Unit R014 - Engineering Manufacture - Topic Area 3 - Retrieval B

Scales of Manufacture & Production Methods

Match the product to the most likely production scale

• Mass

• 
• One off

• 
• Batch

• 

Scales of Manufacture & Production Methods

This shows the automated blow moulding process for making bottles. What is the problem with changing the bottle design?

• Expensive redesign of tool moulds.

• Down time of production line to accommodate install of new moulds/tooling

• Moulds cannot be removed and replaced.

Scales of Manufacture & Production Methods

One off production is.......

• Producing a custom product that is highly specialised and tailored to suit the needs of one end user.

• Products where they sell badly and are removed from sale after a short time.

• Products that are manufactured continually with high levels of automation.

• Trying something once then not doing it again.

Scales of Manufacture & Production Methods

Mass production is.......

• Producing a custom product that is highly specialised and tailored to suit the needs of one end user.

• Products where they have a heavy total weight.

• Products that are manufactured often continually, with significant automation.

• Trying something once then not doing it again.

Scales of Manufacture & Production Methods

When manufacturing jig's are often used. Why?

• Increase in output and productivity.

• Reduction in setting up and cycle times.

• Inspection and quality control expenses should reduce.

• Jigs eliminate all chances of error.

Answer explanation

Jig's are used to hold the work piece and guide the tooling to complete a task.

Here the jig holds the steel section in place providing four clear hole alignments for the drill piece.

This saves the operator having to manually mark out the location of the holes.

Scales of Manufacture & Production Methods

Often engineers will use the phrase "Jig" and "fixture" when explaining the same piece of equipment however they are different. Which statement best explains a FIXTURE.

• A fixture will hold and secure the work piece ready for manufacturing operations.

• A fixture will hold the workpiece secure and guide the tooling for manufacture.

• A fixture is a way of planning upcoming events or activities

Answer explanation

This image shows the difference between the two.

With the jig the the tool only has one possible location it can go.

With the fixture the tool can be used anywhere on the top edge of the workpiece within reason.

Scales of Manufacture & Production Methods

An engineering company who make heavily customised products want to use a JIG moving forward for drilling holes in their products. Would you recommend?

• Yes. The JIG will speed up production significantly and allow the holes to be drilled identically each time.

• No. The JIG will lack the flexibility required to change the location of the holes on the products depending on the customer requirements.

Scales of Manufacture & Production Methods

An engineering company who make heavily customised products want to use a JIG moving forward for drilling holes in their products. Would you recommend?

• Yes. The JIG will speed up production significantly and allow the holes to be drilled identically each time.

• No. The JIG will lack the flexibility required to change the location of the holes on the products depending on the customer requirements.

Scale of Manufacture & Production Scales

Jigs and fixtures come with negatives too. They require regular​ (a)   . Often the JIG or fixture will need to be robust and​ (b)   to hold the component securely, this can mean they are ​ (c)   . Jigs and fixtures are usually highly machined in the first instance to achieve the required tolerances and quality and ultimately they have a ​ (d)   initial cost.

• calibration
• large
• heavy
• high
• low
• small

Scale of Manufacture & Production Scales

Automation is......

• The use of machinery, equipment and robotics to compliment and/or replace human labour.

• Using a lathe to manufacture.

• Using video conferencing.

• The use of JIT and computers for stock management.