Chapter 4 - Production Techniques & Systems

What is automation?

The use of automatic equipment and computer systems in a production process to reduce human interaction.

What is Product Data Management (PDM)?

The software systems that store all product information centrally, update it live, and make it accessible to employees.

What is a primary benefit of using a Product Data Management (PDM) system in a company?

It reduces mistakes, ensures teams work together, and allows for accurate costing and forecasting.

What type of products are typically still made using skilled manual labour?

Bespoke, low-volume, and high-cost items like sports cars or high-end furniture.

Why are customers often willing to pay a premium for hand-built products?

They prefer the quality and craftsmanship associated with hand-built items over mass-produced goods.

What does the acronym CAD stand for in the context of design and technology?

Computer Aided Design

What is the primary function of Computer Aided Design (CAD) software?

It is used to create, modify, and test new 2D or 3D product designs digitally.

What is a key advantage of CAD regarding design modifications?

Designs can be altered easily and quickly without needing to redraw the entire object.

How does CAD software help reduce labour costs and development time?

It allows for the rapid drawing of designs and complex shapes, which is faster than manual methods.

What feature in CAD software allows designers to view a product with different finishes before it is made?

Rendering, which can make the design look photo-realistic.

What type of analysis can be performed using CAD software to predict a product's behaviour under load?

Complex stress testing and associated calculations.

How does CAD facilitate teamwork on a design project?

Designs can be worked on by whole teams simultaneously and sent easily by email for approval.

What is a major disadvantage of implementing CAD software in a business?

The software and required computer hardware can be very expensive to purchase and set up.

What is a significant challenge for staff when a company adopts new CAD software?

The software is often complex and requires a skilled workforce, necessitating training.

What is a potential security risk associated with using CAD?

There is a risk of data being corrupted or hacked.

What does the acronym CAM stand for in the context of manufacturing?

Computer Aided Manufacturing

What is the function of Computer Aided Manufacturing (CAM)?

It uses the data from CAD files to control automated machinery to produce physical parts or products.

The system used by both CAD and CAM to control machine movements with machine code is known as _________ ________ ________ (___).

Computer Numerical Control CNC

On a CNC machine, which axis of movement does the X coordinate represent?

Lateral movement (side-to-side).

On a CNC machine, which axis of movement does the Y coordinate represent?

Longitudinal movement (back and forth).

On a CNC machine, which axis of movement does the Z coordinate represent?

Vertical movement (up and down).

What is post processing?

The stage where a CAD file is converted into the specific machine code that a CAM machine can understand.

What common file types are used to output designs from CAD for use in CAM?

DXF, STL, and OBJ files.

What feature in post-processing software allows a user to check for potential errors before physical production begins?

Running a virtual simulation of the component's production.

What is a significant advantage of using CAM in terms of speed and precision?

It is faster and more accurate than traditional manufacturing methods.

What is a key benefit of CAM for repetitive manufacturing tasks?

It offers high repetitive accuracy and machines can run 24/7 without fatigue.

What is the primary disadvantage of setting up a CAM system?

The initial setup costs for equipment are very expensive.

What is a major social disadvantage of widespread CAM implementation in industry?

It has led to unemployment in many sectors by replacing jobs traditionally done by skilled workers.

Name two common examples of CAM equipment found in schools.

Laser cutters and 3D printers.

What is a Flexible Manufacturing System (FMS)?

A collection of adaptable, automated machines used in production lines where products may change regularly.

How does a Flexible Manufacturing System (FMS) allow a company to react to market changes?

It allows manufacturers to respond quickly to fluctuations in consumer demands, trends, and fashion.

What type of production is a Flexible Manufacturing System (FMS) particularly well-suited for?

Batch production, where quantities and product types frequently change.

What are two key components frequently used in a Flexible Manufacturing System (FMS)?

CNC machines and robot arms, as they are easily reprogrammable.

What is the core philosophy of Lean Manufacturing?

To systematically eliminate all forms of waste, overburden, and bottlenecks within a manufacturing system.

In which country did the Lean Manufacturing movement first gain prominence?

Japan, notably with Toyota.

What is Just In Time (JIT) manufacturing?

A key method in lean manufacturing where the production process is triggered by a specific customer order.

In a Just In Time (JIT) system, when are raw materials and components ordered and delivered?

They are ordered in the correct amounts to cover the order and arrive just as they are needed for production.

What is a major financial advantage of JIT related to storage?

It saves on storage costs as no finished products and very few raw materials need to be stored.

How does JIT manufacturing prevent money from being tied up in unsold products?

