Production techniques and systems

Automation:

Definition: The use of control systems (e.g., computers, PLCs, robotics) to operate machinery with minimal human intervention.

• Machines perform repetitive tasks without human input
• Can be fixed (dedicated to one task) or programmable (reconfigurable)
• Integrated with sensors/feedback for precision
• Common in mass production

Advantages	Disadvantages
High productivity – Continuous 24/7 operation Consistent quality – Reduced human error Lower labor costs – Fewer workers needed Improved safety – Handles hazardous tasks Precision – Ideal for high-tolerance work	High initial cost – Expensive setup Limited flexibility – Hard to adapt changes Unemployment – Reduces low-skilled jobs Maintenance – Requires skilled technicians System failures – Downtime halts production

Uses: Assembly lines (cars), packaging (food), material handling, quality inspection, dangerous environments.

vs FMS:

• Automation = Best for mass production, low flexibility
• FMS = Best for custom batches, high flexibility

Computer aided design (CAD) is used to draw 2D and 3D designs on computer

CAD sofware pacakges can be downloaded and used to create designs on a computer

CAD software:

Advantages	Disadvantages
Designs can be created, saved and edited easily (saves time) Designs can be easily copied/repeated Designs can be easily sent to other offices/clients etc Designs can be worked on by remote teams simultaneously Designs can look photo-realistic to gain opinions from clients CAD is very accurate CAD software such as FEA/CFD can test design ideas under stress/aerodynamics	CAD sodtware is complex to learn Software can be very expensive Need a robust IT system/powerful computer Compatibility issues with software between users Security issues - risk of data being corrupted/hacked

Uses: Design of buildings, bridges, structures

Automated machinery that is controlled by software to manufacture physical parts

CAM uses Computer Numerical Control (CNC) and CAD files to generate 3D tool paths for the machinery to follow

CAM machines include laser cutters, embroidery machines, CNC milling machines, routers and lathes

CAM software:

Advantages	Disadvantages
Very accurate/eliminates human error Repetitive accuracy Save and reload drawings to suit demand High speed/can run 24/7 Reduced labour costs Increased health and safety due to machines covering dangerous human jobs	High set up costs Training people to use/fix CNC machines can be difficult Workers being replaced by machines leads to low worker moral High skilled engineers need to be employed to fix comples machines - expensives Can't detect faults easily

Flexible manufacturing systems (FMS):

• Several machines are linked together controlled by a central computer
• CNC/robotics/ASRS/AGVs are used
• High flexibility
• Routing of material though a system

Advantages

Disadvantages

Fast response to market change/batch size can be altered quickly/shorter lead times/quicker to market/reduced down time Increased market share/higher profit/competitive edge Manufacturers can coordinate with their suppliers Reduces storage space Products can be customised FMS systems are able to check the quality of their own work Machines are flexible/not tied to producing a single product Rerouting workflow to maximise efficiency Low labour costs

High initial set up cost Potential reduction of output due to large batches Staff would need training/retraining Need skilled/flexible technicians Lots of planning is needed Hard to predict the market

Uses: To move materials/tooling/parts

Lean manufacturing using just-in-time (JIT) systems:

• Lean manufacturing is a waste reducing method within a manufacturing system
• It redcues waste in energy/transport/time/staff/materials/processes/systems
• JIT is a key feature of lean manufacturing
• Lean manufacturing is very efficient
• Kaizen - continuous improvement for production processes (small changes add up to large improvements)

Advantages	Disadvantages
No wastage storage, products dispatched when needed No wasted time, production delays are eliminated No wasted energy, movement of materials is minimised No wasted materials, only amount needed ordered Minimised faulty products, rigorous quality assurance systems in place No wasted labour, work tasks are carefully planned No wasted equipment, machinery does not stand ideal	Reliant on supplier being on time with orders High QA is expensive High maintenance costs If one machine breaks system stops High set up cost Unemployment due to high automation Need a robust IT system No room for error Staff illness can cause delays

Just-in-time (JIT):

Advantages	Disadvantages
Parts are ordered when needed/automatically Less money tied up in stock Less storage space needed, cost of warehouse spacing reduced High returns for company Reduces the movement of materials, environmental factor Lean manufacturing reduces prodctuon times Can react quickly to market trends Higher levels of quality assurance Increased job satisfaction Reduces labour costs	Reliant on supplier being on time with orders High QA is expensive High maintenance costs If one machine breaks system stops High set up cost Unemployment due to high automation Need a robust IT system No room for error Staff illness can cause delays Early deliveries can't be accepted as no storage space

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