Manufacturing Brian Russell
Manufacturing Turning raw materials into goods which we need or want and are able to sell to others.
Manufacturing Requires: • Special buildings or places of work • Organisation of people • Organisation of tools & equipment • Communication systems • Efficient working methods • Health and safety considerations
Manufacturing Terms • Primary Processing • Secondary Processing
Primary Processing Turning raw materials into useful stock sizes Materials come from: Out of the ground Animals Trees & plants Oil
Making Paper Boiled up to make wood pulp Trees cut & shredded Water added Chemicals and dyes added Pulp poured over fine mesh and squeezed between rollers
Secondary Processing • • • Casting & moulding Forming Wastage (or separation) Conditioning Assembling Finishing
Casting & Moulding Die Casting Food Moulding Injection Moulding
Forming Pressing Drop Forging Line Bending
Wastage Milling Turning Sawing
Conditioning Cooking Heat Treatment
Assembling Self Assembly Factory Assembly
Finishing Painting Printing
Manufacturing Costs Energy Finance Labour Costs (or Automation) Plant Raw Materials Transportation
Scales of Production • • One-off or Jobbing Production Batch Production Mass or Flow Production Continuous Production
Just in Time • Shared information systems • Reduced lead times • Less finance tied up in stock
Flexible Manufacturing • Benefits of one-off production at mass production prices • Only possible with ICT
Computer Integrated Manufacture All the computer functions are integrated together in a fully automated system. This would include moving materials/assemblies between machining operations.
Quality Issues • • Consistency Right first time every time Working to tolerances Materials in as well as products out
Quality Assurance • Procedures to manage all functions which affect quality • QA checks the systems • Monitors processes • Applies standards Part of the Total Quality Management (TQM) of the company
Quality control • One part of QA • A series of checks – size, strength, weight, taste etc.
Tolerances • Acceptable range of difference from standard • Sometimes measured in plus/minus No product manufactured in quantity can be considered to be perfect in every detail
Certification • Manufacturers who work to recognised standards are awarded certification
BS EN ISO 9000: 2000 One of the most important series of standards, these provide companies with a framework for developing a set of processes that ensure a common sense approach to the management of the organisation.
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