Production & Manufacturing

Methods for eliminating waste, improving flow and optimizing factory efficiency.

• Andonalso andon cord, andon board
  A visual signaling system used on the factory floor to indicate a problem.
• Autonomationalso Jidoka
  Automation with a human touch, allowing equipment to stop automatically when a defect occurs.
• Bottleneck
  The slowest or most restrictive step in a production process that dictates the maximum overall output rate.
• Conservative
  Designed or estimated with a wide margin of safety to prevent failure.
• Digital twin
  A virtual replica of a physical asset or manufacturing process used for simulation and monitoring.
• ICT
  Innovation cycle time is the total duration required to take a new product from concept to full production.
• IL6S
  Integrated Lean Six Sigma is a continuous improvement methodology combining waste reduction with defect elimination.
• JITalso just-in-time
  Just-in-time, a production strategy that coordinates material delivery precisely with manufacturing schedules.
• Just-in-time
  A lean manufacturing model that aligns raw material orders directly with production schedules.
• PDAalso Production Data Acquisition
  The automated collection of real-time data from machines on the factory floor.
• Physical twin
  The actual, tangible machine or system that is modeled by a virtual replica.
• Scalable
  An engineering drawing or model that can be reliably measured to determine actual physical dimensions.
• Scale
  To determine the physical dimensions of a part by measuring its representation on an engineering drawing.
• Takt time
  The maximum allowable time to produce one unit in order to meet customer demand.
• VSUalso vertical start-up
  An abbreviation for vertical start-up, a method of launching a new production line at full capacity immediately.
• Waiting timealso queue time, idle time
  The period a product or batch sits idle before moving to the next step in the manufacturing process.

The physical and chemical techniques used to shape, cut and assemble raw materials.

• 3D print
  To manufacture a physical part by depositing material layer by layer from a digital model.
• AMalso additive manufacturing, 3D printing
  A production method that builds parts layer by layer from a digital model.
• Blowing agent
  A chemical or physical additive that generates gas to create foam or cellular structures in plastics and rubbers.
• CAD/CAM
  Computer-aided design and computer-aided manufacturing software used to design parts and generate machining instructions.
• Clamshell
  To bend or deform an extrusion die under high pressure. Shop talk
• Coextrusionalso coex
  The process of pressing two or more materials through a single die at the same time.
• Die-cut
  To shear shapes out of flat webs of low-strength materials using a custom steel tool.
• Die cutting
  A fabrication process that uses specialized machines and steel tools to stamp out uniform shapes from flat stock.
• Dwell
  A programmed pause in a machine cycle where a tool or component remains stationary under pressure or heat.
• Dwell time
  The duration a part remains inside a specific machine or process step.
• Expression
  A mechanical process that extracts liquid from a solid material by applying high pressure.
• FDM
  Fused deposition modeling is an additive manufacturing process that builds parts by extruding melted plastic.
• Pattalso pattern
  A shortened notation for the pattern used to cast or mold a part. Shop talk
• Platten
  To press or roll raw bulk material into flat, uniform sheets or plates. Shop talk
• Primer
  A preparatory coating applied to a bare part to ensure paint adhesion and prevent corrosion.
• Process
  A defined sequence of operations that transforms raw materials into a finished product.
• Roll-to-rollalso R2R
  A continuous processing method where a flexible material is unwound, treated, and rewound.
• Rotoliningalso rotational lining
  A manufacturing process that coats the interior of metal vessels with a continuous polymer layer by heating and rotating the part.
• Secondary
  An additional manufacturing operation performed on a part after the primary forming process is complete.
• Spherizealso spheroidize
  To force a material into a round or spherical shape during processing.

The presses, printers, beds and tools that physically manufacture the products.

• 3D printer
  A machine that builds solid objects layer by layer from a digital file.
• Bedalso machine bed, print bed
  The flat, stationary base of a machine tool or 3D printer where work is mounted.
• Buncheralso bunching machine
  A machine used in wire and cable manufacturing to twist multiple fine wire strands into a single flexible conductor.
• Die plate
  A heavy metal base that holds the cutting blades or extrusion profiles in a press.
• Hybrid
  A manufacturing system or machine that combines two distinct technologies to produce a part.
• Stripper plate
  A metal plate in a stamping die that pulls the raw material off the punch after a stroke.
• Tramper
  A mechanical press or tamper that compresses loose material into a denser form for processing or packaging.
• Ultrasonic bathalso ultrasonic cleaner, sonicator
  A tank of liquid that uses high-frequency sound waves to clean intricate parts or mix substances.

The strategies and schedules that align raw material delivery with factory output.

• Batch up
  To accumulate a specific quantity of work or materials before processing them together. Shop talk
• Bill of materials
  A comprehensive inventory of the raw materials, assemblies, and parts needed to manufacture a product.
• BoMalso bill of materials
  A bill of materials listing all the raw materials, sub-assemblies, and components needed to manufacture a final product.
• Buyeralso purchaser
  A procurement professional responsible for sourcing and purchasing the raw materials and components needed for production.
• CKDalso completely knocked-down
  A completely knocked-down kit containing all the unassembled parts required to build a final product.
• Demand-driven
  A manufacturing strategy where production schedules are dictated by actual customer orders rather than sales forecasts.
• JISalso just in sequence
  Just in sequence, an inventory strategy where parts arrive exactly in the order they will be assembled.
• Kitting
  The process of gathering separate but related parts into a single package before delivering them to the assembly line.
• Makespan
  The total duration required to complete a specific set of scheduled jobs.
• Product codealso SKU
  A unique alphanumeric string assigned to a specific manufactured item for tracking and inventory.
• QRalso QR code
  Quick response codes are two-dimensional barcodes used to track parts and access digital instructions.
• Verticalize
  To bring previously outsourced manufacturing stages or supply chain steps in-house.

