1.6 Modern and industrial scales of practice

Flashcards covering industrial scales of production, digital manufacturing systems, economic material use, and standardized components based on the provided notes.

What is the meaning of a self-finished polymer?

A polymer that does not require an additional surface coating after the molding process is complete.

What are the three main scales of production identified in the learning outcomes?

One-off, batch, and mass/line production.

What suffix is often added to the end of Unit Production Systems in the context of textile manufacturing?

$$UPS$$

What is 'one-off, bespoke production' sometimes called?

'Job' production.

Why is individually designed manufacturing usually more expensive?

It requires individual client consultation, higher skilled workers, individual setups for unique components, and lacks economies of scale.

What was the word 'batch' used to mean in the year $1700$?

It meant 'bake', referring to making a number of bread loaves simultaneously.

What tools are typically used alongside manual and CNC machines to facilitate faster batch production?

Jigs, fixtures, and other aids.

What does the term 'Division of labour' describe?

Dividing up the tasks needed to mass produce a product into a sequence of stages.

By how many hours was the production time of the 'Model T' reduced after the introduction of mass production?

From $12.5\,\text{hours}$ to $1.5\,\text{hours}$.

Which designer's PP chair had a significant impact on the furniture market due to mass production?

Robin Day.

What defines Unit Production Systems ($UPS$) in textile manufacturing?

The use of an overhead transporter system with hanging carriers to convey garment components between workstations.

What is the definition of 'lead-time'?

The amount of time taken to respond to orders for a part or a product.

What strategy focuses on drastically reducing the time between product concept and completion?

Quick Response Manufacturing ($QRM$).

What is 'Vertical in-house production' also known as?

Vertical integration.

What is 'outsourcing' in the context of manufacturing?

Using external suppliers for parts or sub-systems incorporated into a product.

Name one advantage of vertical in-house production.

Reduction in the risk of unexpected price increases for components.

Name one disadvantage of vertical in-house production.

Reduction in specialisation, potentially leading to dilution of expertise.

What does the acronym $IPR$ stand for?

Intellectual Property Rights.

Who was the executive at Toyota influential in the development of Just in Time manufacturing?

Taichi Ohno.

What material is primarily used for the Ford Fiesta car body according to Table 1.6.1?

Low carbon steel sheet.

What is the estimated material cost per kilogram for the low carbon steel used in the Ford Fiesta?

$\pounds 0.30\,\text{kg}^{-1}$.

What manufacturing processes are used for the Jaguar F-type aluminium car body?

Presswork, fasteners, and adhesives.

What is the average annual production for the Porsche 918 Spyder?

$500$ units.

Why is High Speed Steel ($HSS$) preferred over high carbon steel for commercial twist drills?

It has the ability to retain a sharp cutting edge at high temperatures.

Why is Polypropylene ($PP$) preferred for hinged lids on freezer food containers?

It withstands low temperatures, has excellent fatigue resistance, and displays very good mould flow.

What assembly method is used for aluminium car bodies due to the difficulty of spot welding?

Mechanical fastenings such as rivets, often in conjunction with adhesives like epoxy resin.

What material offers an unparalleled strength-to-weight ratio for supercars like the Porsche 918 Spyder?

Carbon Fibre Reinforced Plastic ($CFRP$).

What special oven is used to cure Carbon Fibre Reinforced Plastic components?

An autoclave.

What is the benefit of 'nesting' multiple parts on a manufactured board using software?

It ensures economical use of sheets and avoids large numbers of unusable off-cuts.

What are the standard dimensions of a standard board of timber or MDF?

$2,440\,\text{mm} \times 1,220\,\text{mm}$.

Why would changing a storage box side from $410\,\text{mm}$ to $400\,\text{mm}$ be beneficial?

It avoids potential wastage of approximately one-third of a standard board.

What type of molding process results in a strong, hollow structure for toys with minimal material?

Rotational or blow moulding.

What is the name of the central section of an I-beam girder that often has large holes?

The web.

By how much has the weight of glass bottles been reduced since the $1980\text{s}$?

Over $30\,\%$.

What does $FEA$ stand for in the context of product design?

Finite Element Analysis.

Who introduced machines for manufacturing pulley blocks for the navy in $1805$?

Marc Isambard Brunel.

How do automated screw-making machines function without relying on computer control?

They work by means of cams and levers.

What is 'mass customisation'?

Producing products in bulk that can have bespoke elements or individual configurations incorporated into the design.

What is the function of an $RFID$ tag in production planning?

It uses an integrated circuit ($IC$) to communicate information in both directions and facilitate stock transfer/security.

How many axes of movement can a robotic arm typically have in a manufacturing cell?

Up to $6$ axes.

What does $AGV$ stand for?

Automatic Guided Vehicle.

What term is used for the stockpiling approach to manufacturing as opposed to JiT?

'Just in Case'.

What does the Japanese term 'Kaizen' represent?

Continuous improvement through regular feedback meetings.

What does the Japanese term 'Muda' refer to?

Reduction of waste and stock.

What serves as an electronic Kanban during vehicle assembly?

An $RFID$ tag.

What are single minute exchange dies ($SMED$)?

A system that facilitates changing dies in a press or molding machine in less than $10\,\text{minutes}$.

What is 'downtime' in manufacturing?

The idle period for a machine while dies or moulds are being changed.

What does the acronym $EPOS$ stand for?

