Manufacturing and Project Management Overview

What are the four stages of industry

industry 1.0, industry 2.0, industry 3.0 (automation/globalisation), industry 4.0

What are issues associated with globalisation

political uncertainty and control of intellectual properties

state two facts about manufacturing industry within scotland

Manufacturing provides the majority of exports for the Scottish economy, manufacturing jobs pay better than the average job in scotland

In a product matrix, where are rising stars positioned

High share in a high growth market

In a product matrix, where are cash cow positioned

High share in a low growth market

In a product matrix, where are problem child positioned

Low share in a high growth market

In a product matrix, where are dogs positioned

Low share in a low growth market

what are the five forces of competition

bargaining power of suppliers, threat of new technology, threat of new competitors, bargain power of customers

how do you overcome bargaining power of suppliers and customers

low cost/ flood the market (B&Q) and focus on customer service (arnold clark)

how to overcome the threat of new competitors

Overcome by new innovations (tesla, apple)

how to overcome the threat of new technology

overcome by adapting the technology (ai)

what is Outsourcing

Business works with a partner to produce or provide required goods or services

what is Offshoring

Business develops its own operations in an overseas territory

what are pros and cons of a Green development

PRO: perfect location, maximum design flexibility;

CON: no infrastructure, local hostility, cost

what are pros and cons of Brownfield Development

PRO: lower cost, available infrastructure, local support; CON: limited availability, limited flexibility, hidden costs

what are the four types of manufacturing layouts

Functional, process, cellular, product

explain a functional layout

products are station at one location, allows high variability, low volume work and is suitable for heavy objects

what is the period in a short term time horizon

Period in which capacity is fixed and resources not flexed.

what is the period in a Long term time horizon

A period in which capacity can be completely changed and new resources added.

what is the definiton of Capacity

Maximum output rate that can be achieved by a facility.

what is the definiton of Capacity Utilisation

Percentage of how well an available capacity is being used.

what is Economic Order Quantity (EOQ)

The optimal order quantity that minimizes total inventory costs.

what is Economic Batch Quantity (EBQ)

The optimal batch quantity that minimizes total production costs.

what is Re-order Level

The inventory level at which a new order should be placed.

what are Variable costs

Costs incurred in a predetermined amount regardless of how many products are manufactured.

what are Costs associated with holding stock (Ch)

Includes working capital cost, storage cost, and obsolescence risk cost.

what are Costs associated with ordering stock (Co)

Includes administration costs, transport costs, and opportunity costs of missed discounts.

what are some issues with re-order level

Order period is unknown if the use rate varies; stock outs may occur if lead time is longer than expected or use rate is greater than expected.

what is a benefit of scheduling in production planning

Builds flexibility into the production plan.

what is a benefit of Integrated business planning software (ERP)

ERP systems can help ensure all the interrelated impacts of a master production schedule can be identified and dealt with.

define Work Measurement

To establish the time a task would take when performed by a qualified worker working at a defined level of performance.

what are pros and cons of Direct Work Measurement

pros: flexible technique, suitable for a wide range of work performed under a wide range of conditions

cons: difficult to time jobs in very short cycle times, relies on subjective process of rating

what are pros and cons of Indirect Work Measurement

pro: avoiding difficulty of ratings, people aspects, dealing with jobs that are difficult to measure directly

cons: inability to provide data for movements made under unnatural enviroments and mental processes. difficulty in coping with work which can be interrupted

what is Six Sigma used for

identifying and eliminate defects and reduce variation in processes

what are benefits of implimenting six sigma

reduced defects, increased yield, improved customer satisfaction and higher profits

what are the five Six Sigma Processes

Define, Measure, Analyse, Improve, and Control.

what is Lean thinking

improving flow in the value stream and eliminating waste

what are the five Lean principles

1. identify value

2. remove waste

3. create flow

4. establish pull

5. purse perfection

what are examples of Lean Metrics

throughput yield, rolled throughput yield, work in process, lead time, waste, value added/non value added, and takt time.

what are 3 key differences between lean and six sigma

lean: non-statistical, low investment, removal of waste

six sigma: statistical, significant investment, reduction of defects

what are Wasteful Activities

Activities that do not add value and should always be challenged in a lean environment.

what is Lean methodolgy

A methodology focused on improving flow in the value stream and eliminating waste.

Six Sigma

A methodology focused on eliminating defects and reducing variation in processes.

what is the systemaic process involved in Continuous Improvement

DMAIC: Define, Measure, Analyse, Improve, Control.

what are the 7 Wastes (timwoods)

Transport,

Inventory,

Motion,

Waiting,

Over processing,

Over production

Defects.

(waste of skills)

what are the 5S's in continuous improvements

Sort, Set in order, Shine, Standardise, Sustain.

what are the 8 factors for new product development success

1. top management support

2. technology

3. NPD teams

4. NPD strategies

5. NPD speed

6. NPD process

7. market orientation

8. knowledge management

what are the 5 Project Management Phases

The five phases of project management:

Initiation, Planning, Execution, Monitoring & controlling, and Close.

what categorizes Concurrent Engineering

• multidisciplinary teams

• simultaneous design of project and manufacturing processes.

• efficient project management and communication structure

what are the 4 Product Strategy Types

Pioneering, Responsive, Imitative, and Traditional.

what is included in product strategy

• product production quantities

• identifying target market

• product lifecycle timescales

who should the Design Brief be comleted by

only the the business and design company to prevent over-complication of the process by including stakeholders

what is Macroenvironment factors

pestel -

politcial, economic, social, environmental, legel

what are Microenvironment factors

customers, competiton, suppliers, resellers

name two product costing methods and briefly describe them

pareto costing - list components and estimate costing

complexity factor - use of equations to estimate costs based upon key cost drivers

what are the three organisation structures and describe them

functional - employees grouped by specialised functions (marketing, admin)

product - employees grouped by product lines/services

matrix - mix of functional and product

name pros and cons of a functional organisation structure:

pro : clear career path, work w/ people of similar backgrounds

cons : communication difficulties, unnecessary layers of management

name pros and cons of product organisation structure

pro: good when company has multiple ranges of products

cons: flexibility of labour reduces, duplication of resources

name pros and cons of matrix organisation structure

pros : flexibility

cons : reporting to two different managers = conflicting priorities

what does a patent cover

new inventions

what does a copyright cover

original creative or artistic forms

when should a Confidentiality Agreement be used

when disclosing the nature of creative work to external parties not bound by the organization's employment terms.

what are three things required for Patent Eligibility

1. novelty

2. must demonstrate an innovative step

3. must have a technical affect

what are the 4 Risk Response Types

avoidance, mitigation, transference, and acceptance.

what is Mitigation

A risk response strategy that involves taking actions to reduce the probability or impact of a risk.

explain a cellular layout

workstations are grouped into cells where each cell produces a family of similar products

explain product layouts

workstations in sequential flow, suitable for mass production of standardized parts

what is a process layout

machines and workstations grouped by function or process type (ie drilling machines in one area)

what 4 factors influence selection of forecasting models

amount and type of data available, degree of accuracy required, length of forecast horizon, data pattern present

what is a trademark used for

distinctive identification of products or services

what are registered designs used for

external appearances

what are trade secrets

valuable information not known to the public