Use of Production Techniques & Systems (AQA GCSE Design & Technology): Revision Note
Exam code: 8552
Automation
What is automation?
Automation refers to the use of a control system, machine or technology to operate processes with less human intervention
Why is automation used in the manufacture of products?
Automation is used to:
increase the speed and accuracy of production
reduce human error
lower production costs in the long term
improve aspects of health and safety for workers
How do manufacturers use automation?
Robotic arms on production lines
CNC machines to cut materials
CAD/CAM approaches to link design and manufacturing
Automated picking and distribution systems
Machines which use sensors to track data throughout a production process
Computer aided design (CAD)
What is computer-aided design (CAD)?
Computer-aided design (CAD) refers to the use of computer software to design products
Designers use CAD to create 2D and 3D virtual designs which can be sent to computer-aided manufacturing machines (CAM) to make parts
Why do designers use CAD?
Designs can be highly accurate using dimensioning
2D and 3D designs can be edited quickly
Virtual 3D designs can be rotated to see different angles
Materials and lighting can be applied to designs to simulate realistic appearance
3D assembled products can be tested and simulated in the software (e.g. stress testing, material flow analysis and eco-efficiency)
Virtual designs can be built from libraries of off-the-shelf or standard parts, speeding up design and eventual manufacture
Virtual designs can link to machines for easier manufacture
Electronic files can be shared, and virtual designs can be worked on collaboratively between people anywhere in the world
What are common disadvantages of CAD?
CAD software can be expensive for design companies to purchase
CAD software requires designers to receive training to use it
Examiner Tips and Tricks
CAD and CAM are closely linked but different — CAD is about designing the product on screen, while CAM is about using that design file to control a manufacturing machine.
In the exam, make sure you can explain the link: a designer creates a product in CAD software, then the design file is sent to a CAM machine (e.g. a laser cutter or 3D printer) to manufacture the part.
Computer aided manufacture (CAM)
What is computer-aided manufacture (CAM)?
Computer-aided manufacture (CAM) refers to the use of design files created in CAD software to instruct computer-controlled machines to make a part
What are examples of CAM machines?
Laser cutter
3D printer
CNC milling machine
CNC router
Water or plasma jet cutter
CNC lathe
Advantages and disadvantages of CAM
Advantages | Disadvantages |
|---|---|
Higher levels of accuracy | Higher start-up and operating costs |
Faster production speeds | Requirements to train operating staff |
Continuous production | Breakdowns in equipment causing production delays |
Improved overall product quality | Less opportunity for customised products |
Potential to reduce levels of waste |
Flexible manufacturing systems (FMS)
What is a flexible manufacturing system (FMS)?
A flexible manufacturing system (FMS) is a computer-controlled manufacturing system where each part of the system is interconnected, allowing it to change what product it is producing quickly
Machines controlled by computer and linked together share data and instructions, and typically include robotics to support production, in order to create differing products on a continuous basis
Why do manufacturers use FMS?
They can quickly respond to a change in customer demand and make different products
Products can be made in smaller batches with customised features
There is less set-up time to begin producing a new product
The system is highly automated, making use of CAM and robotics
By sharing real-time data within the system, production can be changed, updated or adapted without loss of efficiency
Just in time (JIT)
What is just-in-time (JIT)?
Just-in-time (JIT) is an approach to production that reduces the time that materials, components and parts are stored before they are used for the production of a product
Why do manufacturers use JIT?
Reducing the need for storage of materials and parts
Reducing the cost of having storage space
Only manufacturing the amount of product that customers demand
Reducing waste during production
Improving the efficiency of product manufacture through lower waiting times
Allowing production of a product to quickly change as customer demand changes
How can JIT be a disadvantage to a manufacturer?
If a part or material delivery is delayed, this can delay the entire production process
The manufacturer is reliant on its suppliers and the quality of their materials or parts
If demand significantly grows, production lines can struggle to meet demand at scale
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Worked Example
A furniture manufacturer uses just-in-time (JIT) production. Explain one advantage and one disadvantage of using JIT.
[4 marks]
Answer:
Advantage: The manufacturer does not need to pay for large storage facilities for materials [1 mark], because materials and components are only delivered when they are needed for production, reducing storage costs [1 mark].
Disadvantage: If a supplier fails to deliver materials on time [1 mark], the entire production process could be delayed because there is no stock of materials stored as a backup [1 mark].
Lean manufacturing
What is lean manufacturing?
Lean manufacturing is an approach to production which looks to reduce waste by making use of resources efficiently at every step, whilst maintaining the production of high-quality products
Where can lean manufacturing achieve efficiencies?
By avoiding overproduction of products which then need to be stored
Reducing the distance resources (including materials, products and people) need to travel between locations
Minimising waiting times or times where people or machines are not in use
Working to reduce and eliminate defects, faulty products and mistakes in the production process
How does lean manufacturing achieve these efficiencies?
Mapping all of the steps of production and tracking them with live data to ensure they remain uninterrupted
Linking customer orders to the production of products, so that only products that have been purchased are made
Continuous improvement of each step in the manufacturing process through data and analysis
Linking systems together so that different parts of the production process know what is happening and can react (e.g. a delayed delivery of materials will automatically delay the collection date for the finished product)
Examiner Tips and Tricks
Lean manufacturing and JIT are closely related but not the same thing. JIT is one tool used within lean manufacturing.
Lean manufacturing is the broader approach of reducing all types of waste in production, while JIT specifically focuses on reducing storage by having materials delivered only when needed.
If a question asks about lean manufacturing, you can mention JIT as one example of how it works.
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