Modern manufacturing methods and systems

Allocate all resources/tasks in the correct order (efficient production)

Save time/money/energy cost by increasing productivity

Rate of output per unit'

How efficient a person works

How much they produce in a given time

Usually done on a IT system to make paperwork easier to retrieve

IT systems in production scheduling/logistics:

Advantages	Disadvantages
Flexible and easy to adapt Monitor progress of work Ease of access to information Limit access Increased productivity Decrease time to market Improves worker moral (bonuses) Workers are given a statement of what should be done and when	Need a robust IT system Corrupted data can occur Software updates can delay progress Training staff time consuming (some staff reluctant to change) Change over period can be problematic

Computer systems:

• Planning/control software is used to organise complex manufacturing processes
• Spreadsheets/charts always available, giving instant overview of factory schedules and operations
• Barcodes/radio frequencies tags facilitate the reliable transfer of component and stock information by scanning, helps to reduce waste and improve the speed of response to changes in demand

Artifical intelligence:

• A piece of software that can learn and adapt
• Simulations and tests can be performed
• A 'co-worker' (suggestions and ideas)
• Store/retrieve massive amounts of data quickly
• Ability to identify mistakes/problems and fix these issues

Robots on fully-automated production and assembly lines/cells:

• In cells, manufacturing cells combine CNC machines (lathes, milling machines, drills, grinders) in a group
• The cell is programmed to carry out a sequence of operations to make parts (car engine)
• Automatic guided vehicles (AGVs) transport materials/parts to and from buffers zones
• Robots with 6 axes (direction of movement) load and unload machines
• These devices are programmed along with the CNC machines they are servicing

Advantages	Disadvantages
Able to repeat repetitive tasks Can be used in hazardous locations More productive than humans (no breaks) Cost effective Removes human error	Expensive set up cost Not as flexible as humans Expensive to maintain

Uses: Assembly lines for products e.g. cars

Applications: Spot welding, spray painting, pop riveting, routing, milling

Automated guided vehicles (AGVs):

• Used to move toolings/parts
• Controlled by a computer system

*AGVs are GPS guided/laser guided/line guided/radio wire guided

How they work:

• Route determined by computer
• Lasers pick up the route
• Information fed back to microprocessors
• Microprocessors on vehicle follow laser route
• Continuous adjustments made by microprocessors

Uses: To move materials/tooling/parts in factories

Examples of AGVs: Towing vehicles, pallet trucks, fork lift trucks, assembly line vehicles

Automated storage and retrieval systems (ASRS):

• Collect stock materials in racking system
• Selects component that is needed and places it on AGV

Advantages	Disadvantages
Parts are retrieved for the precise time needed Can run 24/7 Reduced employment costs Reduced error/damage of goods Improved safety regrading heights	High set up costs/repair costs Needs a uniform system of unitising Lack of flexibility Puts people ot of work Faulty parts may go undetected

Uses: To move materials/tooling/parts

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

Functional cells:

• Specific function
• One purpose
• Not flexible
• Higher levels of waste

Group technology cells:

• Series of operations for several different product lines
• Works well within a lean manufacturing environment
• Machines are more flexible/not just one job

Product focused cells:

• Product focused
• Manufacture one product through a series of operations
• Perfect for small product range with high volume demand
• Ideal for lean manufacturing

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

Standardised parts:

Parts made to a common, interchangeable standard (nuts and bolts)

Advantages	Disadvantages
Readily available Specification data already known Design decisions are simplified Consumer can source replacements easily Manufacturer does not need to stockpile Time saved by buying in parts, not designing and making them themselves	Dependent on manufacturer to supply a product can be less reliable (production line can be delayed) Can me more expensive than making yourself More storage space may be required Longer time required for ordering and supplying No control of making/quality

Applications: Castors, bolts, washers, hinges, shelf brackets

Quick response manufacturing (QRM):

• Quick response manufacturing (QRM) is a companywide strategy to cut leads times in all phases of manufacturing and office operations
• It can bring your products to the market quicker and help you compete in a rapidly changing manufacturing arena
• It will increase profitability by reducing cost, enhance delivery performance and improve quality
• Stock levels constantly revaluated (JIT)
• Products/materials only bought when needed

Advantages	Disadvantages
Reduces the time to market/lead time Keep up with trends Reduces retooling cost Increased market share Improved cash flow Storage costs reduced Highly automated - reduced labour costs Reduced human error - less waste Allows flexibility Business increases reputation	Large variation in demand will cause problems if the manufacturer can't react to the high production of volume quick enough Employees reluctant to change Need a robust IT system Highly dependent on suppliers to react to demand

Data integration:

Product data management (PDM):

• Use of software or other tools to track and control data related to a particular product
• Data tracked usually involves the technical specifications of the product, specifcations for manufacture and development, and the types of materials that will be required to produce

Enterprise resource planning (ERP) systems:

• Intergrate all departments and data across a company onto one signle computer/server
• Unified database

Advantages	Disadvantages
ERP improves the way a company takes a customer's order Quicker response to orders Increased customer satisfaction Improves communication within business Customers orders can easily be tracked	Robust IT system needed Expensive to install System failure effects all areas of the business

Concurrent manufacturing:

• Simultaneously completing design and manufacturing stages of production
• Systematic approach to the integration of design, manufacture, and related processes
• All life cycle stages of the product are considered simultaneously

Advantages	Disadvantages
Produces 'right-first-time' product Reduces waste Reduces product development times Reduces lead times Enables faster release of new products High quality product	All departments must work together which can cause arguments/stand offs No room for mistakes Need a robust IT system High QA/QC can be expensive Employees can be reluctant to change to new ways

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