Production Planning & Manufacturing Processes
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Questions and Answers

What is a characteristic of wide boards used for dining table tops?

  • They require no manual labor.
  • They are less likely to bend.
  • They are inexpensive to produce.
  • They can bow over time. (correct)

What makes laminated sheets of wood advantageous in construction?

  • They are low labor intensive.
  • They can be bent to shape. (correct)
  • They use a single layer of wood.
  • They provide no structural strength.

What is a challenge associated with large beams made of smaller pieces of timber?

  • They are cost-effective without manual refinement.
  • They are easily produced without labor.
  • They require more time and labor to assemble. (correct)
  • They lack strength due to the grain alignment.

What is a disadvantage of producing thin sheets of wood?

<p>They are resource-intensive and expensive to make. (D)</p> Signup and view all the answers

What feature helps maintain the strength of long beams made from individually pieced timber?

<p>The alignment of grains running throughout. (A)</p> Signup and view all the answers

What are the leftover metal parts from piercing called?

<p>Blacks (D)</p> Signup and view all the answers

Which manufacturing process is characterized by high setup costs but produces highly accurate parts?

<p>CNC (A)</p> Signup and view all the answers

What is a significant drawback of CNC machining?

<p>High volume of waste material (D)</p> Signup and view all the answers

Which of the following is NOT a characteristic of parts produced by turning?

<p>Low quality (A)</p> Signup and view all the answers

What process is used to make molds and dies for injection molding?

<p>Milling (A)</p> Signup and view all the answers

Which aspect is a disadvantage of non-CNC machining that is not typically associated with CNC machining?

<p>Requires skilled labor (B)</p> Signup and view all the answers

What characteristics do engine parts produced by turning need to have?

<p>High accuracy (B)</p> Signup and view all the answers

What is a major limitation of drop forging compared to CNC machining?

<p>Detail of shapes (C)</p> Signup and view all the answers

What is a disadvantage of thermosetting compression moulding?

<p>High set up costs (A)</p> Signup and view all the answers

Which feature is characteristic of extrusion?

<p>Allows for same cross section throughout (D)</p> Signup and view all the answers

In blow moulding, what is a limitation regarding the final product?

<p>Only small products can be produced (D)</p> Signup and view all the answers

What problem can occur during the extrusion process?

<p>Presence of shrinkage marks (D)</p> Signup and view all the answers

Which of the following is NOT a benefit of thermosetting plastics?

<p>They take a long time to set (B)</p> Signup and view all the answers

What is an advantage of using compression moulding for thermosetting plastics?

<p>High accuracy of individual parts (B)</p> Signup and view all the answers

What characteristic of blow moulding is most beneficial for producing bottles?

<p>Ability to produce thin walls (C)</p> Signup and view all the answers

Which process is necessary for ensuring parts fit together after they are produced?

<p>Cutting and assembly procedures (D)</p> Signup and view all the answers

What advantage does rotational moulding have in producing large hollow parts?

<p>Uniform wall thickness (C)</p> Signup and view all the answers

Which issue is associated with split lines in moulding processes?

<p>They may require further work to finish (A)</p> Signup and view all the answers

What is a disadvantage of vacuum forming compared to other plastic forming methods?

<p>Limited design flexibility (B)</p> Signup and view all the answers

In what way does the presence of ribs affect the moulded products?

<p>They enhance strength and rigidity (C)</p> Signup and view all the answers

What factor can contribute to the weakness of plastic products at the corners?

<p>Draw on the plastic during forming (A)</p> Signup and view all the answers

What is a key advantage of using rotational moulding for production?

<p>Uniform thickness of walls (A)</p> Signup and view all the answers

What is the consequence of slow cooling during the moulding process?

<p>Increased warpage and deformation (B)</p> Signup and view all the answers

Which of the following is a common characteristic of products made through vacuum forming?

<p>They fit well due to accurate processes (A)</p> Signup and view all the answers

What is a key benefit of press forming in manufacturing car body panels?

<p>It accurately shapes thin sheets into strong panels. (C)</p> Signup and view all the answers

Which disadvantage is associated with drop forging?

<p>It requires a consistent draft angle for effective production. (D)</p> Signup and view all the answers

What is a primary characteristic of products made through CNC turning?

