CLICK HERE FOR INDEX PAGE

CONTINUOUS PRODUCTION

V. Ryan © 2005 - 2008

 

If a design is to be manufactured by continuous production (sometimes called LINE production) the factory / production line will operate continuously day and night. In this way thousands of the product can be manufactured. All machines are arranged on the factory floor so that the product is passed from machine to machine.

   

CASE STUDY - CAR BODY CONTINUOUS PRODUCTION

   

Take time to look at the body of a car. It is a complex piece of engineering. It is designed to be strong, light and to prevent rust even in the worst weather.

 

 

 

 

PDF FILE - CLICK HERE FOR PRINTABLE VERSION OF EXERCISE SHOWN BELOW

 

Question:

In each of the boxes of the flow chart shown below, write the key words representing each stage.

 

A design team will take months to design a car body. Prototypes will be made and tested to ensure that they can withstand extreme conditions like rough roads and to ensure that they will not rust. A car body is made from steel sheet. To help prevent it rust it is coated with zinc. Rolled steel sheet is ‘dipped’ into a number of zinc plating cells after it has been cleaned. This is a continuous process.

Once coated with zinc, the steel is pressed into panel shapes for various parts of a car body. The ‘press’ is very powerful and is kept behind safety cages so that people cannot get close. When a sheet of steel is pressed into a shape it is automatically moved out of the way. Panels are usually made up of two sides. They are joined by glue and then pressed together.

Robots are used to weld all the panels together. This is done with great precision and can be carried out twenty four hours a day. The robots do not get tired and only need maintenance occasionally. The car body is cleaned very carefully before it can be painted. At this stage the body is called ‘the body in white’. Without careful cleaning the paint will not take to the steel body properly and it will have a poor finish.

The underneath of the car body is sealed with a PVC sealant. This will prevent water getting into areas where it will eventually cause rust. Eventually, the entire underneath of the car is sealed. This helps prevent stones from the road causing damage. The car body is now ready for painting. The paint is applied with special sprays which coat the steel several times with primer paint, coloured paint and a clear finish.

Wax is injected into cavities which could hold rain water. The wax stops water entering and so the car body will not rust for many years
New models of car are tested on the test track. The aim is to make the car body rust. The test results of the tests are used by designers to improve the design so that rust will eventually be a thing of the past.

Question:
1. Explain the difference between continuous production and batch production.

2. Do employees who work in factories that batch produce items have different skills to those who work in factories that use continuous production techniques ?

   

 

   

CLICK HERE FOR PRODUCT DESIGN INDEX PAGE

 

CLICK HERE FOR RESISTANT MATERIALS INDEX PAGE

   
 
Google
 
Web www.technologystudent.com