Technological Design Teacher Resource 5 3 1

Technological Design Teacher Resource 5. 3. 1 © 2011 International Technology and Engineering Educators Association, STEM Center for Teaching and Learning™ [Name of Course Guide]

Lean Manufacturing

Manufacturing ◦ Types Customized Batched Continuous Lean manufacturing Materials ◦ Natural ◦ Synthetic ◦ mixed Durable Non-durable History ◦ Interchangeability ◦ Manufacturing Enterprise

Manufacturing o Manufacturing is when something is made in a large scale using machinery o There are many types of manufacturing n Customized n Batched n Continuous

Types of Manufacturing Customized ◦ Customized manufacturing are when parts are specifically assembled to the wants and needs of each buyer, usually resulting in high standards of quality Batched ◦ Batched manufacturing is when a large scale company manufactures equivalent parts in large batches improving the quantity of parts able to be produced in a period of time.

Types of Manufacturing cont. Continuous ◦ Manufacturing strategy that produces a part via a just-in-time. The goal is an optimally balanced production line with little waste, the lowest possible cost, on -time and defect-free production

Lean Manufacturing Five separate parts drive lean manufacturing ◦ ◦ ◦ Cost Quality Delivery Safety Morale Uses systematic elimination of waste Goal of lean manufacturing: To delete waste and produce materials more effectively.

Manufacturing Materials o Natural Materials n Any product or physical matter that comes from plants, animals, or the ground o Synthetic Materials n Materials that are formed through a chemical process with human input opposed to natural o Mixed Materials n Materials that are composed my two or more materials which are joined together

Durable or Non-durable Durable Manufacturing ◦ Intended to create the strongest possible product that can last very long without breaking. Non-Durable Manufacturing ◦ When a manufacturer intentionally makes their products to break apart and/or malfunction after a short time causing customers to purchase another. Versus

History Eli Whitney ◦ Eli Whitney invented the concept of mass produced, interchangeable parts. ◦ Before interchangeable parts, if a small piece of an item malfunctioned, the whole thing must be replaced. However, with interchangeable parts the specific piece could be replaces.

Intermodalism is the use of different modes of transportation, such as highways, railways, and waterways as part of an interconnected system that can move people and goods easily from one mode to another.

Resources processing (primary manufacturing) Product manufacturing (secondary manufacturing)

Separating Forming Finishing Conditioning Assembling Casting and molding

Manufacturing is part of a larger system that captures, develops, produces, and markets creative ideas and includes: a. Research and development b. Production c. Marketing d. Industrial relations e. Financial management

Managers of manufacturing enterprises have adopted a striking array of integrated automated-process technologies. © STEM Center for Teaching and Learning™

• The umbrella acronym (pronounced “sim”) covers a variety of automated manufacturing technologies. • CIM integrates functions that traditionally have been separate, seeking “to streamline with quality control and just-in-time manufacturing, and to give every machine and employee the ability to talk with each other and ‘watch’ a product as it moves through the entire corporate pipeline. ” • CIM systems rely on the integration of mechanical, electrical, and informational subsystems. © STEM Center for Teaching and Learning™

• CIM does not refer to one specific technology, but to the integrated use of computers in all sections of the enterprise. • The benefits reported from CIM users include: lower energy bills, less scrap and rework problems, better quality control, higher competitive standing, faster product introduction; and increased flexibility in design, product mix, production volumes, and process routings. © STEM Center for Teaching and Learning™

• Is a manufacturing philosophy that attempts to eliminate waste throughout the system, including inventory at both ends of production and all machinery and manpower not adding directly to the value of the product. • Focuses on achieving integrated, highly consistent, short-cycle operations requiring minimal work in process inventory. • Requires the steady purchase of parts in small lot sizes as opposed to conventional purchasing practices in which raw materials are ordered from suppliers in anticipation of future production © STEM Center for Teaching and Learning™

• Concurrent Engineering is a way of integrating many aspects of product design, development, and manufacture so that critical phases of product design proceed concurrently within the boundaries of the manufacturing system infrastructure. • The key element in CE is increased communication between the different stages of the design process. • The goal is to reduce the product cost by designing a product that can be manufactured from the beginning without any problems. © STEM Center for Teaching and Learning™

• Means “manufacturing without waste. ” • Improves material handling, inventory, quality, scheduling, personnel, and customer satisfaction. • Encourages workers to stop production if they find a defect and work together to solve any problems. • Was developed in Japan by Toyota. © STEM Center for Teaching and Learning™

