Lesson video

Hello there.

My name's Mrs. Taylor, and I'm really pleased you can be here to join me for our lesson today.

Our lesson today is Efficient manufacturing systems, and this is part of the Designing and Making Principles unit.

The outcome.

I can explain features of different manufacturing systems. We have five keywords, Flexible Manufacturing Systems, also known as FMS, which is adaptable production systems for changing needs, Just-In-Time, also known as JIT, producing only what's needed, when needed, lean manufacture, a production method that focuses on minimising waste, downtime, which is when a machine or system is not operational due to maintenance or failure, and lead time, the length of time from order to production completion.

There are three parts to our lesson today.

Flexible Manufacturing Systems, or FMS, Just-In-Time, or JIT, and Lean manufacturing.

Let's get started.

Flexible Manufacturing Systems are production systems that can quickly adapt to changes in product types and volumes.

It wouldn't be cost effective for a factory to continually manufacture products.

Therefore, they need to be responsive to market demand.

FMS allow factories to make different products quickly and efficiently without stopping production.

For example, large-scale chocolate manufacturers can change products quickly depending on the market response and the season.

Common features of Flexible Manufacturing Systems include automated machinery and tools, ability to switch between tasks with minimal downtime, integration with CAD and CAM, so computer-aided design and computer-aided manufacture.

Downtime is when a machine or system is not operational due to maintenance or failure.

An example of downtime in the drinks industry is when machinery is switched off to clean between making different drinks.

Let's have a check for understanding.

Which of the following is a key feature of Flexible Manufacturing Systems? A, FMS can only manufacture one type of product, B, FMS require frequent human intervention, C, FMS adapt quickly to changes in product type or volume, or D, FMS cannot scale production up or down? Pause the video.

Great.

Let's check.

That's right, it's C, FMS adapt quickly to changes in product type or volume.

Well done.

Sofia says, "But how can production continue if machines are switched off during downtime?" Factories with Flexible Manufacturing Systems reduce the time machines are off, or even keep some running while others are being maintained.

Using special software helps to organise this.

Other methods to do this include having multiple machines, planning maintenance so not all machines are off, using robots that can self-check and fix minor problems, and parallel production lines, if one stops, the other keeps running.

There are two main types of Flexible Manufacturing Systems, machine flexibility and routing flexibility.

Let's consider machine flexibility first.

Machine can perform various processes on different product types.

It reduces downtime caused by switching between products.

For example, a robotic arm capable of welding, painting, or assembling different parts based on the programme fed into it.

And routing flexibility, use of multiple paths or routes to complete a process, even if resources are unavailable.

Allows continued production during machine failures and maintenance.

For example, if machine A is unavailable, the system can reroute work to machine B.

Advantages of Flexible Manufacturing Systems include the lead time, the time between product order to delivery is reduced, and adaptations are made very quickly.

Efficiency, automation increases speed.

There is less room for human error.

And quality control.

Consistent processing methods and checks can be automated.

Here we have a check for understanding.

What is one advantage of Flexible Manufacturing Systems? Is it A, they can only manufacture one product type, or B, they reduce downtime and improve system flexibility, or C, they eliminate the need for human operators, or D, they are more expensive than traditional systems? Pause the video and have a go.

Great, let's check.

That's right, it's B, they reduce downtime and improve system flexibility.

Well done.

Other industries using Flexible Manufacturing Systems include car manufacturers to produce various car models on the same assembly line, clothing manufacturers to switch between making T-shirts and jackets using the same machines, and toy manufacturers of construction bricks can make different themed sets.

Here we have your first task, Task A.

Part one, how does a Flexible Manufacturing System adapt to changes in production needs, and what is one advantage this brings to a manufacturing process? And part two, give an example of a real-world industry or product that uses FMS and explain why FMS is beneficial in that context.

Pause the video.

Great.

Let's have a look at some of the answers you may have come up with.

For part one, FMS adapts by using computer controlled machinery and robots that can be quickly reprogrammed to produce different products.

An advantage of this is that it reduces downtime, ensuring that production can continue without significant delays when changes are made, leading to more efficient use of time and resources.

And part two, car manufacturers can produce multiple car models on the same assembly line.

FMS allows them to quickly switch between models, adapting to changes in customer demand without stopping the production process, resulting in reduced lead time and increased efficiency.

Well done.

We now move to the second part of our lesson, Just-In-Time, sometimes abbreviated to JIT.

Just in time production is a method that factories use to produce only what is needed, when it is needed.

This means that materials, components, and products are manufactured only when necessary and in the exact quantity required.

Just-In-Time aims to reduce waste, lower costs, and increase efficiency by minimising goods produced.

Features of Just-In-Time include minimal stock levels, only necessary materials are ordered, reducing storage costs.

Quick response to demand.

Production starts when an order is placed, reducing overproduction.

Reduced lead time.

Materials arrive exactly when needed, cutting waiting times.

Number one, the order is received.

Number two, the materials arrive.

Number three, production begins.

And number four, delivery to the customer.

Here we have a check for understanding.

Which statement best describes Just-In-Time manufacturing? Is it A, materials are stockpiled in large quantities to prepare for future demand, or B, production only happens when there is an actual order, or C, factories produce as much as possible and store finished products, or D, products are manufactured months before they are needed? Pause the video and have a go.

Wonderful.

Let's check.

That's right.

It's B.

Production only happens when there is an actual order.

Using a fitted kitchen as an example, Just-In-Time can be explained as follows.

The order is received, a custom order starts the production process.

The materials arrive, the necessary materials are delivered only when needed.

