4.5 Production Systems

4.0 Final Production

4.1 Properties of materials

4.2 Materials

4.3 Scales of Production

4.4. Manufacturing Processes

4.5 Production Systems

4.6 Robots in Production

Essential idea:

The development of increasingly sophisticated production systems is transforming the way products are made.

Nature and Aims of Design

Nature of Design

As a business grows in size and produces more units of output, then it will aim to experience falling average costs of production—economies of scale. The business is becoming more efficient in its use of inputs to produce a given level of output. Designers should incorporate internal and external economies of scale when considering different production methods and systems for manufacture. (1.11)

Aims

Aim 7: The design of a production system requires a complete understanding of a product, its function and the quality of finish. Each system can be unique and specific to the product it is creating, often requiring the designers to adapt their design to be manufactured using certain methods.

Guidance

As DP Design Technology student you should:

Craft production
Mechanized production
Automated production
Assembly line production
Mass production
Mass customization
Computer numerical control (CNC)
Production system selection criteria
Design for manufacture (DfM): design for materials, design for process, design for assembly, design for disassembly
Adapting designs for DfM

Guidance:

Advantages and disadvantages of different production systems
Impact of different production systems on the workforce and environment
Production system selection criteria include time, labour, skills and training, health and safety, cost, type of product, maintenance, impact on the environment and quality management
Design contexts where different production systems are used

Topic 4

4.5: Production Systems

4.5 a Design for Manufacture

Concepts and Principles

Each production system has unique components, advantages, and limitations. For designers, understanding these factors can allow them to optimize the design to reduce costs.

Through careful analysis of the materials, scale of production, and types of production methods, the manufacture of the product can be optimized.

Craft Production

Craft production is a small-scale production process centred on manual skills. Custom designed furniture, pottery, and jewelry are common examples.

Craft production was the dominant form of production in pre-industrialized societies.

Today in the developed world, craft production is typically associated with high-quality, unique goods manufactured by a craftsperson; Accordingly, consumers are more willing to pay a higher price for the product due to the perceived value.

Advantages

Highly skilled and specialized product
Highly customizable to specific needs of client
Higher status associated with craft good due to their unique nature

Disadvantages

low economy of scale
time consuming and labor intensive
high labor costs

Environmental Impact

May not be designed for disassembly
Typically use higher quality materials, and in lower quantities. Higher prices can justify more expensive material choices and processes.

Workforce Impact

Training and apprenticing may take much time.
Craftspersons often have to manage all aspects (marketing, production, design, accounting) of a business.

Mechanized Production

Mechanized production is a volume production process involving machines controlled by humans. The machines assist the workers in increasing their productivity, quality, and safety. These could include conveyor belts to speed up production speed, cranes to move heavy materials, or jigs to assist with the production of parts.

A worker works alongside a robot to sort and manufacture electronic components.

Advantages

repetitive tasks carried out by machines
increased productivity
increased quality of product human error reduced

Disadvantages

increased cost for training and machinery
reduction in consumer choice as mechanization limits customization

Environmental Impact

increased pollution produced
increased energy need

Workforce Impact

higher wages as workers need to be trained
repetitive work
lower job satisfaction
healthy and safety in factories can be an issue.

Automated Production

Automated production is a volume production process involving machines controlled by computers.

Automated systems use CAD, CAM, and CNC to link computers to manufacturing equipment

Advantages

Higher quality
Closer fidelity between CAD drawings and final product
Higher productivity as machines can work 24/7

Disadvantages

High cost of equipment
only economically feasibly for high production runs (economy of scale)

Environmental Impact

Less waste is produced as the production system can be optimized

Workforce Impact

Lower labor costs as fewer workers are needed to oversee production and control
Workers need to be highly trained and skilled to operate machinery
Improved health and safety as few workers are operating machines

Assembly Line Production

Assembly line production is a volume production process where products and components are moved continuously along a conveyor. As the product goes from one work station to another, components are added until the final product is assembled.

Advantages

Economy of scale
High production volume of similar products is possible

Disadvantages

Limited opportunity for customization
Can be expensive to retool for new products
Dependent on reliable supply of parts and materials and timely distribution to be economically viable.

Environmental Impact

Increased pollution due to higher levels of production

Workforce Impact

Repetitive tasks can increase injury and decrease job satisfaction

Tesla Model S assembly line. Note the use of robotics, mechanization, and how and when workers are involved in the process.

Mass Production

Mass production is the production of large amounts of standardized products on production lines, permitting very high rates of production per worker.

See 4.3: Scales of Production for more detail and examples.

Mass Customization Production

Mass customization is a sophisticated CIM system that manufactures products to individual customer orders. The benefits of economy of scale are gained whether the order is for a single item or thousands.

See 4.3: Scales of Production for more detail and examples.

Computer Numerical Control (CNC)

Computer numerical control (CNC) refers to the computer control of machines for the purpose of manufacturing complex parts in metals and other materials. Machines are controlled by a programme commonly called a “G code”. Each code is assigned to a particular operation or process. The codes control X, Y and Z movement and feed speeds.

CNC and CAD (Computer Aided Design) work together. The CAD file contains information about product, dimensions, etc.. This is interpreted by the CNC machine to produce the final product.

3D printers, CNC Routers, and Laser Cutters are examples of CNC machines.

Advantages

Highly accurate and efficient production
Customizable to specific needs and materials

Disadvantages

High cost for equipment and training

Environmental Impact

Materials use can be optimized, reducing waste
Increased energy need

Workforce Impact

Repetitive tasks can increase injury and decrease job satisfaction

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