ib design and tech - topic 10

just in case focuses on..

creating products in anticipation of market demand to reduce costs using economies of scale

3 JIC advantages

• always able to respond to market demand

• higher reliability

• timely distribution of parts

3 JIC disadvantages

• large inventory must be managed

• high capital costs - space for inventory

• higher wastage due to spoilage

just in time is…

a production strategy that aims to reduce inventory costs by receiving goods only when they are needed in the production process

3 JIT advantages

1. highly flexible manufacturing

2. low waste as there isn’t over-production

3. lower costs as there’s no inventory

3 JIT disadvantages

1. greater risk of manufacturing delays

2. delay between customer’s orders and delivery

3. cannot benefit from economies of scale

lean production aims to..

eliminate waste and maximise the value of a product based on the perspective of the consumer

3 advantages of lean production

1. increased productivity (focus on kaizen and waste reduction)

2. increased quality (focus on improvement and reduction of defects)

3. reduced environmental impact (reduction of waste materials)

3 disadvantages of lean production

1. high initial costs (need to invest in new systems)

2. difficult to introduce to an existing workforce

3. no inventory is difficult if there’s a sudden increase in demand

3 characteristics of lean produciton

1. highly trained, multi-skilled workforce

2. quality control and continuous improvement

3. zero defects

4 principles of lean production

1. doing it right the first time

2. taking every customer complaint seriously

3. empowering workers

4. eliminate all waste

values stream mapping focuses on…

identifying areas for improvement to optimise the overall process

workflow analysis focuses on…

the sequences, tools and worker movements to ensure the highest efficiency in the system

kaizen is a…

philosophy of continual improvement

kaizen emphasises the workforce as the…

most valuable component of a manufacturing system

the 5 “S’s” are a method for…

organising the workplace with the goal of improving efficiency of production

name all of the 5 “S’s”

1. sort

2. set in order

3. shine

4. standardise

5. sustain

how many of the 8 wastes in lean manufacturing can you name?

1. defects

2. over-production

3. waiting

4. unused talent

5. transportation

6. inventory

7. motion

8. extra-processing

computer integrated manufacturing uses computers to…

automatically monitor and control the entire production of a product

the 7 elements of computer integrated manufacturing

1. design

2. planning

3. purchasing

4. manufacturing

5. cost accounting

6. inventory control

7. distribution

why is CIM not suitable for small scale production?

there’s a high initial cost of investment and low economy of scale

give 3 pros and cons for using CIM in mass/batch production

pros

• efficient production lowers costs

• high quality of product

• shorter lead time

cons

• high initial cost of investment

• high cost of training workers

• job losses due to automation

give 3 pros and cons for using CIM in mass customisation production

pros

• greater choice for client

• easier to meet unique clients needs

• efficient production

cons

• high initial cost of investment

• high cost of training workers

• job losses due to automation

tolerance

the allowable amount of variation within a particular quality

inspection

the checking of qualities at different stages throughout the production process

destructive testing

testing a product or part that destroys or physically alters the part

non-destructive testing

testing a product or part that measures physical properties

quality control

a product-oriented approach that involves regularly inspecting and testing the final product to identify and fix defects

statistical process control (SPC)

the use of statistical tools to monitor, control, and improve the quality of a manufacturing process by identifying variations and maintaining consistency

quality assurance

a process-orientated approach that focuses on preventing defects by ensuring that every step in the production process meets defined quality standards

cost effectiveness

focuses on strategies that minimise the cost of producing a product

value for money

the balance between the price and quality of a product, where the user feels they are getting fair worth for the amount they paid

variable costs

costs that change with the level of production

how are total costs calculated?

by adding together the fixed and variable costs

cost analysis

a tool used to determine the feasibility of producing a product

price-minus

manufacturers determine a price consumers are willing and able to pay through market research

retail price

the price the manufacturer suggests the product be sold at

wholesale price

the cost of the product sold by a wholesaler

typical manufacturing price

the price the manufacturer sells the product at

target costs

the final cost determined before manufacturing

return on investment (ROI)

the profit made from the product

unit cost

the total cost to produce, store and sell one product

sales volume

the number of products sold within a specific timeframe