Planning - Plan of Manufacture

A ‘Plan of Manufacture’ means choosing the best, safest and most cost-effective method of producing your prototype product; the best / correct materials; and the best way to control the product quality i.e. making sure that parts fit together. 

A Production Plan or Flow chart is a key part of your Quality Assurance and Quality Control (QA / QC) systems, because it documents each stage of manufacture. This enables checks to be made for quality, so each component of the product is made to the same standard. 

A Production Plan also enables faults to be identified at certain times and provides feedback, so that changes can be made, if necessary. 

You are making a one-off product (a test prototype) so it is appropriate to try and plan the process of how you will make it. 

You should also record the evidence of what you have done (through photographs and screenshots) to manufacture your prototype. and then use those photographs and screenshots alongside your Production Plan and Diary of Planning / Diary of Manufacture. This could then be used to inform if you were making another.

You need to produce a clear plan that explains how to manufacture your product, within the realistic (Songkran) deadlines set. 

This involves providing details of how to make your product design proposal, taking into account quality and safety requirements. Realistic deadlines are those that are achievable. They should match the making of the product to the time available - Songkran.

The work that you have already done on development, modelling, prototyping and your final test model should help you to plan but you should also use the guidance below to think through the process. 

Your plan should provide instructions for the stages of designing and making your prototype product. It should be worded ‘what you are going to do next...’. You should identify:

·       The order of designing, manufacturing and assembly of the different components

·       Tools, machines and equipment to be used including hand tools, 3D printers, laser cutters, CAM machines, finishes for your product - spray paints, varnish, oil, wax etc.

·       Construction, component fitting and Assembly processes

·       An approximate time (in hours) each stage of manufacture / process should take

·       Key stages of manufacture where quality is checked (QA / QC) - FEEDBACK. This is usually a question i.e. Do the parts fit together? Y/N

·       Safety requirements and / or procedures that you will need to take

Start: complete Final Design Proposal & accurate test model > Predefined Process: Model 'parts' and 'components' accurately to size in 3D CAD > Process: research dimensions of external (bought in) 'components' > Process: QA / QC check - have you left tolerances between 'parts' so that they will fit together > Process: Assemble 'parts' in 3D CAD > Decision (Y/N): Virtual Test. Do all 'parts' fit together? > Process: Order 'parts', components and electronics > Predefined Process: Create Working Drawings to be A3 printed for manufacture > Process: Export 'parts' as .stl files for 3D printing / CNC machining > Process: Export 'parts' as .dxf file for laser cutting > Decision (Y/N): QA / QC check - are 'parts' the correct sizes on 3D printing / laser cutting software > Process: print 3D 'parts' on 3D printers > Process: print 3D 'parts' on CNC router > Process: print 2D 'parts' on laser cutter > Preparation: prepare materials for machining / manufacture (Cutting list) > Process: Use A3 working drawing and materials to manufacture 'parts' > Decision (Y/N): Check all 'parts' for imperfections and correct manufacture. Do any need to be remade? > Process or Preparation: Clean up all 'parts' / remove unwanted material / smooth surfaces using files and abrasive papers > Decision (Y/N): Do all 'parts' have a good surface finish? > Predefined Process: 'dry' assemble all 'parts' to check fit. Add purchased / external components and check fit > Decision (Y/N): Do all 'parts' and 'components' fit? > Process or Preparation: Solder electronic components and make circuit. Test circuit works > Preparation: Fine finish all 'parts' using abrasive papers > Process: Finish coat to all 'parts' to highest standard (Spray paint x 3 coats, Oil, Wax, Varnish) > Process: Protective layer to 'parts' (lacquer, varnish) > Decision (Y/N): Do all 'parts' still fit? > Process: Fit all electronic components & inserts to join 'parts' > Predefined Process: Assemble all 'parts' securely > Predefined Process: Test final prototype / product against testing strategy and record results > Decision (Y/N): Does everything work as expected? Analyse & Evaluate > Process: Final Photos > Terminator: Stop.