© Folens 2009 Learning ladder You must: describe a range of different systems and ways they can be controlled. identify inputs, processes, and outputs, including those that are less obvious. You should: identify types of feedback and say how they impact on the progress of the system. You could: create your own system flow chart for the production of different products.

© Folens 2009 Introduction Outline the main points of making a t-shirt by making a human action plan! Each member of your group will be given part of a flow chart and you will be asked to put yourself in the correct order for manufacturing a t-shirt.

No © Folens 2009 Manufacturing a t-shirt Yes Sew shoulder seams Attach sleeves Attach collar Hems Final press and checks Match notches? Ease into position Straight stitches Yes Is it in position? Accurate 1.5cm? Print motif Yes Sew side seams Accurate 1.5cm? Cut fabrics No

© Folens 2009 Systems A system is a sequence of events or series of processes, materials and components that are transformed into products. The aim is usually to achieve a quick, reliable, efficient and cost- effective system. A system works by taking an input and transforming it into an output, e.g. using fabrics, components, energy, worker skill and transforming them through a variety of manufacturing processes into a textiles product. Note that systems don’t always have a visible end product, e.g. when an iron is turned on energy (input) is transformed into heat (output).

© Folens 2009 Different types of systems There is a range of different systems in industry. Many overlap or complement each other and when done efficiently all of them contribute to a successful business. Manufacturing/production Systems Computer /ICT PDM/CIM Quality assurance/ quality control Marketing /selling Safety Stock control

© Folens 2009 Controlling systems Production Managers control and monitor industrial systems. They might use Product Data Management and Computer Integrated Management systems to help them control and monitor systems. Production Managers will monitor a range of things, e.g. planning against Gantt charts and flow charts, stock control, production line and subassembly processes, how long production takes, how much waste is produced, costs, and so on. Most systems have to work with limits, e.g. money, time and it is the job of the Production Manager to try to maximize these. See the sample Gantt chart on the following slide.

© Folens 2009 Sample Gantt chart

© Folens 2009 Inputs, processes and outputs Inputs The things needed to start the system and begin the work. Processes Transforming the input into an output Outputs The end result What the client wants Your ideas Workers and skills Materials and components Money and time Energy Building/space Designing Cutting Planning Making Finishing Checking Anything that changes the input into an output Products Waste materials Paid workers Happy customers Profit Reputation/image Any other end result

© Folens 2009 Task 1: product analysis Identify the main inputs, processes and outputs for this bag. Inputs Processes Outputs

© Folens 2009 Feedback (1) Feedback tells us if the system is working properly and helps us make appropriate changes to improve it. Feedback can be physical, e.g. a visible mistake on a product, or an opinion or judgement. An open loop system works with no feedback. Closed loop systems use feedback to monitor and maintain the system, e.g. a pressing machine that regulates its own temperature or a quality controller that monitors accuracy.

Feedback (2) Action planning and the use of flow charts rely on the use of feedback to ensure the planning is accurate. A systems analysis examines the systems for waste and inefficiency, and uses feedback to try to make improvements. Success of a system is usually judged by looking at feedback on how efficiently inputs are transformed into outputs. © Folens 2009

Flow charts A flow chart is a system that plans a sequence of events to try to ensure accuracy and to avoid problems. It shows how the inputs are transformed into outputs by the manufacturing system and how feedback can be used to monitor and check the system. Standard symbols are used to produce a flow chart. Start/finish of the system Start/finish of the system Process/action Quality control/ decision making If the product fails the inspection at the quality control point,an arrow directs you back to the point on the flow chart where the correction needs to be made.

© Folens 2009 Task 2: flow chart Create a flow chart for the product in the photo. Can you also predict where in the system key risk assessment areas and where an industrial machine will be used?

© Folens 2009 Extension Explain why a manufacturer needs to produce a production plan before it begins to manufacture the item. What information would a manufacturer need to be able to produce an accurate production plan?