Introduction to Manufacturing

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Introduction to Manufacturing
Written by Roland Williams
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GPS Standard

• ENGR-EET-5 Students will analyze the designed
  world of engineering, electronics, manufacturing,
  and energy systems.

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Critical Knowledge/Elements

• Examine Manufacturing

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Essential Question

• How are assembly lines used to used in the
  manufacturing of products?

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Word Wall
Manufacturing Separating Forming Combining Con
ditioning
Durable Goods   Non-Durable Goods   Manufacturing
Process   Push Production   Pull Production
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The History of Manufacturing
Whats up in Manufacturing?
http//www.aptv.org/APTPLUS/Digitalibrary/digitalm
ediadetail.asp?ConVidID15
Click on link or picture to watch video.
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Manufacturing a Product
Split the class into two groups.
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The Problem
You and your team are assembly-line workers in
Company XYZ. Your line manager has given you a
new product to assemble. You will assemble the
product according to the managers instructions.
Then you will brainstorm ways to improve the
overall production. The product is a bolt with
three washers and a nut that holds the washers
firmly in place. The diagram shows how the
product should be assembled and what the finished
product looks like.
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Bolt Object Project
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Assemble the bolts.Record total time to
assemble bolts.
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Discussion

• Is there a better way of distributing materials?
• Is there a better way of arranging the line to
  make the flow of work smoother?
• Is there a better way of assembling the item?
• Is there a way of cutting down on the number of
  people involved?
• How can you improve the quality of the item in
  order to make an inspector and rework team
  unnecessary?

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Each team member should choose one of the jobs
below. Task 1 Place small washer on bolt and
pass to position 2. Task 2 Place large washer
on bolt and pass to position 3. Task 3 Place
lock washer on bolt and pass to position 4. Task
4 Tighten washers onto bolt with a nut. Task 5
Check the quality of each product. Any piece
that does not meet the standards shown in the
illustration should be sent to position 6. Task
6 Rework any defective products to bring them up
to acceptable standards. Task 7 Oversee the
line production to make sure the assembly process
runs smoothly. Task 8 Supply each position on
the line with needed parts.
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Bolt Object Project
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Assemble 10 bolts with washers and nuts. Time
how long it takes you.
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Discussion

• Is there a better way of distributing materials?
• Is there a better way of arranging the line to
  make the flow of work smoother?
• Is there a better way of assembling the item?
• Is there a way of cutting down on the number of
  people involved?
• How can you improve the quality of the item in
  order to make an inspector and rework team
  unnecessary?

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Whats up in Manufacturing?
New Trends in Manufacturing
http//www.aptv.org/APTPLUS/Digitalibrary/digitalm
ediadetail.asp?ConVidID16
Click on link or picture to watch video.
Worksheet New Trends in Manufacturing
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Push and Pull

• Push Production Each person is to do their
  individual task, and when it is complete, they
  are to give the product to the next person. (It
  is pushed to the next person.)
• Pull Production Each person is only to do their
  task when there is one product waiting to be
  assembled. (It is pulled from them.)

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Assemble the bolts.Record total time to
assemble bolts.
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Compare Push and Pull

• Push Production
• Pull Production

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Push and Pull

• Push Production
• Faster production.
• Increased chance of error-less quality.
• Pull Production
• Increased quality.
• Slower production.

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The Assembly Line Challenge
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Rules

1. Winning team will be determined by time. A 5
   second penalty will be given for each defective
   part (dropped or laying out not used) and a 25
   second penalty for any defective bolt object
   (rattles or assembled in wrong order).
2. Teams will have 10 minutes to form their quality
   circles to discuss ways to improve production.
3. You do not have to assign duties the same as use
   in the previous assembly lines. More than one
   student may now do the same job, or simpler jobs
   may be combined as one job. Students will not be
   allowed to help others with their job or to
   switch jobs after the competition begins.
4. Team leader will give the instructor a list of
   student names and their duties.

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Form teams, elect a leader, discuss how to
improve the assembly line, and assign each
members duty.
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Assemble the bolts.Record total time to
assemble bolts.
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One more time, form your quality circles and
improve your assembly line procedures.
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Assemble the bolts.Record total time to
assemble bolts.
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Discussion

• Is there a better way of distributing materials?
• Is there a better way of arranging the line to
  make the flow of work smoother?
• Is there a better way of assembling the item?
• Is there a way of cutting down on the number of
  people involved?
• How can you improve the quality of the item in
  order to make an inspector and rework team
  unnecessary?

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The Assembly Line ChallengeWinning Team
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Essential Question

• How are assembly lines used to used in the
  manufacturing of products?

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Conclusion

• The Assembly Line Challenge, Lesson 3

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(Optional Slide if you include math in Lesson 3)
Assembly Line Efficiency

• Quality control can be expressed as a rate that
  tells what portion of the bolt objects that
  were made passed inspection.
• Production rate is the number of quality bolt
  objects produced per minute. (total made per
  minute).

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(Optional Slide if you include math in Lesson 3)
Assembly Line Efficiency
Complete the Push/Pull Production and Efficiency
Worksheet