Systems & Control
Edexcel Product Design - Graphics
Today: Systems & Control
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Manufacturing Systems
Computer Integrated Manufacture (CIM)
Robotics & Artificial Intelligence
Flow Charts
Reminders
• QA – Quality Assurance
– Monitors the quality of a product through its design
and development stages through to manufacture
– QA is an assurance that the end product has quality
• QC – Quality Control
– Is the achievement of QA
– Uses inspection and testing
• TQM – Total quality management
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Also called TQC – Total quality control
Integrated into the manufacturing system
QA at every stage of the production process
Eg production team must produce a high quality
component that the assembly team know is quality
assured and will fit perfectly
Reminders
• JIT – just-in-time
– Everything is made just-in-time
– A pull system
• QFD – Quality function deployment
– Creating successful products
– Incorporates consumer satisfaction
– Advantages:
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Reduced time to market
Less design modifications
Less design and manufacturing costs
Better quality
Enhanced customer satisfaction
Lines and cells
• Production lines
– Fixed
– Single task
• Cells
– Flexible
– Various required skills,
techniques, machinery etc
Manufacturing Systems
• Advanced manufacturing technology
– When computers are used at every stage of the
manufacturing process
– Ensures fast, efficient, high quality production
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Manufacturing Systems
• Quick response manufacturing (QRM)
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Makes companies more efficient and profitable
Instead of batch production, ‘flow’ production
Respond to demand, instead of planning for expected demand
Uses TQM, JIT and manufacturing cells (teams)
It’s main aim is to increase flexibility and responsiveness
Teams have specific tasks, but can alter if needed
No excess products are manufactured
Suppliers deliver raw materials directly to the production line
Products are finished and flow directly to a waiting truck for
delivery
– Pull system according to markets demands
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QRM
Manufacturing Systems
• Concurrent Manufacturing
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All stages of the manufacturing process working together
Does change to one part mean changes to another?
Designs become ‘right first time’
Reduces product development time
Earlier release of products
Brings together design, manufacturing, project
management, technical support, marketing
– Communication is vital
– Internationally computer networks are essential
– Uses QFD – quality function deployment
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Manufacturing Systems
• Flexible manufacturing
systems (FMS)
– Several machines linked
together by a material
handling system (robot or
conveyor)
– Uses CNC
– Can produce different
products at the same time
– High flexibility
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FMS continued
• Two main features:
– Machine flexibility
• Whole system produces a different product
• Can change the order of the machines
– Routing flexibility
• Same machine for different products
Computer Integrated Manufacture
(CIM)
• One step further than FMS
• All aspects of the company’s operations (not just manufacture)
• Uses computer networks
– Business information
– Production information
– Manufacturing operations
• Tasks:
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Uses CAD
Planning cost effective workflow
Controlling machines
Business operations – ordering stock, materials and invoicing
customers
• Relies on computers and data (sometime incompatible)
CIM Systems
• Data integration
– Product data management (PDM)
– Lean manufacturing (including JIT)
– CAM, CNC, computer aided quality (CAQ)
– Material handling systems
• Automated storage and retrieval systems (ASRS)
• Automatic guided vehicles (AGVs)
Product data management systems
(PDM)
• Passes data from design to manufacture
• Data:
– 3D models
– CAD drawings
– CNC programs
• Advantages:
– Reduced time to market
– Improved productivity
– Improved control
Lean manufacturing & JIT
• Manufacturing has no “fat” in the process
• Same idea as JIT
– No warehouses, materials arrive just when
needed
• Right materials, components and products
arrive at the right time
• Reduces waste and overstocking
• Manufacture must predict the market
CAM, CNC, computer aided quality
(CAQ)
• CAM – computer aided manufacture
• CNC – computer numerical control
• CAQ – Computer aided quality
– Coordinate measuring systems
– Uses a probe
– Finds “zero”
Material handling systems
• Automated storage and retrieval systems
(ASRS)
– Robotic system for sorting, storage and retreival
– Uses racking systems
– Conveyor belt or truck
• Automatic guided vehicles (AGVs)
– Uses radio frequency wires in the floor
– Or use optical sensors
– Computer controlled
Robotics & Artificial Intelligence
• Robots on fully automated production and
assembly lines/cells
– Manipulate and transport parts, tools or
implements
Flow Charts
• Start/stop
• Processes
• Decisions
• Arrows
Flow Charts
• Open loop
Start
Process
Process
• Closed loop
Start
Process
Decision
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Process
Stop
Stop
No
Task
• Produce a sheet (title: Manufacturing) with the
following information on:
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Manufacturing Systems
Computer Integrated Manufacture (CIM)
Robotics & Artificial Intelligence
Flow Charts
Use key points (in YOUR OWN words)
Thin columns with information
Advantages and disadvantages where relevant
Try include images / colours to ease its use