Manufacturing Systems And Processes

Question 1

ASRA

Answer 1

Automated storage and retrieval systems

Question 2

What is ASRA

Answer 2

ASRA are computer-controlled systems used to automatically place and retrieve goods or materials from defined storage locations with precision, speed, and efficiency.
They are widely used in warehousing, manufacturing, distribution, and logistics to optimise inventory handling, reduce labor costs, and improve accuracy.

Question 3

Advantages of ASRA

Answer 3

• Reduced labor costs (less need for manual picking)
• Improved accuracy and inventory control
• Faster storage/retrieval times
• Better space utilisation (taller, denser storage)
• Increased safety (fewer human interactions with machinery)

Question 4

Disadvantages of ASRA

Answer 4

• High Initial Cost (Expensive to buy and install the system).
• Complex Setup (Requires careful planning and skilled workers to set up and run).
• Maintenance Needs (Machines need regular maintenance to avoid breakdowns).
• Limited Flexibility (Hard to quickly change layout or process once installed).
• Downtime Risk (If the system fails, it can stop the whole operation).
• Training Required (Staff need training to operate and manage the system).
• Not Ideal for All Products (May not work well for very large, heavy, or oddly shaped items).

Question 5

AGV

Answer 5

Automated guided vehicles

Question 6

What is AGV

Answer 6

AGV are driverless, computer-controlled vehicles used to transport materials in warehouses, factories, and distribution centres without human input.
They follow predefined paths using sensors, magnets, lasers, or cameras.

Question 7

Advantages of AGV

Answer 7

• Reduce labor costs (less need for manual costs)
• Improve safety (fewer human interactions)
• Increase efficiency and accuracy
• Run 24/7 with minimal supervision

Question 8

Disadvantages of AGV

Answer 8

• High setup cost
• Limited flexibility (fixed paths)
• Not ideal in very dynamic environments
• Requires maintenance and tech support

Question 9

FMS

Answer 9

Flexible manufacturing systems

Question 10

What is FMS

Answer 10

A Flexible Manufacturing System (FMS) is a type of production system designed to easily adapt to changes in the type of products being made, the quantity of production and the sequence of operations.
It combines automated machines, material handling systems, and computer control to produce different products with minimal manual setup.

Question 11

Advantages of FMS

Answer 11

• Produces a variety of products on the same system
• Reduces production time and manual labor
• Quickly responds to market changes or custom orders
• Improves use of equipment and reduces waste

Question 12

Disadvantages of FMS

Answer 12

• Produces a variety of products on the same system
• Reduces production time and manual labor
• Quickly responds to market changes or custom orders
• Improves use of equipment and reduces waste

Question 13

QRM

Answer 13

Quick response manufacturing

Question 14

What is QRM

Answer 14

Quick Response Manufacturing (QRM) is a business strategy focused on reducing lead times in all parts of the manufacturing and supply process — from order to delivery.
Help companies respond quickly to customer demands, especially in custom, low-volume, or high-mix production environments.

Question 15

ADAVNTAGES of QRM

Answer 15

• Reduces lead times
• Boosts customer satisfaction
• Lowers inventory and holding costs
• Increases flexibility and responsiveness
• Enhances quality

Question 16

Disadvantages of QRM

Answer 16

• High initial investment
• Cultural resistance to change
• Less effective in high-volume environments
• Requires strong coordination
• May cause short-term disruption

Question 17

PDM

Answer 17

Product data management

Question 18

What is PDM

Answer 18

is a system or process used to manage all the data and information related to a product throughout its lifecycle.

Question 19

Advantages of PDM

Answer 19

• Eliminates data silos and duplication
• Increases collaboration between departments
• Reduces errors and rework caused by using outdated data
• Shortens product development cycles
• Ensures regulatory and compliance traceability

Question 20

Disadvantages of PDM

Answer 20

• High initial setup cost
• Requires training and change management
• Integration with existing systems can be complex
• May slow down work if not properly configured

Question 21

ERP

Answer 21

Enterprise resource planning

Question 22

What is ERP

Answer 22

is a type of software that helps organisations manage and integrate their core business processes in one centralised system.

Question 23

ADAVNTAGES of ERP

Answer 23

• Saves Time and Effort (Automates tasks so employees don’t have to do everything manually)
• All Data in One Place (Stores information from all departments together, so it’s easy to find and use)
• Better Decisions (Gives real-time information and reports to help managers make smart choices)
• Improves Teamwork (Departments share information easily, so everyone works better together)
• Grows with Your Business (Can add new features as the company gets bigger)
• Follows Rules (Helps companies meet laws and regulations)
• Better Customer Service (Access to customer info helps serve them faster and better)
• Saves Money Over Time (Reduces costs by making work more efficient and cutting waste)
• Manages Inventory Well

Question 24

Disadvantages of ERP

Answer 24

• Very expensive (costs a lot of money to buy and set up)
• Takes time (setup and training can take months)
• Hard to learn
• People may resist (some workers don’t like changes)
• Not easy to customise
• Can fail (if done wrong the whole project can go wrong)
• Security risk (important data can be stolen)

Question 25

Concurrent manufacturing

Answer 25

• Is a method of producing goods where different stages of production are done in parallel, rather than a linear sequence • Uses simultaneous operations of product design, process planning and production activities. • The primary objective of concurrent manufacturing is to reduce time to market, improve product quality and achieve greater efficiency to maintain a competitive advantage.