Transcript Manufacturing Processes

Manufacturing Processes
(Mass Production)
Mr. Pottkotter
Ohio Academic Content Standards Technology: Standard 7, Benchmark C
Definitions
• Manufacturing:
– the mechanical, physical, or chemical
transformation of materials or substances into
new products
• Mass-Production:
– the production or manufacture of goods in
large quantities, esp. by machinery.
• Production:
– the act or process of producing something
Where can manufacturing
processes be found?
• Anywhere an item is made or produced?
– Examples:
• Factories
– Retail factories- clothing, personal items
– Automobile factories
– What are some others?
– Fast Food Restaurants
– Ridgedale’s Technology Lab
How is everything made?
• Every product that is produced goes
through some sort of manufacturing
process, whether it is mass-production
manufacturing or production
manufacturing.
Mass Production
• Is large scale production and is carried out
by a number of workers on a production
line each doing one part of the
manufacturing process. The product is
then passed on to the next person in the
line. Identical products are made very
quickly and sometimes the same style is
repeated for months on end.
The view above is taken from inside the Coats Viyella Factory. It
shows Assembly line Mass Production of Boxer Shorts.
Mass Production
• Disadvantages:
– Production halts if there is a problem.
– Changing the line to making a different
product or style can take a long time.
• Advantages:
– Identical products made quickly
– Reduction in costs
– Interchangeable parts
7.C.10.4
Mass Production/ Cost Effective
• The first industrialist to make full use of this system was
Henry Ford and as a result it became known as Fordism.
• This has been described as "the mass production of
standardized goods, using dedicated machines and
moving assembly lines, employing unskilled and semiskilled labor in fragmented jobs, with tight labor discipline,
in large factories."
7.C.10.4
Model T
• Initially it took 14 hours to assemble a Model T car. By
improving his mass production methods, Ford reduced this
to 1 hour 33 minutes. This lowered the overall cost of each
car and enabled Ford to undercut the price of other cars on
the market. Between 1908 and 1916 the selling price of the
Model T fell from $1,000 to $360. Following the success of
Ford's low-price cars, other companies began introducing
mass production methods to produce cheaper goods.
7.C.10.4
CAD/CAM
CAD- Computer-Aided-Design
CAM- Computer-Aided-Manufacturing
7.C.9.7
7.C.12.2
Types of Manufacturing Processes
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Batch Production
Lean Manufacturing
Just-In-Time
Others
7.C.9.2;
7.C.10.3
Batch Production
• This type of production is used when a number of
identical items are produced by a team. It is cost
effective because it takes less time for the team to
make a garment than it would for one person
working alone. The team share the responsibility of
the different tasks and equipment. The members of
the team are usually skilled in more than one
particular task. This flexibility allows the team to be
able to respond quickly to changes in market
demand by being able to switch from one design to
another. For instance they may be making a batch of
1,000 sweatshirts of one design one week and be
able to switch to another design making 2,000 items
the next.
7.C.9.2
Batch Production Cont.
• Advantages:
– Allows for flexibility of the workforce
– Quick response to changes in the market
place
• Disadvantages:
– More training required for workers to be mutliskilled
7.C.9.2
Lean Manufacturing
• Lean is reducing the time from customer
order to manufacturing and delivering
products by eliminating non-value added
waste in the production stream. The ideal
of a lean system is a one-piece flow.
7.C.9.2
Just-In-Time Manufacturing
• JIT is a philosophy of
continuous improvement
in which non-valueadding activities (or
wastes) are identified and
removed for the purposes
of:
-Reducing Cost
-Improving Quality
-Improving Performance
-Improving Delivery
-Adding Flexibility
-Increase innovativeness
JIT is not about automation. JIT eliminates waste by
providing the environment to perfect and simplify the
processes. JIT is a collection of techniques used to
improve operations It can also be a new production
system that is used to produce goods or services.
7.C.9.2
JIT: Elimination of Waste
• JIT usually identifies seven prominent
types of waste to be eliminated:
– Waste from Overproduction
– Waste of waiting/idle time
– Transportation Waste
– Inventory Waste
– Processing Waste
– Waste of Motion
– Waste from Product Defects
JIT Principles
• When the JIT principles are implemented successfully,
significant competitive advantages are realized. JIT
principles can be applied to all parts of an organization:
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Order taking
Purchasing
Operations
Distribution
Sales
Accounting
Design
Etc.
Health and Safety in the Workplace
• Designers and manufacturers must ensure
that new products will be safe to use and
safe to make.
• The designer must ensure that the product
conforms to all the relevant safety
standards. There are many laws in
existence which help to ensure that
products are safe to use.
7.C.9.3
7.C.11.3
Lab Safety
• Lab safety will be covered once again this
year, before we enter the lab.
• We will review each of the tools in the lab,
including one new one.
7.C.9.3
7.C.11.3
The four main areas to consider in
order to avoid potential accidents in
a factory are as follows:
• The layout of the factory work area must
be safe
• The workforce must be trained in safety
precautions.
• The design of machinery and tools being
used in the manufacturing process must
be safe.
7.C.9.3
7.C.11.3
• Safety devices and procedures must be
set up in order that the workers are in a
safe environment.
– An example of this is if a machinist breaks a
needle, then the broken needle must be found
at all costs. If the needle is not found the
machinist may have to take the machine apart
in order to find it. If it is still missing the
garment may have to be destroyed.
7.C.9.3
7.C.11.3
Possible Jobs
• Degree in Manufacturing- (MFG)
– Floor Supervisor
– Shipping Supervisor
– Line Engineer
• Solves problems
– Line Worker
– Quality Control
– Supplier (Honda has many suppliers)
7.C.9.1
7.C.9.5
Management
We will set this class up like a factory.
• What are the major components of a factory
that influence cost of production?
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Materials
Labor
Energy
Time
Location
7.C.11.2
Management of Product & System
• All factories continuously look for ways to
improve their production system.
– Look for ways to lower cost by:
• Changing processes
– Introducing Robots & New Technology
• Changing materials
– Cheaper materials
• Changing suppliers
– May offer more options/ or are willing to work with you
• Preventing/ Fixing Problems
– Trouble shooting, diagnosing, recalling, maintaining, repairing,
altering, & upgrading
7.C.11.5
The Product
• Durable
– We want our game to
be well built so it will
last a long time.
• Examples
– Steel
– Furniture
– Washing machines
• Nondurable
– We do not want a
game that fall apart
• Examples
– Food
– Batteries
– Paper
7.C.11.6
Flow Chart Process Symbols
• The flow chart process symbols are
recognized internationally and have been
standardized so they have only one
meaning. This permits easier
communication between all personnel who
may need to use the flow process chart.
The symbols and their definitions are as
follows:
7.C.11.1
OPERATION
• Something which takes place or happens in
one place. Object is intentionally changed
physically or chemically, assembled or
disassembled.
– Examples: casting & molding, forming,
separating, conditioning, assembling, finishing,
drilling, sawing, mixing, sewing, typing, putting
together, or taking apart.