• Makes use of prototypes early in the development stage to identify errors in design and make necessary modifications. • Allows designers to produce a prototype within minutes of completing a computer-aided design (CAD) drawing of a part. • Avoids the lengthy process of traditional design using conventional tooling and casting processes. • Uses data from a three-dimensional CAD file to construct a model. • Systems have increased in recent years and include stereolithography, laser modeling systems, solid ground curing, and laminated object manufacturing. © STEM Center for Teaching and Learning™

Manufacturing Enterprise

Manufacturing Enterprise This presentation discusses o Manufacturing enterprise concept o Components of enterprise wheel o Significance of wheel components

Manufacturing Enterprise Setting Up the Enterprise • PRODUCT DESIGN AND SELECTION • PROCESS CREATION • PRODUCTION • MARKETING, SALES, and MANAGEMENT

(First) Product Design and Selection • Each student will design and create an idea of a product to be mass produced for a given purpose • Students will create a design using design software • Students will vote on best product to be produced

(Second) Process Creation o Students will create an overall process for producing the product o Students will design a Flow Chart that will depict the production line o Students will divide the process into different job sections. Each student will be assigned a job in the production line o Describe how the process will minimize the waste of resources

(Third) Production o Students will create the process for their specific jobs o Students will Create jigs, fixtures, and go/no-go gauges o Products will be finished at the highest quality

(Fouth) Marketing o Students will create the process for their specific jobs o Students will Create jigs, fixtures, and go/no-go gauges o Products will be finished at the highest quality

Job Selection The following jobs will be broken down into specific parts based on the product selected 1. President/foreman 2. Vice President/Foreman 3. Design team 4. Production team 5. Quality Control 6. Marketing and Sales 7. Purchasing/Materials/Impacts

President/ Vice President/Foreman • Makes all final decisions when dealing with the design, purchasing, production, and marketing of the product • Makes contacts with suppliers of materials • Promotes the product • Ensures the proper use of tools, machines, and materials • Sets production dead lines • Safety inspector • Ensures the flow of production in order to meet given deadlines Vice President/ Foreman • Assists with all the duties of the president • Aids President in decision making • Assumes all responsibility when in the absence of president

RESEARCH & DESIGN TEAM The team will be responsible for the following tasks n Creating the final product design n Checking all product specification and dimensions n Creating final Flowchart of the Production Process n Minimize the waste of resources n Create a sustainability plan n Create Product presentation n Prototype testing and evaluation

MATERIALS & PURCHASING The team will be responsible for the following tasks – Locating the best materials based on use and cost – Cost analysis – Calculate the amount of materials needed – Locating the required materials at the lowest cost – Purchase all necessary materials – Storing Materials – Monitoring Machine and Tool Maintenance – Use materials waste based on the sustainability plan

Production Team The team will be responsible for the following tasks ( The Largest Team) –Breaking down the production team into specific jobs based on the production process –Creating all product parts –Sanding and finishing the products –Assembling the final products –Running a smooth and efficient production line –Creating products of the highest quality –Minimizing waste –Safely using all tools, machines, and materials –Creating all necessary fixtures and jigs Examples of separate jobs for production –Part Fabrication (Should be a job for each machine used) –Sanding –Finishing –Assembly

QUALITY CONTROL for the following The team will be responsible tasks –Create go/no-go gauges for each part of the product –Inspecting parts after each phase of production to ensure the highest quality –Will test part to see if they fit within the given tolerance –Will declare whether the parts of the product pass for use or need to be adjusted. –Will inspect all final products

MARKETING & SALES The team will be responsible for the following tasks –Creating advertisement for the product –Setting the price for the sale of the product –Designing the distribution methods for the product –Designing and creating the packaging for the product –Creating an instruction manual if necessary –Creating a plan for all funds

Manufacturing Enterprise Wheel © STEM Center for Teaching and Learning™

Engineering Journal Review • Written ideas • Sketches (preferably annotated) • Work session summaries • Research findings • Interview information: who was contacted, when, and what was discussed or learned

Jigs & Fixtures Jig: A device that holds the work and locates the path of the tool. Fixture: A device fixed to the worktable of a machine and locates the work in an exact position relative to the cutting tool.

References http: //www. biomerieux-industry. com/ servlet/srt/bio/industry-microbiology/dyn. Page? node=Customized_Manufacturing o Computer and Automated Systems Association of the Society of Manufacturing Engineers (3 rd ed. ). (1993). The new manufacturing enterprise wheel. Dearborn, Michigan: Author. © 2011 International Technology and Engineering Educators Association, STEM Center for Teaching and Learning™ [Name of Course Guide]