QETA-002

QETA-002

1. PRODUCTION

   • TYPES OF PRODUCTION
     • Mass Production – a method of producing goods in large quantities at low cost per unit. But mass production, although allowing lower prices, does not have to mean low-quality production. Instead, mass-produced goods are standardized by means of precision-manufactured, interchangeable parts.
     • Flow Production – involves the use of production lines such as in a car manufacturer where doors, engines, bonnets and wheels are added to a chassis as it moves along the assembly line. It is appropriate when firms are looking to produce a high volume of similar items.
     • Automated Production – is the use of various control systems for operating equipment such as machinery, processes in factories, boilers and heat treating ovens, switching on telephone networks, steering and stabilization of ships, aircraft and other applications with minimal or reduced human intervention within the production process.
     • Batch Production – is a technique used in manufacturing, in which the object in question is created stage by stage over a series of workstations, and different batches of products are made. With job production (one-off production) and flow production(continuous production) it is one of the three main production methods.
     • One-off/Bespoke Production – One off production is the manufacture of a single product/item. This can include large scale projects, such as a bridge, ship, stadium, multi-storey building or tower, Other examples of one offs are - specialist jewellery, made to measure clothing, bespoke furniture and many more.
   • Method for Different Types of Product
     • Market Requirements i.e. what is the scale of demand for the product? Is it going to be shipped locally/nationally/globally? Are there other production plants that are producing the same product?
     • Design of the Product i.e. is the product able to be put into an automated or mass production process? Is it highly bespoke and have to be manufactured individually?
     • Plant and Equipment Availability i.e. Although the product can be manufactured in masses, do you have the equipment/plant available to deliver the production in mass/flow production?
     • Personnel i.e. do you have the trained personnel to manage the process of mass production – robot machines could break down? Do you have enough trained staff to deliver batch production or is there a skills shortage and have to do them one at a time?
     • Production Control “Production control is the activity of monitoring and controlling a large physical facility or physically dispersed service. It is a "set of actions and decision taken during production to regulate output and obtain reasonable assurance that the specification will be met” are there plant control rooms, production planners, SAP software in place?
     • Quality Control - is a specialised type of system control designed to check that a product meets the design specification and quality. Before making a product, the designer decides what quality checks are needed and when they should be carried out. A high-quality product will; meet the specification, function correctly, be free of defects, satisfy customer requirements.
     • Cost i.e. is it going to be cost effective to engage in the particular production method to satisfy the current demand? Will the purchase of the necessary plant/equipment be cost effective to be worthwhile swapping to the alternative production method?
   • Methods and Application of Cellular and Just in Time (JIT) Production
     • Cellular Production is a lean method of producing similar products using Cells, or groups of team members, workstations, or equipment, to facilitate operations by eliminating setup and unneeded costs between operations. Cells might be designed for a specific process, part, or a complete product. This allows for specialisation in a particular cell area to reduce errors made by production staff in the production process. It also allows for the identification and improvement of cells individually as each can be monitored and targeted separately.
     • Just in Time (JIT) Production is a strategy companies employ to Increase Efficiency and Decrease Waste by receiving goods only as they are needed in the production process, thereby reducing inventory costs. This method requires that producers are able to accurately forecast demand. Many parts of a Just in Time process are included from the point a supplier raises a parts delivery note, to the time of delivery into the factory and how long it takes for the part to go from the delivery area into the assembly/loading area.
   • Push and Pull types of Production
     • A Pull System is a lean manufacturing strategy used to reduce waste in the production process. In this type of system, components used in the manufacturing process are only replaced once they have been consumed so companies only make enough products to meet customer demand.
     • Technology push is a part of a business strategy of a company. In the innovation literature, there is a distinction between technology push and market pull or demand pull.
     • The original meaning of Push and Pull, as used in operations management, logistics and supply chain management. In the pull system production orders begin upon inventory reaching a certain level, while on the push system production begins based on demand (forecasted or actual demand).
   • Cost Factors to be Considered in the Production Process
     • Production Costs are: “A cost incurred by a business when manufacturing a good or producing a service. Production costs combine raw material and labour. To figure out the cost of production per unit, the cost of production is divided by the number of units produced. A company that knows how much it will cost to produce an item, or produce a service, will have a clearer picture of how to better price the item or service and what will be the total cost to the company.”
     • Direct costs refer to materials, labour and expenses related to the production of a product. Other costs, such as depreciation or administrative expenses, are more difficult to assign to a specific product, and therefore are considered indirect costs.
     • Indirect costs are costs that are not directly accountable to a cost object (such as a particular project, facility, function or product). Indirect costs may be either fixed or variable. Indirect costs include administration, personnel and security costs.
   • The different stages of Production Planning
     • Scheduling – is the process of arranging, controlling and optimizing work and workloads in a production process or manufacturing process. Scheduling is used to allocate plant and machinery resources, plan human resources, plan production processes and purchase materials. It is an important tool for manufacturing and engineering, where it can have a major impact on the productivity of a process. In manufacturing, the purpose of scheduling is to minimize the production time and costs, by telling a production facility when to make, with which staff, and on which equipment. Production scheduling aims to maximize the efficiency of the operation and reduce costs.
     • Loading – The Production Planner defines which style to be loaded to the production line and how much of each quantity needs to be loaded.
     • Dispatching (co-ordination of pre-production activities) – It refers to the control of processes of operation planning, giving operation order and controlling operations in the manufacturing site. Its purpose is to improve the operability by properly controlling the capacity of delivery date management. Thus the order delivery date, stock on hand, allocation of work in process, operation status of workers and machine/equipment are grasped as needed, and the operation planning is performed.

2. Schedules and Charts

   • Producing Work Schedules
     • Engineering Drawings – of the desired product/component
     • Technical Data – what technical data needs to be required to ensure the product is manufactured to drawing/specification
     • Personnel – What personnel are available in order to meet the production demand that is required
     • Machinery/Tools – What machinery/tooling/equipment is required in order for the component/product to be manufactured successfully
     • Components – What components are required in the production process? Is there anything that could hinder the process? Will there be lower components that interfere with the upper components of the end component?
     • Materials – What lead times is there for the materials? Are any difficult to obtain?
     • Consumables – Are there any consumables in the process that are required in great quantities, have a long lead in time, or are difficult to get hold of?
   • Flow Charts
   • Gantt Chart

3. Quality

   • Definitions
     • Quality: defining somethings fitness for purpose or the standard that meets the customers expectations
     • Quality Control: is carrying out the procedures that have been set out and designed in the quality assurance criteria
     • Quality Assurance: is the writing and implementing the procedures that ensure quality control

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