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.