team will be determined by time. A 5 second penalty will be given for each defective part (dropped or laying out not used) and a 25 second penalty for any defective bolt object (rattles or assembled in wrong order). Teams will have 10 minutes to form their quality circles to discuss ways to improve production. You do not have to assign duties the same as use in the previous assembly lines. More than one student may now do the same job, or simpler jobs may be combined as one job. Students will not be allowed to help others with their job or to switch jobs after the competition begins. Team leader will give the instructor a list of student names and their duties.

23. Form teams, elect a leader, discuss how to improve the assembly line, and assign each member’s duty.

24. Assemble the bolts.Record total time to assemble bolts.

25. One more time, form your quality circles and improve your assembly line procedures.

26. Assemble the bolts.Record total time to assemble bolts.

27. Discussion • Is there a better way of distributing materials? • Is there a better way of arranging the line to make the flow of work smoother? • Is there a better way of assembling the item? • Is there a way of cutting down on the number of people involved? • How can you improve the quality of the item in order to make an inspector and rework team unnecessary?

28. The Assembly Line ChallengeWinning Team

29. Essential Question How are assembly lines used to used in the manufacturing of products?

30. Conclusion The Assembly Line Challenge, Lesson 3

31. (Optional Slide if you include math in Lesson 3) Assembly Line Efficiency Quality control can be expressed as a rate that tells what portion of the “bolt objects” that were made passed inspection. Production rate is the number of quality “bolt objects” produced per minute.(total made per minute).

32. (Optional Slide if you include math in Lesson 3) Assembly Line Efficiency Complete the Push/Pull Production and Efficiency Worksheet