1.6 The Use of Computer Systems

Define RFID

Radio Frequency Identification

What are the applications of RFID for planning and control?

Barcodes and radio frequency identification (RFID) tags are used to facilitate the transfer of information relating to components and stock to and from computer systems. Barcodes are more reliably read than text when scanned from various angles and RFID tags contain a small integrated circuit (IC) that can communicate information in both directions, when used with a scanner, as well as providing security against theft in retail enviroments.

Define modular/cell production with the benefits

Modular/cell production, is a manufacturing approach that organizes workstations or production units into self-contained modules or cells. Each cell is responsible for completing a specific subset of tasks in the overall production process. This methodology aims to improve efficiency, flexibility, and quality by breaking down the production process into smaller, manageable units.

Define AGVs

Automatic guided vehicles (AGVs) are used, which are programmed to move materials or parts along the manufacturing cells that they are servicing.

Define JIT manufacturing

JiT production is a method of organising the manufacture of products in such a way that they are made to order rather than being produced in the hope of them being sold at some point in the future.

Define Just in Case manufacturing

Just in Case manufacturing is a production strategy focused on stockpilling to meet potential future demand fluctuations or uncertainties.

What are the potential problems of stockpilling?

The stockpiling of products is a potentially problematic strategy, particularly for goods such as modern digital devices, since new models with updated and improved features will quickly make older devices obsolete and result in stock that is difficult to sell. The unsold stock has to be stored in warehouses, which involve considerable costs, as well as rendering goods vulnerable to damage and theft.

What are the modern industrial practices that were developed Japanese manufacturing?

• increased consultation, discussion and co-operation between management and workers

• regular feedback meetings to ensure continuous improvements (Kaizen)

• careful selection of suppliers, often in relatively close proximity to the factory where assembly takes place

• reduction of waste and stock (Muda)

• optimisation of the configuration and layout of machinery

• stock labelling systems, which give instant visual and/or electronic indication of current levels and reordering requirements (Kanbans).

What is the main potential disadvantage of JiT systems?

The dependence on reliable suppliers and transport infrastructure.

Toyota lost millions of dollars' worth of business in 1997 due to a fire at a subsidiary company that supplied them with braking system valves.

What does quick response manufacturing (QRM) rely on?

QRM makes extensive use of CAD and rapid prototyping with 3D printers in the product development stage, and flexible manufacturing cells and multi-skilled workers in product manufacture.

Why are QRM principles approiate for relatively low volumes of production that incorporate elements of customisation?

• Machines are designed and built to carry out a particular sequence of operations for the goods they are packaging; therefore customised requirements have to be accommodated.

• The use of QRM facilitates rapid generation of design proposals and prototypes as well as a smooth, fast transition into the manufacturing stage.

• Customers can take delivery of their machines more quickly than would otherwise have been possible.

Define flexible manufacturing systems

Flexible manufacturing systems (FMS) make extensive use of modular/ cell production, and other systems that facilitate easy transfer of production from one part or product that is being made, to another. This makes it possible to respond quickly to changes in demand, so factories can switch production to accommodate this.

What are the advantages of flexible manufacturing systems?

• Very quick transfer of the dies and moulds.

• Reults in reduced idle period, known as downtime.

• Offers. finanical advantages since keeping expensive machines like this in operation for the maximum time possible is a key element in running a manufacturing facility efficiently.

• Very quick in response to demand for a different part.

Define modular/cell production

The use of groups of CNC machines, robots and AGVs to facilitate efficient, flexible manufacturing.

Define the term 'standardised components'

Standard components are those that must be able to fit other elements of a design to ensure interchangeability.

Why are bought-in components used in designs?

Bought-in components are used extensively where it would not be practicable or economical to manufacture those components, often due to their specialist nature and/or the high numbers involved.

The most common include fastening devices such as screws, nuts, bolts and rivets, along with electronic components such as ICs, transistors and resistors.

Define the term 'bought-in components'

Products parts that are sourced from external suppliers rather than being manufactured in-house.

Define the term 'sub-assembly'

A self-contained element of a product that is made separately and incorporated in the final assembly stages.

Why might companies change standards?

Sometimes necessary for companies to make major changes to their products to ensure that they stay competitive.