Manufacturing Audit
A guide to making processes and procedures.
The Processes of Making
Generally
Before the process of making can take place, the maker requires
a detailed plan of the object to make, a list of materials and
a step by step plan showing in what order things should be done.
Doing this has two advantages- the information can be used to
get the resources ready at the time that they are needed and parts
can be identified from the drawing and checked for marking out
or what is to be done to them.
Selecting and checking
The material that is to be used needs to be selected for its suitability. The weight that it has to take or the finish that is required can determine whether or not one piece is suitable or should be replaced. Material size would require checking. A lot of preparation can be avoided if, at the design stage, the use of standard or stock sizes is considered.
Marking Out and Coding
One of the most crucial stages of making is to ensure that materials are accurately marked. It is a pointless exercise to continue with cutting or processing the material if the marking out is wrong. There is a craft saying; mark twice, cut once.
Jigs or Patterns are prepared and marked out at this stage.
The code marked on each piece is a helpful method of identifying each part and its relationship to others. Use the correct tools for marking. Avoid pen where possible as this may permanently stain some material surfaces. Ensure that each component has your name on it or is labelled. Small components can be sealed in a polythene bag. Apply a light coat of oil if there are ferrous metals included.
Processes of manufacture
Try to identify all materials that require the same process and organise your working area to carry that process out. If one part requires sawing then identify all the parts that need the same process and do them at the same time. If making is done in this way it ensures a more economic use of time and resources. It will follow that work surfaces do not get cluttered with unnecessary equipment and will lead to an improved and safe working environment.
When repetitive tasks are to be carried out, use jigs, patterns or measuring devices to check the quality and accuracy of the parts being made. If checks are made on a regular basis it will give confidence to things fitting properly rather than having to keep trying parts together.
The plan that you have produced before making will allow you to concentrate upon the manufacturing processes and avoid problems of sequence.
Working with other students there will be times when, because some machines and tools are in short supply, you could be kept waiting. Develop a plan that makes allowances for such circumstances and plan alternatives to overcome such difficulties. Specific time other than in lessons will be made available on a regular basis to accommodate reasonable needs and requests.
During the process of manufacturing, it is important to ensure that your work pieces are not lost, mislaid or suffer damage. Take personal responsibility for safely storing your work. If parts need to be left out in the workshop overnight then return to the workshop the following morning to ensure that they are put away safely in readiness for the next lesson.
Finishes
Finishing processes can be time consuming. Watching glue, paint or varnish dry is a comment often made to indicate poor organisation. Try to anticipate these time consuming processes.
Preparation of material to receive its finish is a crucial stage of making. The visual impression of a product is very important and not hard to achieve if carried out correctly. This process is not to be seen as only needing to be carried out at the point where the product is completed. Some areas that would be difficult to finish properly once assembled should have the finish applied beforehand and care taken to protect those areas. Those awkward corners can be more successfully finished before they are put together.
Cleanliness when finishing is important. Putting a final finish on your work when the environment is dusty will just cause further work.
Testing
Adequate time must be allowed for the product to be tested (against the specification). Some tests may be needed whilst the work is in progress. Remember to make a diary of events, difficulties, how they were overcome, changes to plans, recording of tests and present them in your coursework folder presentation. Products are not only tested by consumers, but also during the process of design and manufacture.
Evaluation
Evaluations are mainly based upon the success of the final product and the processes that lead up to its final completion.
The specification set at the early stages of identifying the
need is compared to what has been made. An evaluation should also
contain comments relating to the time when it was being made and
whether procedures, quality assurance, processes and organisation
could be improved.
Guidance sheets and resources for carrying out an evaluation are
available from staff.
