Production techniques and systems (AQA GCSE Design and Technology): Revision Notes
Production techniques and systems
Introduction
Modern manufacturing is being transformed by new technologies that change how we design and make products in factory systems. These advanced production techniques help companies work more efficiently, reduce waste, and respond quickly to customer demands.
Computer aided design (CAD)
Computer aided design brings together software and hardware tools that help engineers and designers create, develop, modify, test, communicate and record design information digitally.
Benefits of CAD systems
CAD technology offers several advantages for modern product development. Design files can be shared electronically between team members and departments, making collaboration much easier. Ideas can be tested, evaluated and modified directly on screen without needing physical prototypes. Parts can be expanded to show fine detail, and complex calculations can be performed automatically. The system also allows processes to be simulated, which reduces the expense of creating physical prototypes.
The ability to simulate processes digitally before physical production is one of the most significant cost-saving features of CAD systems, as it prevents expensive mistakes and reduces material waste.
Limitations of CAD systems
While CAD systems are powerful, they do have some drawbacks. Workers need proper retraining to use the software effectively. There's also a risk that electronic files might be lost or accidentally sent to the wrong recipients, which could cause serious problems in production.
Computer aided manufacture (CAM)
Computer aided manufacture uses computer software and hardware to convert CAD models into manufacturing instructions for computer numerical controlled (CNC) machine tools.
Benefits of CAM systems
CAM technology provides greater reliability and quality compared to manual manufacturing methods. The system also offers flexible production capabilities and improved productivity overall. Machine tools operated through CAM are faster and more accurate than manual alternatives, and they can be quickly reprogrammed and linked directly to customer demand. This helps reduce costs significantly. Additionally, workers are protected from potentially dangerous manufacturing processes.
The direct link between CAM systems and customer demand allows for rapid response to market changes, making production more agile and responsive to consumer needs.
Limitations of CAM systems
The main challenges with CAM systems include potential negative effects on worker morale due to reduced human involvement and fewer traditional 'machine minding' job roles. There are also high initial setup costs that companies must consider.
Lean manufacturing
Lean manufacturing is a systematic method designed to eliminate waste throughout a manufacturing system in several key areas.
This approach focuses on minimal storage practices, where stock materials are delivered precisely when needed and products are manufactured only to fulfil specific orders. Production processes are carefully organised to eliminate delays and reduce unnecessary material or component movement. Rigorous quality assurance systems are put in place to prevent defects, and labour resources are used as efficiently as possible.
Core Principles of Lean Manufacturing:
- Materials delivered exactly when needed
- Production only for specific orders
- Organised processes to minimise delays
- Quality assurance to prevent defects
- Efficient use of all labour resources
Flexible manufacturing systems (FMS)
Flexible manufacturing systems are designed to deliver high-value products quickly, such as cars with various customer options. These systems can respond rapidly to changes in demand or supply conditions.
FMS works by grouping machinery together for maximum efficiency, often controlled by integrated computer systems. These systems are highly effective and maintain close relationships with suppliers, manufacturers and retailers to enable fast delivery times.
The integration of computer systems with machinery grouping allows FMS to automatically adjust production schedules and processes, making them ideal for industries with frequent product variations or customisation requirements.
Just in time (JIT)
Just in time manufacturing helps companies fulfil quality orders quickly while minimising time and resource usage through information and communications technology (ICT). Under this system, new stock is only ordered when actually needed, preventing over-ordering and improving space utilisation efficiency.
Benefits of JIT systems
JIT offers several key advantages for manufacturers. Materials and components arrive at exactly the right place at the right time, reducing storage costs since stock doesn't need to be stored unnecessarily. Small batches of products can be produced cost-effectively, making the system very efficient.
Limitations of JIT systems
The main risk with JIT systems is that any break in the supply chain can cause significant delays in production, since there's no buffer stock available to maintain operations during disruptions.
Key Points to Remember:
- CAD systems allow digital design creation, testing and sharing but require worker training and carry file security risks
- CAM technology improves manufacturing reliability and speed while protecting workers, though setup costs are high
- Lean manufacturing eliminates waste through minimal storage, efficient processes and quality assurance systems
- Flexible manufacturing systems can quickly adapt to changing demands through integrated computer-controlled machinery
- Just in time production reduces storage costs and improves efficiency but creates vulnerability to supply chain disruptions