Manufacturing processes and systems

One-off production: This involves the creation of a unique, bespoke item, usually by a skilled craftsman.
Batch production: This involves the manufacture of a small quantity of identical items. This method allows for economies of scale and can also allow for customisation.
Mass production: This is when thousands or even millions of identical products are manufactured. It’s a cost-effective method, but offers little scope for customisation.
Continuous production: This is typically used in industries where the product is a flow, such as water or electricity.

Machining processes: Understand different machining processes such as milling, drilling, turning and finishing processes.
Joining processes: Know various joining techniques including welding, soldering, brazing, screwing, nailing and gluing.
Forming processes: Be familiar with various forming methods such as moulding, casting, forging and pressing.
Heat treatment processes: Understand heat treatment processes such as annealing, hardening, tempering, and quenching, and their effects on different materials.
Finishing processes: This includes sanding, polishing, painting, and varnishing, for improved aesthetics and protection.
Use of jigs, fixtures and patterns: Understand the role these tools play in ensuring accuracy, repeatability and quality in a production process.

CNC machining: Computer Numerical Control (CNC) is a process used in the manufacturing sector that involves the use of computers to control machine tools.
Robotics: Realise the application of robotics in industries for tasks that are dangerous, monotonous or require precision.
Full automation: This is the use of automatic equipment in manufacture of goods. Recognise the impact on cost, speed, precision, and volume, and the implications for human labour.

Inspection and testing: Understand the role of regular inspection and testing in ensuring standards are maintained.
Tolerance levels: Know the importance of setting tolerance levels – a permissible limit or limits of variation in a physical dimension.
Feedback and feedforward control systems: Be familiar with how these systems are used to monitor and adjust the manufacturing process and to prevent errors before they occur.

Reducing waste: Lean manufacturing aims to cut down on waste while maintaining productivity. Waste could be in terms of time, raw materials or overproduction.
Just-in-time: Utilise this strategy that seeks to improve a business’ return on investment by reducing in-process inventory and associated carrying costs.

Workshop safety: Understand the general health and safety guidelines in a workshop setting, including use of personal protective equipment (PPE), safe use of tools and machinery, and first aid provision.
Material safety: Recognise the risks associated with different materials, such as toxicity, flammability, and the importance of proper handling and disposal.
Machine safety: Understand the potential dangers of machine use, including mechanical hazards, noise, vibration, heat, and the need for regular safety checks and maintenance.
Ergonomics: Understand how the design of products and tools affect user comfort, safety, and productivity.