The use of computer systems.

Planning and control software

Planning and control software is used to organise complex manufacturing processes, schedules and resources.

Spreadsheets, charts and live production data can give managers an instant overview of factory schedules and operations.

Barcodes, RFID and EPOS

Barcodes and RFID (radio frequency identification) tags allow components, products and stock to be identified and tracked accurately.

EPOS (electronic point of sale) records product sales. Sales information can be used to monitor stock, trigger re-ordering and provide useful marketing data.

Linking EPOS data to production planning helps manufacturers respond to changes in demand.

PPC and the supply chain

Production planning and control (PPC) systems help to:

• plan and control production
• organise the availability of materials and components
• coordinate suppliers and customers
• schedule machines and skilled workers

An efficient supply-chain network is especially important for just-in-time (JIT) manufacture because materials and components must arrive when they are required rather than being held as large stocks.

Kanban and master production schedules

Kanban is a material/component monitoring and re-ordering system associated with JIT production. Traditional cards may be replaced by RFID tags and scanners.

A master production schedule (MPS) coordinates materials, production timings, machines and labour. It can trigger supplier orders and help keep the flow of components through a factory synchronised.

Modular / cell production

CNC machines, robots and AGVs (automated guided vehicles) can be organised into manufacturing cells.

Robots may load and unload CNC machines while AGVs transport materials and components between workstations and buffer zones. Cells can be reprogrammed to manufacture different products, improving flexibility.

JIT and lean production

JIT manufactures products and receives components when they are needed, reducing stockholding, storage space, damage and the risk of components becoming obsolete.

Lean production aims to remove waste from manufacturing. It can involve continuous improvement (kaizen), visual/electronic stock control, reliable suppliers, efficient factory layouts and a right-first-time approach.

Limitation: JIT depends heavily on reliable suppliers and transport; disruption can stop production quickly because little reserve stock is held.

Flexible manufacturing systems and QRM

FMS (flexible manufacturing systems) use programmable CNC and robot-based cells so production can switch between different products or variants.

QRM (quick response manufacturing) focuses on reducing lead time for lower-volume or customised products. CAD, rapid prototyping, flexible cells and multi-skilled workers can shorten the transition from design to manufacture.

SMED (single-minute exchange of dies) reduces machine downtime by making die or mould changes very quick, often using quick-release and interchangeable elements.

CIM

Computer integrated manufacture (CIM) links computer-controlled stages of bringing a product to market. This can include CAD, rapid prototyping, material and stock monitoring, CAM, automated storage/warehousing and EPOS sales information.

Integration allows information to move between design, manufacture, storage, distribution and sales rather than each area operating separately.

Standardised components

Standardised components are manufactured to common, interchangeable standards. They improve compatibility, replacement and assembly.

Examples: ISO-standard screw threads, bolts, light bulbs and standard fittings.

Bought-in components

Bought-in components are sourced from specialist external suppliers rather than manufactured in-house.

• bulk purchasing can reduce unit cost
• specialist suppliers provide equipment and expertise
• greater consistency can be achieved
• supplier CAD files can be incorporated directly into product designs
• the manufacturer avoids investing in facilities to make every component

Examples: tyres, batteries, fuses, motors, memory cards and printer cartridges.

Sub-assemblies

A sub-assembly is a self-contained group of components manufactured separately and then incorporated into the final product. This can simplify and speed up final assembly because different parts of a product can be produced at the same time.

Example: bicycle manufacturers may produce their own frame while using bought-in gear, chain and braking sub-assemblies from specialist suppliers.