Introduction to manufacturing
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Introduction to Manufacturing. Written by Roland Williams. GPS Standard. ENGR-EET-5: Students will analyze the designed world of engineering, electronics, manufacturing, and energy systems. Critical Knowledge/Elements. Examine Manufacturing. Essential Question.

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Introduction to manufacturing

Introduction to Manufacturing

Written by Roland Williams


Gps standard

GPS Standard

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


Critical knowledge elements

Critical Knowledge/Elements

  • Examine Manufacturing


Essential question

Essential Question

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


Word wall

Word Wall

Manufacturing

Separating

Forming

Combining

Conditioning

Durable Goods

Non-Durable Goods

Manufacturing Process

Push Production

Pull Production


The history of manufacturing

“What’s up in Manufacturing?”

The History of Manufacturing

http://www.aptv.org/APTPLUS/Digitalibrary/digitalmediadetail.asp?ConVidID=15

Click on link or picture to watch video.


Manufacturing a product

Manufacturing a Product

Split the class into two groups.


Introduction to manufacturing

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 manager’s 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.


Bolt object project

Bolt Object Project


Assemble the bolts record total time to assemble bolts

Assemble the bolts.Record total time to assemble bolts.


Discussion

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?


Introduction to manufacturing

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.


Bolt object project1

Bolt Object Project


Introduction to manufacturing

Assemble 10 bolts with washers and nuts.

Time how long it takes you.


Discussion1

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?


Introduction to manufacturing

“What’s up in Manufacturing?”

New Trends in Manufacturing

http://www.aptv.org/APTPLUS/Digitalibrary/digitalmediadetail.asp?ConVidID=16

Click on link or picture to watch video.

Worksheet: New Trends in Manufacturing”


Push and pull

“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.)


Assemble the bolts record total time to assemble bolts1

Assemble the bolts.Record total time to assemble bolts.


Compare push and pull

Compare “Push” and “Pull”

  • Push Production

  • Pull Production


Push and pull1

“Push” and “Pull”

  • Push Production

    • Faster production.

    • Increased chance of error-less quality.

  • Pull Production

    • Increased quality.

    • Slower production.


The assembly line challenge

The Assembly Line Challenge


Introduction to manufacturing

Rules

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).

Teams will have 10 minutes to form their quality circles to discuss ways to improve production.

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.

Team leader will give the instructor a list of student names and their duties.


Form teams elect a leader discuss how to improve the assembly line and assign each member s duty

Form teams, elect a leader, discuss how to improve the assembly line, and assign each member’s duty.


Assemble the bolts record total time to assemble bolts2

Assemble the bolts.Record total time to assemble bolts.


Introduction to manufacturing

One more time, form your quality circles and improve your assembly line procedures.


Assemble the bolts record total time to assemble bolts3

Assemble the bolts.Record total time to assemble bolts.


Discussion2

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?


The assembly line challenge winning team

The Assembly Line ChallengeWinning Team


Essential question1

Essential Question

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


Conclusion

Conclusion

The Assembly Line Challenge, Lesson 3


Optional slide if you include math in lesson 3 assembly line efficiency

(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).


Optional slide if you include math in lesson 3 assembly line efficiency1

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

Complete the Push/Pull Production and Efficiency Worksheet


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