Materials & manufacture · Higher
Production systems & planning
7 cards · 4 quiz · 1 exam
Design & Manufacture · Higher · mrkellydt.co.uk
What you're learning in this topic
Learning intention WALT
We are learning about production systems & planning, specifically to understand:
- one-off and mass production
- why standard components and knock-down fittings are used
- batch production and the issues that decide the production system
- how automation, CAD/CAM, CNC, Gantt and flow charts, jigs and JIT improve production
Success criteria WILF
- I can compare one-off and mass production
- I can explain why standard components and knock-down fittings are used
- I can describe batch production and the issues that decide the production system
- I can explain how automation, CAD/CAM, CNC, Gantt and flow charts, jigs and JIT improve production
Production systems
| One-off | Batch (H) | Mass | |
|---|---|---|---|
| Quantity | Single unique item | Set quantities of a product | Very large numbers of identical items |
| Workforce | Highly skilled, labour intensive | Skilled, quite labour intensive | Low skill, highly automated |
| Cost | Expensive per item | Moderate | High set-up, low unit cost |
| Flexibility | Very flexible | Flexible | Inflexible |
| Examples | Made-to-measure gates, prototypes | Seasonal products, furniture ranges | Drinks bottles, kitchen utensils |
Choosing a system (Higher): expected demand and sales, unit cost, investment in tooling and machines, size and skill of the workforce, type of product and how often it changes, lead time.
Standard components
Parts made in huge numbers to an agreed standard (nuts, bolts, hinges, motors).
- Benefits: low cost, consistent quality, reliable, easy to source and replace, save design and manufacturing time.
- Drawbacks: depend on outside suppliers (delays, quality out of your control), need storage, may restrict the design.
Methods to improve production (Higher) HIGHER
- Automation / CNC: fewer errors, smaller workforce, more output, runs 24 hours.
- CAD/CAM: flexible manufacturing, efficient, shared files, simulations, links to stock control.
- Gantt charts: tasks against time; show concurrent tasks and critical tasks; manage workforce and deadlines.
- Flow charts: sequence of events and decisions (terminator, process, decision, input).
- Jigs (guide the tool) and fixtures (hold the part): accuracy, repeatability, no marking out, less skilled labour.
- Just-in-time: materials and parts arrive exactly when needed. Saves warehouse cost and waste, shortens lead time; but depends on suppliers and can't cope with a sudden rise in orders.
- Standard components: known quality, less assembly time, lower costs.
Key terms
| Mass production | Large volumes of identical products; automated; low skill; low unit cost. |
|---|---|
| One-off production | A single unique product made by highly skilled workers. |
| Batch production | A set quantity made at once; production can switch between products. |
| Standard component | A part made in large numbers to an agreed standard (e.g. bolts, hinges). |
| Just-in-time | Supplies arrive exactly when needed, so no large stock is held. |
| Jig | Device that guides a tool for accurate, repeatable work. |
| Gantt chart | Bar chart showing tasks against time, including concurrent tasks. |
Quick check
1. Which system has the highest set-up cost but the lowest cost per item?
- One-off
- Mass
- Prototype
- Hand-made
Show answer
B: Mass. Tooling is spread over huge numbers.
2. Which is a disadvantage of standard components for a manufacturer?
- Quality can't be guaranteed at all
- They are difficult and slow to source
- Dependence on an outside supplier
- Parts must always be made in-house
Show answer
C: Dependence on an outside supplier. Delays at the supplier stop production.
3. What is a drawback of just-in-time production?
- Large warehouses are needed to store spare stock
- Deliveries to customers are always much slower
- More materials are wasted during production
- Cannot easily cope with a sudden increase in orders
Show answer
D: Cannot easily cope with a sudden increase in orders. No stock is held to absorb extra demand.
4. How does a jig improve production?
- Reduces marking out and improves accuracy and repeatability
- Removes the need for accurate measuring tools altogether
- Lets every part be made to a slightly different size
- Replaces the need for skilled workers in the factory
Show answer
A: Reduces marking out and improves accuracy and repeatability. It locates or guides consistently.
Exam-style questions
1. Describe four ways in which a manufacturer could improve the efficiency of a batch production line. (8 marks)
Show marking guidance
- Up to 2 marks per method described
- Jigs/fixtures: no marking out, accurate repeat parts
- CAD/CAM or CNC: automated, accurate, 24/7
- Just-in-time: no stockholding, less waste
- Standard components: no need to make parts, known quality
- Gantt/flow charts: plan tasks, identify critical tasks, manage workforce
Printable worksheet
An I do, we do, you do worksheet for this topic, with a separate answer sheet.