<p>They are accurate and identical parts. (A)</p> Signup and view all the answers

What does the presence of bends, folds, and ridges in metal sheets do?

<p>It increases the strength and rigidity of the product. (B)</p> Signup and view all the answers

What is an advantage of using drop forging for tool production?

<p>It allows for the creation of complex shapes and patterns. (D)</p> Signup and view all the answers

What is a common drawback of using traditional skilled labor in wood processes?

<p>Increased production costs. (B)</p> Signup and view all the answers

Which of the following statements is true about products made by turning in wood processes?

<p>They can be produced with a high level of accuracy. (C)</p> Signup and view all the answers

One of the disadvantages of CNC machining in wood processes is the:

<p>Potential for large volumes of waste material. (C)</p> Signup and view all the answers

What is the primary purpose of production planning in manufacturing?

<p>To manage the order of processes and integrate quality control (C)</p> Signup and view all the answers

How do flow charts contribute to the production process?

<p>They assist in planning stages and quality control. (D)</p> Signup and view all the answers

What is one advantage of using Gantt charts in production planning?

<p>They help in determining when to order materials. (A)</p> Signup and view all the answers

What is a key outcome of having multiple quality control stages in manufacturing?

<p>Greater identification and correction of problems (C)</p> Signup and view all the answers

Why is it important to plan the order of manufacturing stages?

<p>To avoid unnecessary delays and reduce costs. (D)</p> Signup and view all the answers

What does production planning help companies avoid?

<p>Expensive mistakes with materials and components (B)</p> Signup and view all the answers

What role do specialized workers play in complex manufacturing projects?

<p>They contribute to specific stages that require their expertise. (B)</p> Signup and view all the answers

What is a potential consequence of poor production planning?

<p>Higher production costs and waste. (C)</p> Signup and view all the answers

Flashcards

Production Planning

Planning the order of production steps and incorporating quality control measures in advance.

Flow Chart

Visual representation of production stages, quality control checks, and decisions related to defective parts.

Gantt Chart

A tool for planning complex projects, showing the timeline of tasks and dependencies.

Quality Control Stages

Multiple quality control checks throughout the production process to minimize waste and identify problems early.

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Lead Time

The complete time it takes to produce a product, from the start of the first stage to the end of the final stage.

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Materials Management

The process of managing materials and components used in production, ensuring the right materials are available at the right time.

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Off-the-Shelf Components

Components or materials readily available for use in production.

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One-Off Products

Products that are unique and not mass-produced, requiring careful planning and coordination.

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Compression Moulding

A moulding technique that involves injecting molten plastic into a mold. This method is ideal for producing complex shapes with high quality surfaces.

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Extrusion

This technique involves using heated plastic in a cylindrical form that is forced through a die. It's a simple and efficient process for creating long products with consistent cross-sections.

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Blow Moulding

A moulding process where a hollow tube of heated plastic is inflated with air to create a hollow shape. This method is widely used to produce containers like bottles.

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Rotational Moulding

A manufacturing process where melted plastic is poured into a mold and spun rapidly, creating a hollow object with uniform wall thickness.

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Vacuum Forming

A manufacturing process where a sheet of heated plastic is stretched over a mold, creating a hollow object.

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Split Lines

The visible lines that form on the surface of a plastic product during the manufacturing process.

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Draft Angle

The angle designed into a mold to enable the removal of the product.

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Draw

The amount of stretching that is required for a plastic product to take its final shape.

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Screw Threads

The area where a screw cap is attached to a bottle, allowing for a watertight seal.

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Plastic Weakness at Corners

The strength of a plastic product is concentrated in the corners, making it weak at these points.

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Press Forming

A metalworking process where a sheet of metal is shaped by pressing it into a mold. This method is used to create complex shapes with high accuracy and dimensional stability.

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Drop Forging

A metalworking process where a piece of metal is hammered or pressed into a die to create a desired shape. This process is often used to produce strong, intricate parts.

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Turning

A machining process where a piece of wood is rotated against a cutting tool to create a cylindrical shape. This technique is often used to produce banister posts, legs for furniture, and other round components.

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Piercing

A sheet of metal with holes punched into it.

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Blacks

The leftover metal pieces after punching holes in a sheet.

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Milling

A process that uses a milling machine to remove material from a workpiece to create complex shapes.

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CNC Turning

A type of turning machine that is controlled by a computer.

