Transcript Automating large-scale production

Automating largescale production
Lesson objective to understand the
difference between one-off production,
batch production, mass production and
continuous production
How many products?
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Products are made in a range of quantities and
the numbers of products made at one time is
referred to as the ‘Scale of Production’
What is a ‘one off’?
What is a ‘batch production’?
What is ‘mass production’?
What is ‘continuous production’?
Lesson objective to understand the difference between one-off production,
batch production, mass production and continuous production
One off production
Key words – single –
special – client –
performance
characteristics
List three items - List three items
that you may order in your lifetime
that could be a ‘one off’’
Lesson objective to understand the difference between one-off production,
batch production, mass production and continuous production
Batch production
Task – list three types of products that you have
bought that have been made in a batch production
process
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Batch production
products are identical
and made at the same
time in either large or
small numbers.
Once these products
have been made, more
of the same products
may be made using the
same equipment
Lesson objective to understand the difference between one-off production,
batch production, mass production and continuous production
Mass production
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This involve the product going
through many stages of a
production line. The workers
and machines at each stage
are responsible for making
certain parts of the product.
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Typically, mass production
workers are less skilled as
there is more reliance on
machinery. Workers tend to
specialise in a small range of
takss.
Lesson objective to understand the difference between one-off production,
batch production, mass production and continuous production
‘Continuous Production’
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This means the products are
produced over a period of
hours, days, weeks or even
years. The production line
never stops.
Very few workers are used
in comparison with the
number of products made.
Typically, the force forces
is less skilled due to the
high levels of automation.
The cost of the plant is high
and is often designed to
produce a very limited
range of products
Lesson objective to understand the difference between one-off production,
batch production, mass production and continuous production
Task – draw a flow diagram of the process for
making bread buns – extra marks for listing the
ingredients
You need arrows – images – words – inputs – outputs – machine names -
Inputs
process
outputs
Extra marks for listing the
ingredients
Water
Yeast
Flour
Salt
Sugar
Olive oil
AfL - 2 marks for every correct key
word
1.
2.
3.
4.
5.
6.
Tell me what a ‘one off’ is
What is batch production, what scale and numbers?
What is mass production?
Tell me about the work force during mass production?
Now tell me about continuous production, is it man or
machine that does most of this?
Is you talk about production methods what is the
correct term?
Automating largescale production
Lesson objective 2 - understand the
application of computer numerical
control (CNC) in manufacturing
Questions
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Does anyone
know what a
CNC system is?
Has anyone ever
seen a robot
building a large
scale product or
completing a
delicate job that
would normally
be carried out by
a person?
Surgeons
in Australia are excited over
new surgical robots they are
with to work surgical operations
on patients. These new robots
tolerate surgeons to work
operations using enhanced
precision in a way that reduces
post-operative complications
and actually requires fewer
poles during the surgical
method
Lesson objective to understand the application of computer numerical control (CNC)
in manufacturing
Task 1 - Name robot and film
Robots
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A first generation robots responds to
a pre-set program, doing the same
job repeatedly. If this robot were
pouring soft drinks into bottles and
the liquid missed the opening of one
bottle, it would carry on filling the
bottles regardless.
Lesson objective to understand the application of
computer numerical control (CNC) in manufacturing
names
Maria - 1927
Gort 1951
Robby the robot 1956
Ash
Alien, 1979
C-3P0 and R2-D2 1977 - 2005
Johnny 5
Short Circuit,
1986
Terminator
Terminator,
1984
Robocop
Robocop 1, 2 & 3,
1987 - 1993
NS-5
I, Robot, 2004
Marvin the
Paranoid Android
The Hitchhiker’s
Guide to the
Galaxy, 2005
Optimus Prime
Transformers, 2007
The leader of a pack of robots battling the Decepticons, (another, more evil class of
robots) Optimus takes it upon himself to protect the planet Earth and kick some metal
ass in the meantime.
A second
generation
robot has sensors that
relay information to the
computer in the factory.
These robots can perform
a similar automated job on
many different products or
processes.
On
a car assembly line, a
second generation robot
might insert a car
windscreen and then the
dashboard.
Lesson objective to understand the application of computer numerical control (CNC)
in manufacturing
AfL 1.
2.
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What two types of robot systems are
there
What type of tasks can this type of
automation do?
Advantages of these systems?
Disadvantages to these systems?
AfL – when we have discussed the advantages
and disadvantages I want you to make small notes
on each
Precision and Efficiency Long-term
 Cost Ease of Exchange/Upgrade
 Technology limits
 The research and development cost
 The automation of a plant
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Answers Because humans require resources like
sleep, nutrition and mental stimulation to be fully functional,
robots have replaced people on many assembly lines with
great success.
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Precision and Efficiency - It is a well-founded
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scientific fact that no matter how focused the individual may
be, a human being will always fatigue both physically and
mentally during long hours of intense physical or mental
exertion, like that found on an assembly line.
Robots, however, require no breaks to rest, nor do they grow
weary and uncoordinated after 10 hours of ceaseless labor. A
robot can be left to do its job for much longer hours than
humans can manage without losing quality in their work,
especially during precise operations such as soldering
microchips.
Long-term Cost
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- A manufacturing robot can seem unbelievably
expensive at first. There's the cost of the
machine itself, plus the operating software and
hardware, and the installation to pay for.
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When compared to hiring and maintaining a
human worker, however, the long-term cost
comparison favors an automated workplace.
Ease of Exchange/Upgrade
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If an application comes into your company from someone who is
better qualified, better educated or otherwise superior to one of your
human workers, you are faced with a dilemma.
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While hiring the new person would be the correct move for your
company, it would require first removing the existing worker from his
post.
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Aside from the tedious paperwork and general upheaval this can
cause, it is also a terrible blow to a person's ego and financial
situation, is generally seen as unfair by the existing worker.
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It can result in unlawful-termination lawsuits, or other problems.
Disadvantage
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Technology limits. Current technology is unable to automate all the desired
tasks.
Unpredictable development costs.
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The research and development cost of automating a process is difficult to
predict accurately beforehand. Since this cost can have a large impact on
profitability, it’s possible to finish automating a process only to discover that
there’s no economic advantage in doing so. Initial costs are relatively high.
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The automation of a new product required a huge initial investment in
comparison with the unit cost of the product, although the cost of
automation is spread in many product batches.
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The automation of a plant required a great initial investment too, although
this cost is spread in the products to be produced.