Fig 5 shows a factory production line that manufactures aluminium drink cans. The factory produces 500,000 cans per day using continuous production. (a) Def...

(a) Continuous production is defined as:

1. A manufacturing system that operates 24 hours a day, 7 days a week, without stopping. [1]
2. The same product is made constantly on a dedicated, automated production line. The process runs continuously with raw materials entering at one end and finished products (500,000 cans per day in this case) emerging at the other. [1]

Continuous production is only economically viable for very high volumes of a single product, where the enormous set-up cost of the dedicated line is offset by the extremely low per-unit cost.

(b) Advantages and disadvantages of each scale of production:

[4 marks total]

(c) The role of quality control (QC) on this production line:

1. Quality control involves inspecting and testing products at specific stages during or after production to check whether they meet the design specification. [1]
2. Its purpose is to identify and reject any defective cans before they reach the customer, ensuring that only cans meeting the required standard for dimensions, pressure resistance, and surface finish are packaged and dispatched. [1]

(d)(i) Difference between quality control and quality assurance:

• Quality control (QC) involves checking finished products or samples against specifications to find and remove defects after they have occurred. It is reactive. [1]
• Quality assurance (QA) is a proactive system of procedures, standards and training built into every stage of the production process to prevent defects from occurring in the first place. QA covers the entire workflow, not just inspection points. [1]

(d)(ii) Two specific quality checks on finished drink cans:

1. Checking the can diameter is within the specified tolerance (66 mm ± 0.5 mm) using a go/no-go gauge or digital callipers. [1]
2. Pressure testing (or leak testing) to ensure the can does not leak, by pressurising it and checking for air escaping. [1]

(e)(i) CNC machining explained:

1. CNC (Computer Numerically Controlled) machining uses a computer program to control the movement and operation of a machine tool automatically. [1]
2. The program contains numerical data and coordinates that direct the tool paths, speeds, feeds and operations with high precision, eliminating the need for manual control of the machine. [1]

(e)(ii) Two advantages of CNC machines over manual machines in this factory:

1. Greater accuracy and repeatability than manual operation - every can blank is stamped to exactly the same dimensions, reducing reject rates. [1]
2. CNC machines can run continuously without operator fatigue, enabling 24-hour production to match the continuous production schedule. [1]

(f)(i) Just-in-time (JIT) manufacturing explained:

1. JIT is a manufacturing strategy where raw materials and components are delivered to the factory only when they are needed for immediate production, rather than being stockpiled in advance. [1]
2. This minimises the need for large storage areas/warehouses and reduces the capital tied up in holding raw material inventory. [1]

(f)(ii) One advantage and one disadvantage of JIT:

• Advantage: Lower storage costs and less waste from obsolete or deteriorating stock, freeing up factory floor space and reducing capital tied up in inventory. [1]
• Disadvantage: Any delay in supplier delivery immediately stops the production line. The system is vulnerable to supply chain disruptions (transport problems, supplier shortages), which can halt output entirely. [1]

(g) The purpose of using a jig in manufacturing:

1. A jig holds the workpiece (the can) in the correct position and orientation during the labelling stage. [1]
2. This ensures that every label is applied in exactly the same position on each can, giving consistency, accuracy and a professional appearance across the entire production run without the need for individual measurement or alignment by an operator. [1]

(h) Advantages and disadvantages of replacing manual workers with robotic arms for packaging:

• Advantage: Robots can work faster and more consistently than humans, operating 24/7 without breaks, fatigue, or shift changes, increasing packaging throughput and reducing errors. [1]
• Disadvantage: High initial capital cost for purchasing, installing and programming the robotic equipment, plus the need for skilled technicians for ongoing maintenance. Jobs are also lost for existing manual workers. [1]

(i) With a tolerance of 66 mm ± 0.5 mm:

• Maximum acceptable diameter = 66 + 0.5 = 66.5 mm
• Minimum acceptable diameter = 66 - 0.5 = 65.5 mm

[1] Any can with a diameter outside this range (less than 65.5 mm or greater than 66.5 mm) would be rejected by quality control.