2.9 Design for Manufacture & Project Management

What is Lean Manufacturing?

A method focused on eliminating waste (time, materials, energy), improving efficiency, and delivering more value to the customer.

What is Lean Six Sigma?

A combination of Lean Manufacturing and Six Sigma that aims to improve efficiency and product quality through waste reduction and defect control.

What is Six Sigma?

A data-driven strategy aiming to reduce errors and improve quality by identifying and removing the causes of defects and ensuring process consistency.

What is Critical Path Analysis (CPA)?

A planning tool that identifies the longest sequence of dependent tasks in a project to determine the shortest time possible to complete it.

What is a Go/No-Go gauge used for?

A pass/fail tool used in quality control to quickly determine whether a dimension is within tolerance limits.

What is Co-ordinate Measuring Machinery (CMM)?

A device that uses a probe to accurately measure the geometry of physical objects, ensuring dimensional accuracy against CAD models.

What is Non-Destructive Testing (NDT)?

A method of testing that does not damage the product, often used to detect internal flaws (e.g. using X-rays, ultrasound, or magnetic particle testing).

Why is design for manufacture important?

It ensures that products are easier, cheaper, and faster to produce while meeting quality standards — reducing errors, time, and cost.

What is Total Quality Management (TQM)?

A project management system focusing on QA through the full involvement of the workforce in continual improvement.

What is the Scrum method in project management?

A project management system method, which focuses on the organisation of workforce teams to reduce lead time of projects.

What does the acronym TIMWOOD represent in Lean Manufacturing?

The 7 types of waste (Muda):

- Transport

- Inventory

- Motion

- Waiting

- Overproduction

- Over-processing

- Defects

What does Allied Glass specialise in and what is the scale of their production?

Allied Glass produces high-quality glass containers, making over 600 million containers per year for premium drinks brands, with a strong focus on QA procedures and QC controls.

What happens at Stage 1: Customer Specifications in Allied Glass's process?

The customer provides specific design criteria, including aesthetic elements, maximum sizes, volume, and market requirements, which guide initial design development.

What is the purpose of Stage 2: Concept Development in Allied Glass's process?

Concepts are modelled using 3D CAD software and rapid prototyping to create visual and physical models for customer feedback, improving communication and design accuracy.

What does Stage 3: Mould Design and Sampling involve?

Moulds are created with 3D CAD, and prototype bottles are produced and tested. QA checks include dimensional checks, sample testing, and visual inspections for faults like 'shorts'.

What types of equipment are used for QA and QC during sampling?

Vernier callipers, jigs, fixtures, and gauges are used to check accuracy and tolerance. Non-destructive tests check for internal volume, stress, and pressure resistance.

What happens in Stage 4: Production at Allied Glass?

QA procedures are followed for every batch. Raw materials like sand, soda ash, limestone, and cullet are tested and stored. Each furnace and mould is calibrated for precise forming.

What is the purpose of QC Testing at Allied Glass?

Every container is camera-checked for imperfections, and each hour, samples are tested for volume, stress, and dimensional accuracy. Issues are traced back to specific moulds.