Scales of production and manufacturing systems
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课程笔记
Scales of production
- One-off production makes an individual item or project, often tailored to a customer or site. Batch production makes a finite run before stopping or changing; mass production makes high volumes of standardised discrete products, often on lines. A project can combine patterns at different assembly levels.
- Continuous production maintains a sustained process flow over long periods, often for materials. Maintenance and interruptions still occur. A finite bakery run can be a batch, while an industrial baking line can use another pattern; do not classify every product name without its process context.
- High output can spread setup costs but does not guarantee lower average costs or higher quality. In an invented example, £600 setup plus £4 direct cost per item gives £10 per item for 100 saleable units and £6 for 300, before other costs. Demand, capacity, defects and waste determine whether the larger run is useful.
Choose a pattern for the context
Manufacturing systems
- JIT coordinates production and supply with demand: what is needed, when needed and in the required quantity. Toyota’s description includes minimum stocks and replenishment loops, so JIT must not be taught as literally no inventory. Lower buffers can reduce storage and obsolescence while increasing exposure to disruption.
- Lean seeks to remove avoidable waste such as defects, waiting and unnecessary movement while retaining value. Removing training or a necessary check merely to save time can increase defects and total waste.
- Cell production groups related operations and resources for a product, family or subassembly. CAD/CAM and automation can support accuracy, repeatability and throughput, but correct inputs, maintenance and monitoring remain essential; automation can repeat an error consistently.
JIT reduces buffers; plan resilience
Quality
- Quality assurance consists of planned systematic arrangements supporting confidence that requirements will be met, including appropriate procedures, training and process control. It does not promise zero faults. QC includes operational checking and testing against requirements; it can occur on incoming materials, during manufacture and at final inspection.
- A tolerance defines acceptable dimensional variation. For 20.0 ± 0.2 mm, the limits are 19.8 and 20.2 mm, interpreted using the specified inspection procedure. Check that the measurement equipment and method are suitable for the required precision.
- Sampling checks a subset rather than every item. It can reduce inspection cost but has a risk of missing defects; a sample pass is not proof that every unit complies. Quality decisions should reflect the product and consequence of faults.
Assurance and control work together
Product life cycle
- The simplified market life cycle uses introduction, growth, maturity and decline to discuss sales and market conditions. It is a conceptual model, not an inevitable trajectory or a numerical forecast; extension strategies, changing demand and withdrawal can alter a product’s path.
- Distinguish this from a physical product life cycle or environmental assessment, which considers stages such as raw materials, manufacture, distribution, use and end of life. Similar wording does not make the two models interchangeable.
A simplified market life-cycle model
Enterprise
- Entrepreneurs compare financing options such as loans or crowdfunding with investment and cash-flow needs. A loan involves repayment obligations; crowdfunding arrangements differ and do not guarantee sufficient funding or delivery success.
- Online selling is a distribution or sales channel, rather than automatically a source of upfront finance. Production planning must consider actual demand, lead times, capacity and working capital, including stock and disruption risks.
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1.What is one-off production?
Easy- Amaking a single item
- Bmaking thousands
- Cmaking a batch
- Dnon-stop production
2.What is batch production?
Easy- Aone item only
- Bnon-stop production
- Cno production
- Dmaking a set number of identical items
3.What is mass production?
Easy- Aa few items
- Bnone
- Cproducing large numbers on an assembly line
- Done item
4.What is continuous production?
Easy- Anone
- Ba process operating for long periods with a sustained material flow
- Cone-off
- Dshort runs
5.What is lean manufacturing?
Easy- Areducing waste in the process
- Bmaking more waste
- Cincreasing stock
- Dslowing production
6.Which is a potential advantage of well-utilised mass production?
Easy- Avery high skill
- Bunique products
- Cno machinery
- Dlow cost per item
7.What is a disadvantage of mass production?
Easy- Ano consistency
- Bno automation
- Chigh set-up costs and little flexibility
- Dvery low output
8.What is an advantage of one-off production?
Easy- Ano skill
- Bit can be tailored to the customer’s requirements
- Clow cost per item
- Dvery fast
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