The standards, inspections and specific flaws that determine if a part is acceptable.

• Clickability
  A material's ability to be die-cut cleanly without permanent deformation.
• Clickable
  Capable of being cleanly die-cut without losing shape.
• Cosmetic secondalso factory second, B-grade
  A fully functional product with a visual defect that is sold at a discount.
• CQV
  Commissioning, Qualification, and Validation of new equipment or facilities.
• Defect
  Any deviation from product specifications that impairs cosmetic appearance or functional performance.
• Escape
  A defective part that slips past all quality controls and leaves the factory. Shop talk
• Factory secondalso cosmetic second
  A product with minor cosmetic or manufacturing flaws that is sold at a discount.
• Fit and finish
  The overall physical alignment and surface quality of an assembled product.
• Industrial quality
  A standard of durability and performance designed to withstand heavy, continuous use in a factory setting.
• Initial reject
  A manufactured item that fails its first quality inspection but can still be salvaged.
• Molding flashalso flash, burr
  A thin layer of excess material forced out of a mold cavity at the parting line.
• MRBalso Material Review Board
  A cross-functional team that evaluates nonconforming materials to decide their fate.
• Overkillalso false reject, type I error
  The rejection of perfectly acceptable parts due to overly strict inspection standards. Shop talk
• Process tomography
  A non-invasive imaging technique used to visualize the internal dynamics of industrial operations.
• Racetracking
  A molding defect where liquid resin flows too quickly around the edges of a mold cavity.
• Rebuild
  The process of tearing down and repairing a returned or defective product to restore it to working condition.
• Rework
  The correction of defective, failed, or non-conforming items during the manufacturing process. Shop talk
• Slack fill
  The empty space inside a container that is not filled by the product.
• Underkillalso false accept, Type II error
  A quality control failure where defective parts are mistakenly passed as acceptable.

The individual pieces, subassemblies and hardware elements that make up a final product.

• Blisteralso blister pack
  A thermoformed plastic cavity used to house a product in retail packaging.
• Bootleg
  An unauthorized or counterfeit component that enters the supply chain and mimics genuine parts. Shop talk
• Calico
  A plain-woven unbleached cotton fabric used in industrial manufacturing for buffing wheels, backing, or prototyping.
• Commonality
  The degree to which different products share the same parts or subassemblies.
• Drop-in
  A replacement component designed to fit exactly into an existing system without requiring modifications.
• KDalso knockdown, knock-down
  Knockdown, a kit of manufactured parts shipped unassembled to be put together at a final destination.
• LH
  Left hand, a designation for parts designed specifically for the left side of an assembly.
• Model number
  A manufacturer code that identifies a specific design or version of a product.
• Part numberalso PN, P/N
  A specific alphanumeric code assigned to a distinct component or assembly.
• RH
  A designation for parts designed specifically for the right side of an assembly.
• Semi
  A partially finished component that requires further processing before it becomes a final product. Shop talk

The daily routines, shop floor shorthand and logistical realities of running a plant.

• Assembly line
  A manufacturing setup where a product moves sequentially through workstations.
• Churn
  The disruptive turnover of personnel, schedule changes, or excessive rework that degrades factory efficiency. Shop talk
• CMOalso contract manufacturer
  A contract manufacturing organization that produces goods for other companies.
• Cookie cutter
  Mass-produced using identical, unvarying templates. Shop talk
• Downtime
  A period when a machine or production line is halted and unable to produce goods.
• Drop
  A scheduled delivery of parts, materials, or finished goods to a specific location on the floor. Shop talk
• Interplant
  Occurring or moving between different manufacturing facilities within the same company.
• Learning curve
  The graphical representation of a worker or plant's increasing efficiency as they gain experience with a new process.
• Lights-out
  A manufacturing process or facility that operates fully autonomously without direct human presence.
• Makeupalso make-up, makeup material
  Fresh material added to a system to replace what was lost during the process.
• Output
  The total quantity of goods produced by a machine, line, or factory over a specific period.
• Production linealso assembly line, line
  A sequential arrangement of machines and workstations used to assemble or process goods.
• Pump outalso crank out
  To mass-produce items quickly and continuously at a high volume. Shop talk
• Reoperate
  The act of returning a piece of machinery or a production line back into active service after a shutdown.
• SFCalso shop floor control
  Shop floor control is the set of software and methods used to track, schedule and report on production progress.
• Smokestack industryalso heavy industry
  A traditional heavy manufacturing sector characterized by large facilities, high energy use and visible emissions.
• Superplantalso megafactory
  A massive, highly integrated manufacturing facility that consolidates multiple production stages under one roof.