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CNC Milling

A type of milling machine that is controlled by a computer.

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Recycling of excess material

The process of recycling excess material. This can involve melting down the metal to be reused.

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Use of leftover material

The leftover metal parts after piercing and turning are called blacks. These parts can be recycled for future use.

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Laminating wood

A method of joining thin sheets of wood to create stronger, thicker boards. This technique involves layering the sheets with alternating grain directions to counterbalance weaknesses and improve stability.

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Beams made from smaller pieces

Large, strong beams made from smaller individual pieces of timber, creating a durable structure. The grain runs throughout the entire beam, resulting in superior strength and stability.

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Wide boards

Wide, flat boards of natural timber, used for various purposes, including dining table tops and skateboard tops. The alternating end grain on the edges provides stability and strength.

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Thin sheets of wood

Thin, strong sheets of wood that can be bent to shape during forming. This process allows for creating curved beams with greater structural strength, ideal for architectural projects.

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Large, curved beams

Large, potentially curved beams created by joining small wood pieces. These beams are strong and durable, suitable for large structures and architectural elements.

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Study Notes

Production Planning & Manufacturing Processes

  • Manufacturing in large quantities presents challenges due to the variety and volume of materials, components, and "off-the-shelf" items needed. Quality control is crucial to ensure the product meets consumer expectations.
  • Complex projects like ships, buildings, and bridges require meticulously planned manufacturing stages in the correct order. Expensive materials and specialized labor need to be onsite when required.
  • Production planning systems help companies plan the order of processes and implement quality control. These systems track and manage the volume of materials and components, reducing costly mistakes.
  • Flow charts are used to visually outline the stages of production and quality control, showing the sequence and the consequences of decisions. Based on quality checks, components can be sent back, recycled, or discarded.
  • Gantt charts are used to schedule large projects with multiple, separate stages. These charts allow for the completion of stages simultaneously or sequentially, increasing efficiency and decreasing lead times.

Just-in-Time (JIT) Production

  • JIT, pioneered by Toyota, prioritizes maximizing profits and minimizing capital investment.
  • JIT is an "orders-led" approach where customer orders trigger production.
  • Minimizing inventory and raw material storage saves money and reduces warehousing costs. The system relies on strong relationships with suppliers to provide materials quickly and in the correct quantities.
  • JIT has a major goal of "zero inventory", where material and components are kept at a minimum, thus keeping costs down and the need for warehousing space minimized.

Kanban

  • Kanban, generally a visual system, signals work stoppage at one manufacturing stage and a shift to the next as needed (e.g., low/high stock levels).
  • Experienced and versatile workers are essential for Kanban systems. They must manage different manufacturing steps.
  • Efficient processes and quick changes are essential. This means that equipment and machinery are designed for quick adjustment for different stages.

Advantages of JIT

  • Reduced capital outlay for stock and raw materials
  • Elimination of storage costs
  • Fast turnaround on profits thanks to effective processes
  • Improved efficiency through multi-skilled workers
  • Prevention of material obsolescence or spoilage
  • Reduced reworking time through quality control

Disadvantages of JIT

  • Heavy reliance on supplier relationships for timely material delivery
  • Lack of spare materials to accommodate unexpected demand fluctuations
  • Traffic jams or other transportation issues can affect deliveries
  • Cost of transportation, increased due to continuous deliveries.
  • Limited room for errors since there's little extra material

Plastics Manufacturing Processes

  • Plastics manufacturing uses mass production methods to create high volumes of output. The high cost of machinery and tools is compensated for by the increase in manufacturing volume.

Metal Manufacturing Processes

  • Metal manufacturing processes can be classified as mechanical or thermal. The selection depends on the type of material being used and the desired product features. Different products demand differing standards.
  • Various processes exist, each with specific advantages and disadvantages regarding cost, time, flexibility, and quality.

Wood Manufacturing Processes

  • Wood-based products typically require skilled craftspeople for their production.
  • Steps involved in assembly and finishes are also part of the wood manufacturing process and are essential when determining factors for efficiency.

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Production Planning & Manufacturing Processes PDF

Description

Explore the intricacies of production planning and manufacturing processes. This quiz covers key concepts like quality control, production planning systems, and project management tools like flow charts and Gantt charts. Test your understanding of how to effectively manage materials and stages in large scale manufacturing.

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