Topic 4.5 - Production systems (no tasks) (1)

IB TOPIC 4: RAW MATERIAL TO FINAL PRODUCT

Essential Idea: The development of increasingly sophisticated production systems is transforming the way products are made.

4.5: Production Systems

  • Nature of design:

    • As a business grows, it aims to reduce average production costs, known as economies of scale.

    • Businesses become more efficient in the use of inputs to produce a set level of output.

    • Designers should consider internal and external economies of scale when selecting production methods.

Concepts and Principles

  • Types of Production Methods:

    • Craft Production

    • Mechanized Production

    • Automated Production

    • Assembly Line Production

    • Mass Production

    • Mass Customization

    • Computer Numerical Control (CNC)

  • Design for Manufacture (DfM):

    • Key Aspects:

      • Design for Materials

      • Design for Process

      • Design for Assembly

      • Design for Disassembly

    • Adapting designs for DfM is crucial in developing efficient production systems.

Guidance:

  • Evaluation of Production Systems:

    • Advantages and disadvantages impact both workforce and environment.

    • Criteria for selection include time, labor, skills, training, health & safety, costs, product type, maintenance, environmental impact, and quality management.

    • Contexts where different production systems are utilized vary significantly.

Aims

  • The design of a production system requires a comprehensive understanding of a product's function and finish quality.

  • Each system is tailored to the product being created, often necessitating design adaptations for manufacturing methods.

Craft Production

  • Definition: Small-scale production centered around manual skills, often referred to as One-Off production.

  • Characteristics:

    • Labor-intensive, producing unique products based on customer requirements.

    • Commonly used for prototype development before larger-scale production.

  • Historical Context:

    • Prior to the Industrial Revolution, most goods were made using craft techniques limited by technology and energy sources.

    • Craftsmen doubled as designers and consumers, leading to slow skill development and localized sourcing.

Advantages:

  • High-quality output due to time and care invested in manufacturing.

  • Customization based on individual user needs.

Disadvantages:

  • Requires highly skilled labor, leading to high production costs.

  • Inability to manufacture at large scale is a limitation.

Typical Examples:

  • Unique handmade products such as buildings, furniture, artworks, and clothing.

Mechanized Production

  • Definition: A production process that employs machines controlled by humans, replacing manual skills.

  • Background:

    • Until the 1700s, most production was cottage-based with limited machinery; mechanization grew significantly during the Industrial Revolution.

Advantages:

  • Cost-effective and faster production methods leading to improved quality and efficiency.

Disadvantages:

  • Workforce redundancy due to machinery substituting skilled labor.

    • Workers may experience job dissatisfaction and decreased skills due to less manual involvement.

Typical Examples:

  • Machines such as cotton pickers, which were transformative in agriculture.

Automated Production

  • Definition: Machines operate without human input, substituting human labor in manufacturing processes.

  • Background:

    • Early automation relied on punched cards for machine control, evolving with numerical control systems to include computers.

Advantages:

  • Enhances safety by eliminating human involvement in hazardous environments and monotonous tasks.

    • Improves quality and production efficiency through precision in manufacturing.

Disadvantages:

  • Potential job loss as automation reduces workforce needs.

  • High capital investment required for technology deployment.

Typical Examples:

  • CNC machines and automated production lines.

Assembly Line Production

  • Definition: A method of mass production where products move continuously along an assembly line, allowing efficient addition of components.

  • Background:

    • Key to the Industrial Revolution, it dramatically increased productivity at reduced costs.

Advantages:

  • High volume output, leading to decreased production costs.

  • Components made for easy replacement allows for efficient maintenance.

Disadvantages:

  • Workforce becomes deskilled due to repetitive tasks, lowering job satisfaction.

Typical Examples:

  • Production of bicycles using manual assembly lines.

Mass Production and Mass Customization

  • Mass Production: Producing large quantities of standardized goods, maximizing output per worker.

  • Mass Customization: Incorporating customer orders into mass production systems while achieving economies of scale.

  • Computer Numerical Control (CNC): Computer-aided machine control for manufacturing complex parts.

Design for Manufacture (DfM)

  • Focuses on optimizing designs for specific manufacturing capabilities across four areas:

    • Materials

    • Process

    • Assembly

    • Disassembly

International-mindedness and Knowledge Theory

  • The geographic distribution of production modes implicates economic and political factors.

  • Automation's impact on craftsmanship raises questions about technology's effect on traditional knowledge and practices.

Utilization

  • Relevant design technology topics and internal assessments connect to broader economic and design discussions.

Aims

  • Both the unique design of production systems and adaptation for effective manufacturing are essential in design education.