Manufacturing Processes & Production Semester 1, 2016 X’s company, the world’s l
ID: 460540 • Letter: M
Question
Manufacturing Processes & Production
Semester 1, 2016
X’s company, the world’s largest manufacturer, seeks to extend business in New Zealand. To develop manufacturing plants, the X’s company called on manufacturing experts to deliver a complete report to advise the company for their keys products as followings
Group 6: Refrigerator
Each product contains different parts and each part is made from various materials and processes. The material and manufacturing processes are chosen based on the design intent. As six groups have been engaged in this project, for each group member, you are responsible to undertake one of the following topics and produce a report types to collect all necessary key information. Each member will select at least two components of the product and choose the most suitable process for manufacturing.
Section 1: Manufacturing Production: Provide several keys factors and methods needed for manufacturing production controls.
Quality control in manufacturing
Inventory control in manufacturing
Facility layout
Logistics and transportation
Section 2: Manufacturing Process: for the each chosen part, list all the design intent and discuss how to select the material used and manufacturing process used to make parts. Also, provide a summary of each chosen process as below
Casting
Forming
Extrusion and Drawing
Powder-Metal
Plastic Forming and shaping
Rapid Prototyping
Machining
Abrasive machining and finishing
Welding
Surface treatment, coatings
Section 3: Computer-Integrated Manufacturing: Provide details how computer systems and communication networks affect product development and manufacturing selection, the topics are:
Cellular Manufacturing
Flexible Manufacturing
Holonic Manufacturing
Just-in-time Production
Lean Manufacturing
Communications Network in Manufacturing
Artificial Intelligence
Economic Consideration
Explanation / Answer
Section 1:
Quality control in manufacturing
Quality is the finest requirement for any process or product. Quality means a lot and it helps the company to attain a long run and helps to stabilise in the market. Quality control can be done via statistical analysis, manual or analytical quality checks, frequent quality audits etc.
Inventory control in manufacturing
Inventory is a dead stock for all production or service industry. Managing and optimising the inventory level is necessary to reduce the overall inventory cost. Analysing the order level, throughput or demand of the product in market, follow operations and production plan properly etc can reduce unwanted inventory stocks.
Facility layout
Facilities are facilitating the entire process in an organisation. It includes storage facilities and space, administrative and other resource accommodating facilities.
Logistics and transportation
This involves transfer of goods from one point to other It can be inbound, intra transfer and outbound ( secondary, primary & last mile distribution).
Section 2:
Casting: The manufacturing process where mould is made and liquid hot metal is pour into the mould to get the desired shape and size.
Forming: It uses several pressure related process like compression, tension, shear to get the product formation.
Extrusion and Drawing: The process is a plastic deformation process through hot or cold application. One common analogy is squeezing tooth paste. Drawing is changing the cross-sectional area or shape of a solid rod, wire, or tubing by pulling it through a die.
Plastic Forming and shaping: Plastic, Elastomers and composites for developing the finest stage of plastics based on the requirement of business is called plastic forming.
Rapid Prototyping: Prototyping is used to quickly fabricate a material by making a miniature model or design of the same. It must have the same features of that products, so that testing can be done.
Machining: It is a very generic term we used for removing materials from a work. It can be of abrasive, cutting , grinding etc.
Abrasive: It is a process of polishing, cleaning a hard surface by rubbing, grinding etc.
Welding: It is a again a machining process where heat or electricity ( arc) is used for cutting and shaping the metal pieces or to merge the pieces.
Cellular Manufacturing: It uses lean production and just in time approach together .The major purpose of cellular manufacturing is to move the work as early as possible and whole process will be aligned in a cellular mode,.
Flexible manufacturing: It is a technology where process and production setups can be change from one form to another and customisation is possible.
Holonic manufacturing: Developing discrete, continuous and batch manufacturing trough automation capabilities. CIM and CAM has more application in this field.
Just In Time & Lean Production: JIT eliminates storage of inventory and use production lines based on demand, Lean production is an advanced technology where waste is reduced , ( elimination on non value added process & including only value added things).
Communications Network in Manufacturing: This is gained via better automation tools and intra and inter collaboration units like CIM, CAM ERP etc.
Artificial Intelligence: This uses machine rational thinking possibilities by developing intelligent automation. It helps in incorporating industrial electronics processors.
Economic consideration: This includes intra and inter functions and parameters like market situation, economic social relationships, customers need and money spending capability , nations trade policty and foreign trade scopes etc.
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