Electronic Point of Sale.

What is Computer Integrated Manufacture ($CIM$)?

Using computer systems to control all stages of bringing a product to market, from design to distribution.

What was the universal standard spacing adopted by stationary manufacturers for notepad holes?

$80\,\text{mm}$.

When was the British standard Whitworth screw thread introduced?

$1841$.

What metric system for threads is now used internationally for compatibility?

The International Standards Organisation ($ISO$) system.

Which British Standard covers the specification for bayonet fittings in light bulbs?

$BS\,EN\,61184$.

What is a 'bought-in component'?

A component sourced from an external supplier rather than being manufactured in-house.

Give an example of a sub-assembly mentioned for power systems.

An electric motor, hydraulic valve, or gearbox.

What quality management certification is used to ensure consistency in bought-in goods?

$ISO\,9001$.

How much can an 'Ergochair Adapt' chair cost when configured for individual specs?

Thousands of pounds.

What technology was removed from many modern laptops, making it difficult to use DVDs?

Optical disc capability.

What type of software is used by professional woodworkers to plan cuts from MDF?

Computer technology for nesting parts economically.

What is the primary material of a budget computer chair mentioned in figure 1.6.10?

Injection moulded $PP$ shell and welded tubular low carbon steel frame.

What is the definition of a 'sub-assembly'?

A self-contained element of a product that is made separately and then incorporated into the final assembly stage.

What does cellular beam construction achieve?

It makes optimum use of the material by creating a light but strong beam with holes along the web.

What is the main disadvantage of a $JiT$ system?

Dependence on reliable suppliers and transport infrastructure.

What is 'Lean production' focused on?

Reducing waste and maintaining stock levels at the minimum possible.

What was the target time for die changes established by the $SMED$ methodology?

Less than $10\,\text{minutes}$ (single digit minutes).

What organization's website contains information about 'plastipedia'?

The British Plastics Federation ($www.bpf.co.uk$).

What does the Materials Today website explain?

Various metal finishes.

What is the definition of Scale of Production?

Consideration of the number of products to be made, using manufacturing methods suited to a particular market.

What is the definition of Batch Production?

Manufacture of groups of products to increase efficiency and economy.

What is the definition of Line Production?

Manufacture of large numbers of products in factories where processes are carried out by workers/teams in a sequence.

What is the definition of Mass Production?

Manufacture of large numbers of products in factories that are usually highly mechanised.

What is the definition of Flexible Manufacturing Systems ($FMS$)?

Production using work cells of CNC machines and robots to make a wide range of different products.

What is Modular/cell production?

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

What is 'Just in Time ($JiT$) production'?

Manufacture of products as needed, in response to existing orders.

What is 'Quick response manufacturing ($QRM$)'?

Use of computer-based technology to facilitate efficient production of low-volume, customised products.

Identify four sub-assemblies of a bicycle.

Gear cassette, derailleur gear mechanism, braking system, lighting system.

What are standard components?

Parts such as screws and light bulbs made to a common standard to ensure interchangeability.

How did Marc Isambard Brunel contribute to mass production in $1805$?

He introduced machines for manufacturing pulley blocks.

What material is noted for having excellent flexural strength in ladders?

Aluminium (used in tubular or I-beam extrusions).

What design philosophy pioneered the movement towards economy of materials using tubular steel?

The Bauhaus.

What is used to track the inventory of parts during manufacturing in a $JiT$ system?

Barcodes or $RFID$.

What assembly technique do prestige vehicles like the Jaguar F-type increasingly use?

Mechanical fastenings like rivets along with epoxy resin adhesives.

In vehicle manufacturing, what is the 'lead-time' generated by software used for?

To give the customer an anticipated delivery date.

Why is spot welding difficult for aluminium compared to low carbon steel?

It doesn't fuse as easily as steel, requiring different joining methods.

How many products were produced annually for the Ford Fiesta (Economy) in the example?

$375,000$.

What is the material cost per kilogram for Carbon fibre reinforced polymer pre-preg?

$\pounds 6.38\,\text{kg}^{-1}$.

Which process is typically used for the final finish of drive shafts in a CNC cell?

Grinding using a CNC grinder.

What does a robotic arm use to handle different tasks?

Various types of gripping mechanisms.

According to the transcript, how many Robin Day $PP$ chairs have been sold?

Tens of millions.

What is a 'Kanban'?

A stock labeling system giving an electronic or visual indication of current levels and reordering requirements.

Where is the Piquette Avenue car plant located?

Detroit.

Which component in flat-pack furniture requires precise hole positioning for ease of assembly?

$KD$ fittings.

Why is standardisation of screw threads important for maintenance?

It ensures replacement parts from different manufacturers match the original threads.

What is pre-preg?

Carbon fibre which is pre-impregnated with epoxy resin.

In which decade did Toyota experience key success by developing Just in Time manufacture?

The $1970\text{s}$.

How are glass bottles manufactured mentioned on page $105$?

Blow moulding process.

What are 'narrow aisle stacking machines' used for?

To use warehouse space very efficiently in automated systems.

What does the abbreviation $QA$ stand for in production management?

Quality Assurance.

What organization's website has fact sheets about printing and packaging?

The $PNEAC$ ($www.pneac.org$).

What is the primary focus of the Timber Trade Federation ($ttf.co.uk$)?

Sustainability and responsible sourcing.