7.C.10.1
7.C.11.1
TRANSPORTATION
• Something is moved from one place to another,
except where the movement is considered to be
a part of the operation.
– Examples:
• moved from typing desk to filing desk
• moved from machine to an assembly bench
• moved from finishing room to drying area.

7.C.11.1
INSPECTION
• Verification. Objects are examined for
quality, quantity, or identification.
– Examples: checking for correct size, color,
number, or shape.

7.C.11.1
DELAY
• Delay or interference. Object is held up
for a short period of time before it can
move into the operational sequence.
– Example: drying time for paint or varnish to
dry.
D
7.C.11.1
STORAGE
• Retention of object in a location in which it
is protected against unauthorized removal
for a relatively long period of time.
– Example: in warehouse waiting to be shipped.

7.C.11.1
Jigs & Fixtures
• What is a jig:
– A device used to guide a tool to a precise spot
on a part or piece of material.
• Used when an operation must be repeated
numerous times. (a stop block on a miter saw)
• What is a fixture:
– A device used to hold material in place while it
is being worked on.
• Usually some sort of clamping device
7.C.9.6
Questions
?
Mass-Production Paperwork
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Process Flow Chart
List of machines and tools used
Safety Precautions
Jigs/ Fixtures Used- pictures with explanations
Special Setups
Time Sheet- figure our effectiveness
7.C.11.1
FLOW PROCESS CHART
PRODUCT NAME _________________________
Name ______________________
 OPERATIONS  TRANSPORTATIONS 
INSPECTIONS D DELAYS  STORAGES
PROCESS SYMBOLS
Task No.
Process Symbols
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Description
of Task
Machine
Required
Tooling
Required
# of pcs
Size
7.C.11.1
Possible Example
Cornhole Games
Cornhole Game Materials
• Types of Materials • What types of materials will
we be using?
– Natural
– Synthetic
– Mixed
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Wood
Screws
Cloth
Corn
Nails
Glue
7.C.9.4
Cornhole Game Tools/ Equipment
• What types of tools or
equipment will we
need?
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Table saw
Radial-Arm Saw
Compound Miter Saw
Nail Gun
Drill
Drill Bits
7.C.9.6
Cornhole Jigs & Fixtures
• Jigs
– Stop block on miter saw & radial arm saw
– Placement of 6” hole
• Fixtures
– Assembly fixture
What’s going to be our biggest
problem?
• Space
• Storing Materials/
Finished Product
• We will need to
develop a plan or
system that will be
effective for our class,
along with other
classes that use the
lab.
7.C.10.2
Examples
• Sliding DVD Holder
• Birdhouse
• Windmill