Registration NO: 190133872

MEC 304 Manufacturing Systems – Individual Short Answers

Question 1:

Ford an automobile industry has taken advantage of good decisions to create an efficient
plant layout that builds a car in less than 48 hours on average. [1] Fords first venture into
automobile assembly for model A was first deigned setting up a stand on which vehicles was
built on. This was done by a single assembler who did the exact same thing of putting a
whole section of the car together in the same place. It was efficient but it took the
assembler 8.5 hours to set the whole section up. By the time ford was building Model T it
was decided to use multiple assembly stands with assemblers doing a specific function on
each stand. This reduced the time for each fitter from 8.5 hours to 2.5 minutes . Assembly
line was later introduced which passed on the part to each worker stand, this change in
plant layout created a more efficient environment. With no workers moving between
stands, the time to set each section was reduced from 2.5 minutes to just below 2 minutes.
Following the previous steps Ford was able to make a high jump in sales and profit because
less time is required to generate large volume of cars.

Question 2:

Companies are trying to accomplish what Toyota has done years ago which is JIT (Just in
time) production. Several steps have been taken by automotive manufacturers to become
more efficient and sustainable. To prevent overproduction automotive manufacturers are
now producing their vehicles based on the orders they receive from the dealers. [2] This will
allow the supply chain to be used in such a manner where only the parts needed to
manufacture vehicles are received on time from suppliers.[2] Therefore, overproduction is
avoided as well as the waste associated with unprocessed inventory, as both manufacturing
and transportation are taking place simultaneously which minimizes inventory of parts.
Manufacturers are now producing cars in one order, so components fit in from first time
which avoids defects as there is one organized production flow. Manufacturing cars are
becoming more sustainable and reliable because of following the previous steps. Companies
are now making only what is needed when it is needed, and in the amount needed.
Moreover, plenty of money is saved as less workforce is required, less transportation, less
inventory, and less waste. This creates a more sustainable production which has less effect
on the environment.
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Question 3

Automotive manufacturers are responsible to deliver high-quality standards for all their
production. Ford is engaging with quality assurance from the training of their workers to
work on one thing per station which insures consistency and precision. Another way in
which automotive manufacturers ensure quality is the test that they take on the cars before
their release. There are thousands of checks to ensure that safety, performance, and build
quality are outstanding. [3] An example of an automobile check in Germany is the
Nürburgring test track, car porotypes undertake the track under certain conditions to check
the automobile performance and stability. [4] Regarding the safety another test called the
Euro NCAP, where the car undergoes multiple designed crashes with sensors inside the
vehicle to measure the impact forces the driver may experience and how the car will react
to certain crashes. This will give the car a safety rating which ensure the consumer knows
how safe the vehicle is. [5] Such quality control tests add credibility to the company. This
generates more trust, sales, and profit to the company. Therefore, investing in this sector
will allow the manufacturers to identify and solve problems before releasing a product.

Question 4

HVM (High Value Manufacturing) catapult is a way of how manufacturing sectors in high-
cost economies should react to increase global competition from low-cost economies. [6]
Companies are approaching HVM in multiple ways one of which is Cloud Analytics for the
automation of manufacturing product design which reduces time to plan and program
manufacturing equipment from days and weeks to minutes or seconds. Companies are also
using next generation recyclable materials ranging from composites and polymer based.
These materials are recyclable alternatives which drives towards circular economy that
improves supply chain resilience. [7] Rolls Royce is using advance analytics, industrial
Artificial intelligence, and machine learning techniques in developing, this will have data
applications that unlocks design, manufacturing, and operational efficiencies. Moreover
creates new service propositions for customers. [6] Automotive industries are also moving
towards using digitally enhanced design tools that draws data through a digital thread from
in-service manufacturing experience to optimize the performance of the engineered
product through its lifecycle. Next generation advance machinery is another way of
engagement which joins and assembles products with decarbonization of transport and
energy. All the mentioned techniques have strong potential to bring sustainable growth and
high economic values.
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References

[1] HowStuffWorks, Auto, Safety, & Devices. (2021). How Car Testing Works. Retrieved 15 December 2021,
from https://auto.howstuffworks.com/car-driving-safety/safety-regulatory-devices/car-testing.htm

[2] How automobile is made - production process, manufacture, making, used, parts, components, product.
Retrieved 15 December 2021, from http://www.madehow.com/Volume-1/Automobile.html

[3] Why Toyota’s Just-in-Time Method Is Critical to Its Success. Retrieved 15 December 2021, from
https://marketrealist.com/2016/05/toyotas-just-time-method-critical-success/

[4] HowStuffWorks, Auto, Safety, & Devices. How Car Testing Works. Retrieved 15 December 2021, from
https://auto.howstuffworks.com/car-driving-safety/safety-regulatory-devices/car-testing.htm

[5] Solutions, T. The Benefits of Quality Assurance for Businesses. Retrieved 15 December 2021, from
https://theappsolutions.com/blog/development/the-benefits-of-quality-assurance-for-businesses/

[6] Retrieved 15 December 2021, from https://committees.parliament.uk/writtenevidence/16976/pdf/

[7] Retrieved 15 December 2021, from https://www.rolls-royce.com/country-sites/india/discover/2019/06-a-