Production begins.

Work starts as soon as materials arrive, reducing storage.

And delivery to the customer.

The units are shipped promptly after production, ensuring fast delivery.

The benefits of a Just-In-Time model include reduced waste.

Ordering materials at the exact time they're needed prevents wasted resources.

Short lead time.

The length of time from order to production completion is short because there are no delays in waiting for materials.

Cost savings.

Reduced spending on materials and no need for expensive storage space as materials are used as soon as they arrive.

Let's have another check for understanding.

What are the main advantages of Just-In-Time manufacturing? Is it A, it eliminates the need for suppliers, or B, it ensures large amounts of materials are always available, or C, it reduces waste and improves efficiency, or D, it decreases storage costs? Pause the video and have a go.

Well done.

Let's check.

That's right.

It's both C and D.

It reduces waste and improves efficiency and it decreases storage costs.

Well done.

Whilst there are benefits of a Just-In-Time model, there are also disadvantages.

These include suppliers.

There is a reliance on suppliers delivering materials and components on time.

Demand.

If the market demand is higher than expected, suppliers and manufacturers need to maintain production levels.

Downtime.

Machine breaks down can cause delays, especially if replacement parts are unavailable.

Let's have another check.

Which of the following is a potential challenge of Just-In-Time manufacturing? Is it A, companies must stockpile large amounts of raw materials, or B, Just-In-Time reduces reliance on suppliers, or C, Just-In-Time increases storage costs, or D production can stop if suppliers are late? Pause the video.

Great.

Let's check.

That's right.

It's D.

Production can stop if the suppliers are late.

Well done.

We now have task B.

Part one, how does Just-In-Time manufacturing reduce waste and why is this beneficial for businesses? And part two, explain one possible risk of using Just-In-Time and how a company might manage this risk.

Pause the video and have a go.

Wonderful.

Let's have a look at some of the answers you may have come up with.

For part one, you may have said, "Just-In-Time reduces waste by ensuring that only the necessary amount of materials and components are ordered and used.

This prevents overproduction, wasting resources, and unnecessary storage costs.

By minimising waste, businesses save money and operate more efficiently, improving their overall profitability." And part two, "One risk of Just-In-Time is that if suppliers are delayed, production can come to a halt, leading to missed deadlines and lost sales.

To manage this risk, companies can establish strong relationships with multiple suppliers, ensuring they have backup options in case of delays." Well done.

We now move to the third part of our lesson, lean manufacturing.

Lean manufacture is a production method that focuses on minimising waste whilst maintaining high quality and efficiency.

It was developed by Toyota, a Japanese car manufacturer, who wanted to reduce costs but improve their productivity.

The goal is to make production as lean as possible, meaning no extra waste.

After World War II, Toyota didn't have much money or space to manufacture their cars and needed a solution to continue production.

Let's have a check for understanding.

Which of the following is a key focus of lean manufacture? Is it A, ensuring extra materials are available, or B, producing as much as possible without considering demand, or C, reducing waste while maintaining efficiency and quality, or D, increasing storage space for extra stock? Pause the video.

Fantastic, let's check.

That's right.

It's C.

Reducing waste while maintaining efficiency and quality.

Well done.

Just-In-Time production forms a part of lean manufacture.

There are also seven types of waste that should be eliminated to make manufacturing cost-efficient.

Overproduction, weighting, transport, stock, movement, defects, and overprocessing.

The seven wastes can be eliminated as follows.

Overproduction.

Not manufacturing too much too soon.

Waiting.

Limit delays and downtime.

Transport.

Reduce travel of items between places.

Overprocessing.

Additional manufacturing processes are unnecessary.

Defects.

Don't make mistakes that need more time to fix.

Movement.

Have items nearby for workers to use when needed.

And stock.

Only order items when required.

Here we have a check for understanding.

Which of the following is not one of the seven wastes in lean manufacture? Is it A, overproduction, B, waiting, C, defects, or D, worker training? Pause the video.

Wonderful.

Let's check.

That's right, it's D.

Worker training is not one of the seven wastes in lean manufacture.

Well done.

Lean manufacture has several benefits for manufacturers.

It reduces costs.

Less waste means lower production expenses.

It improves quality.

More efficient processes lead to fewer defects.

It increases efficiency.

Time and resources are used effectively.

Enhances worker satisfaction.

A more organised, efficient workspace.

Here we have Task C.

Part one, what are two examples of waste in manufacturing and how does lean manufacture address them? And part two, why is reducing lead time important in lean manufacture? Explain with an example.

Pause the video.

Wonderful.

Let's have a look at some of the answers you may have come up with.

For part one, you may have said, "One example of waste is overproduction, where companies make more products than needed, leading to excess stock.

Lean manufacture reduces this by using Just-In-Time production, ensuring only necessary products are made.

Another example is defects, which require costly rework or disposal.

Lean manufacture focuses on reducing errors to prevent wasted materials and time." Well done.

And part two, "Reducing lead time is important because it allows products to be made and delivered faster, improving customer satisfaction and reducing storage costs.

For example, a smartphone manufacturer that reduces lead time can get new models to market more quickly.

This ensures they stay competitive and avoid excess stock of outdated models." Well done.

Here we have a summary of our learning today.

Flexible Manufacturing Systems, or FMS, allow quick adaptation to changes in product type or volume.

Just-In-Time, or JIT, minimises waste by producing only what's needed, when needed.

Lean manufacture eliminates waste to improve efficiency and quality.

These systems reduce downtime and lead times, boosting productivity.

I'm so pleased you could join me here today.

Well done.