1.6 Modern and industrial scales of production*

one off/ bespoke production

a product made for a unique situation which is designed individually. Usually costs more, requires skilled work which takes longer to produce and doesn’t have the benefit of economies of scale and each manufacturing process has to be set up individually. High communication with client.

examples of bespoke products

a luxury custom made yacht

a chair made for a disabled child

personalised wedding cake

suits

batch production

manufacturing processes are carried out simultaneously on a number of products at the same time to be more efficient and cost effective. 1-1000 units

simple production line, some automation, skilled/semiskilled workers, lower unit costs

what can be used to aid batch manufacturing?

Jigs, fixtures, CNC machines, manual machines

examples of batch products

seasonal goods, clothing, perishable food, newspapers/magazines

Mass/line production

products that are manufactured many times which is usually automated to improve efficiency of manufacture. uses production/assembly line and has high initial set up costs, works 24/7 skilled and unskilled workers, expensive machinery, low unit cost, less flexibilty to diversify products

examples of mass produced products

• clothing

• bicycles

• mobile phones

• cameras

• TVs

• ready meals

• self assembly furniture

unit production systems - UPS

uses overhead tracks to move components like garments between workstations. Sometimes manually operated but more often computer controlled. Reduces the number of handling operations, increases control of workflow and speed of production. Automation decreases labour costs and improves quality control because the stages of production are logged.

what is lead time?

the time taken to respond to orders for a part of a product

Quick response manufacturing - QRM

makes lead time as short as possible to be as successful as possible. Reduces lead time in response to demand rather than trend forecasting.

features of QRM

• reduction in external and internal lead times by improving communication systems

• ability to respond more efficiently to customer pull, market demand

• increased flexibility in manufacturing process

• increased value

• meet user need as quick as possible while delivering high quality

Vertical in-house production

a company that controls many of the stages of production like having control of raw materials, manufacturing and distribution processes. This improves efficiency, reduces costs, ensures greater control and timing in production

example of vertical in-house production

a clothing brand that has access to cotton fields, textile factories and retail shops.

strengths of vertical in-house production

reduction in the risk of unexpected price increase for components

less susceptible to suppliers going out of business

protection of their brand and improved security of intellectual property rights

weakness of vertical in-house production

reduction in specialisation, potentially leading to dillution of expertise

increase in administration

reduced flexibility

why is selecting material carefully important?

it has a knock on effect on the entire product. One may want to select the most economic cheap material but that affects the quality, durability, weight, bending strength (material properties) manufacturing processes, sustainability

how does the suitability of materials and process change with the scale of production?

• handmade items made one one avoid the high cost associated with mass production

• CNC or CAD/CAM process are idea for flexible manufacturing while maintaining accuracy and efficiency

• mass production favours automation with few labour intensive processes

how can marking and cutting be make economic?

by carefully cutting what you need from stock material you can make the most of it. CAD/CAM allows you make optimal use of materials. The shape and size of the design could be modified to make the most of the material. Nesting ensures that the smallest amount possible of unusable cut offs is left over when cutting material. More economical to plan projects around the material to avoid wastage.

how can manufacturing methods be more economical?

mass produced children’s toys are made by rotational or blow moulding which gives a hollow structure which reduces the amount of material needed while still keeping a strong structure.

Other methods like injection moulding requires two parts which will need a joining method, and mould which creates a lot of costs.

economical use of metals

different shaped beams created by different metals can be more economic than others. Beams that have large holes (tubular) made of aluminium are seen as the best because they are structurally strong, more economical, and are lightweight.

This contrasts using more traditional materials and is often used by Bauhaus that focused on affordability

recycling to be economical

offcuts or wasted materials can be recycled and reprocessed in-house so they can be reused. by designing for disassembly products can be recycled easier.

how can you ensure accuracy in manufacturing?

automated machinery in large scale production that use cams and levers rather than computers. CNC is good because it offers design flexibility but if you want accuracy you won’t need to change the design. However, CNC is good for mass producing a range of different parts in a short time so flexibility is needed there.

how does the cost of manufacturing in bulk compare to one-off

bulk production has the benefit of discounts when buying raw materials and transportations costs are reduced. It makes automated manufacturing financially viable because of the high set up costs - but it saves time and reduces labour costs.

one off takes a long time to create which in that time could create a lot more products if made in bulk

how are computers used for planning?

the use of barcode scanners (RFID) are useful in gathering information about stock and sales which is input to computer systems. Good for communicating this as they contain small integrated circuits which prevent theft in stores.

modular/cell production

a group of CNC machines in a module/cell which can be programmed to carry out a sequence of operations on a number of machines. Transfering the workpiece from machine to machine is done by a robotic arm.

JiT manufacturing

products are made to order rather than made before they are needed. This prevents financials burdens and storage problems of making too many unsold products.

lean production

making products right the first time rather than assuming what customers want to reduce waste and maintain stock levels

when is JiT production appropriate

when manufacturing vehicles and computers, making fast food

how is JiT implemented?

• increased consultation between management and workers

• regular feedback meetings to ensure continuous improvement

• carefully selecting suppliers in close proximity

• reduction of waste and stock

• optimising of the layout of machinery

• keeping track of stock and reordering systems -Kanban

what are the advantages of JiT?

• takes less storage space in the warehouse

• limits wasted materials

• prevents wasting money on unused materials

• orders are made specific to orders so no order can be made wrong unless there is a manufacturer error

• allows for mass customisation

what are the disadvantages of JiT?

• manufacturers are dependant on reliable suppliers to deliver products

• can’t directly meet the demand of your customers

• must be prepared for higher level of demand in different times of the year

• not protected from accidents

QRM

the use of mainly computer based technology to facilitate efficient, competitive production of low-volume, customised products

Flexible manufacturing systems (FMS)

production using work cells of CNC machines and robots that can be used to made a wide range of different products, typically one off/bespoke items in small batches

single minute exchange dies SMED

changing dies quickly in response to demand. Able to change dies in less that 10 minutes using quick release locking devices. This results in lesser idle time and saves money and time as the machinery is too expensive for it to not run

electronic point of sale (EPOS)

Computer system for storage, records the sale of products and feeds this information to warehouses for stocking information.

computer integrated manufacture (CIM)

used to describe the use of computer systems to control all stages of bringing a product to market from design. Warehouses are increasingly fully automated/machinery with the use of AGVs, forklifts and stacking machines so there is no manual handling involved

standardised components

parts such as screws and light bulbs that are made to a common standard to ensure interchangeability, used within production

bought in components

Using standard components allows for the interchangeability of parts within products and design

examples of brought in components

• door locks

• audio connectors

• batteries

• fuses

• memory cards

sub assemblies

groups of parts that are preassembled and brought into a larger group of parts as a single unit - mostly standard components that are bought in

changing standards

Companies may have to make changes to their standards for legal reasons, competitivity with other designs/companies, or technological advancements. Important for brand identity.

examples of changing standards

• apple’s lighting cable and removal of the standard headphone socket

• HDMI instead of SCART on HDTV

• removal of optical disk on computers making it difficult to use dvd

sub-assembly

a self-contained element of a product that is made separately and incorporated in the final assembly stages. simplifies and speeds up the manufacturing process and all parts are made and assembled in the same factory.