Products are made to order, so there is no excess stock that might remain unsold.

What is a significant disadvantage of the JIT manufacturing model?

It relies heavily on a high-quality, fast, and reliable supply chain; a breakdown can halt all production.

Why might a customer prefer a traditional retail model over JIT?

With JIT, stock is not available 'off the shelf,' and some consumers prefer not to wait for their order to be produced.

How can JIT manufacturing be negatively affected by supplier pricing?

Discounts from suppliers for bulk purchasing of materials may not be available due to ordering smaller quantities.

How does JIT manufacturing improve a company's cash flow?

Orders are often secured with a deposit or full payment upfront, so money is in the bank before it is spent on materials.

What is ‘kaizen’?

The Japanese concept of 'continuous improvement' that supports lean manufacturing.

How does the principle of 'right first time' benefit JIT manufacturing?

It reduces the time and money wasted on correcting mistakes or on faulty products, which is critical in a time-sensitive system.

An example of Lean Manufacturing is redesigning a packaging net to include a _____ pattern to reduce material waste.

tessellating

How has the automation of workplaces impacted the labour force?

It has led to an increase in skilled worker roles but a decrease in overall job opportunities as machines replace manual labour.

What is one reason many designers still prefer to start sketching with pen and paper despite having access to CAD?

Ideas can sometimes be expressed more freely and spontaneously than on a computer.

What technological improvements are encouraging more designers to move to a totally digital design process?

Improvements in touch-sensitive screens and styluses.

In the context of the Amazon warehouse case study, what are the robotic vehicles called that move goods through fulfillment centres?

Drives

What is a negative consequence for human workers in highly automated warehouses like Amazon's?

There are concerns that keeping up with the pace of the technology is taking a toll on workers' health, safety, and morale.

According to the crisp factory case study, how are blackened crisps removed from the automated production line?

An automated camera identifies them and a precise jet of air blows them off the conveyor.

What is one advantage of using an automated quality control system, like the one in the crisp factory, over manual inspectors?

High accuracy, as the system can operate indefinitely without fatigue.

Why might a manufacturer advertise their crisps as being 'hand cut'?

To create an 'air of quality', as some consumers deem hand-produced items to be of a higher standard.

How does CAM use CNC and CAD files to create a part?

It uses the files to generate 3D tool paths for the machinery to follow.

What is a disadvantage for an organisation using CAM regarding staff expertise?

CAM machines need specialist engineers for maintenance and repair, who can be expensive to hire.

How can laser cutters perform different actions like cutting through or just etching a material's surface?

By cutting at different speed rates and power levels.

Flexible Manufacturing Systems (FMS) are commonly used for what type of production runs?

Short-run batch production lines

What are the three main areas of waste that the Lean Manufacturing philosophy aims to eliminate?

Overproduction, transportation, and defects.

In JIT, how is the relationship with suppliers critical to success?

Suppliers must be carefully selected, reliable, and are often located in close proximity to the factory to ensure timely delivery.

How does JIT prevent stock from becoming obsolete or out of date?

Because stock levels are kept extremely low and products are made to order, there is no large inventory to age.

What are two common forms of CAD software?

Autodesk and Solidworks.

How does the use of automated systems in manufacturing typically affect error rates?

It reduces errors compared to manual production lines.

What is a drawback of JIT for a business if a single supplier fails to deliver a crucial component?

All production could stop, causing significant delays for all customer orders.

What is an ethical consideration developers of autonomous self-driving vehicles might need to make?

Programming the vehicle to make a choice in an unavoidable accident scenario (e.g., who to protect).

How can CAD be used to gather consumer feedback before costly production takes place?

Designs can be rendered photo-realistically and shown to the public to gauge opinion on different finishes or styles.

What is a technological disadvantage of relying on CAD/CAM systems that are frequently updated?

It's difficult and costly to keep up with constantly changing and improving technology and software updates.

Why is the ability to easily copy or repeat designs a major advantage of CAD?

It saves a significant amount of time and effort when creating products with symmetrical or repeating features.

What is a potential data-related issue when using CAD, especially in the event of a power outage?

Data can be lost if not saved properly before the power cut.

What type of manufacturing was slower and more expensive to operate compared to today's automated lines?

Manual production lines.

What is the role of a robot arm in a Flexible Manufacturing System (FMS)?

It can be programmed to perform many different tasks, allowing for real-time changes and greater manufacturing flexibility.

When manufacturers focus on the reduction of waste during production, it is called

lean manufacture

Which one of the following is a production method based on providing stock as it is needed?

Just in Time Manufacturing