Systems and production methods

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A system is a set of components arranged to carry out a particu ar function. A systems ha!e inputs" processes and outputs# often they $i ha!e feed%ac& as $e . Systems for manufacturing graphics products re'uire p anning# system f o$charts are usefu for this. (hey a so need to %e contro ed" and these system contro s can %e !isua " mechanica or e ectronic de!ices. Production systems a so need to %e chec&ed for 'ua ity ) a procedure ca ed 'ua ity contro . *raphics products manufacture can %e either one)off" %atch" mass) produced or continuous)f o$" depending on the sca e of production. +omputer)aided manufacture ,+A-. is $idespread in a production. &inds of graphics

Systems
A system is a set of components arranged to carry out a particular function. Systems may include mechanical, electrical or electronic components. The block diagram below represents a system for producing a batch of leaflets.

/nput is what goes into the system - the raw materials. In a music system the input usually comes from a CD player or radio tuner. Process is the shaping and forming of the materials, or the e change of information needed to effect the output. In a music system it is the amplifier that does the processing.

0utput is what comes out of the system - the finished product. In a music system, the speakers take care of the output. System feed%ac&
!ost systems ha"e a fourth element - feed%ac& - which is simply a way of changing the input or process as a result of what happens at the output. In a music system, feedback is a human response to the output from the speakers# if the music is too loud, or the radio tuned to the wrong station, the user will reduce the "olume or retune the radio. In a system diagram feedback is shown like this#

An e ample of feedback in a production system is checking that the product meets the specification, and ad$usting the process to make sure it does. !any systems ha"e an automatic type of feedback, where feedback from one part of the system switches another part of the system on or off. This sort of system is called a c osed system.

P anning systems

System f o$charts %hen planning a production system you need to work out how the different elements of the system fit together, with each part in the right order. A flow chart is a good way of doing this. The one below shows how to organise the production of a school newsletter.

-anufacturing systems
Any large-scale production system of the kind you would find in manufacturing is likely to include the following processes#

Storage of raw materials, bought-in components, sub-assemblies and part finished products. /nspection of bought-in components to make sure they are of the re&uired &uality' Inspection of part-finished products to ensure they meet specifications' artwork. Inspection has to be done at all the crucial points in the production process.

0peration is the processes of manufacturing. -o!ement of raw materials, part-finished products and complete products.

(se these symbols when drawing a flowchart for large-scale production system

System contro s

Systems need to be controlled if they are to continue functioning the way they were designed to do.

1isua contro s
Controls can be simple "isual aids for the designer. Two e amples are registration marks and colour bars. 2egistration mar&s are used to make sure that colour printing lines up, because the "arious colours must line up with each other. )egistration marks are usually shown in a cross shape. Sometimes work that is to be printed has co our) separated art$or&, where the artwork for each colour is on a separate sheet.+o our %ars are standard bars of colour with blocks of each colour printed. This is done to show the strength and e"enness of the ink used and that the registration of the colours is correct.

-echanica 3 e ectronic contro s

The table lists mechanical or electronic e&uipment used for control and feedback in graphic production.
Equipment Rotary paper trimmer Type of systemType of control Mechanical Speed of movement of cutting blade; cutting fence can be set to required distance, which allows repetition Example of feedback Paper cut is ragged: blade may need sharpening/replacing; cut fewer sheets Wrong si e: reset fence

Computer printer

!lectronic or "umber of copies; paper type; quality of "umber of copies wrong: reset on computer mechanical printout #epetition through repeat $uality of print poor: change paper or in% copies cartridge !lectronic or Si e of copy/enlarge/reduce; number of mechanical copies made; type of paper or other materials; quality of printout; copy too dar%/light Si e is wrong: reset si e "umber of copies wrong: reset number required $uality of print poor: change paper or toner cartridge &ontrast wrong: ad'ust contrast control

Photocopier

CAM 2D card !inyl cutter C"C #D millin$ machine

!lectronic or Speed/depth of cut; pressure on cutter; &utting incorrect: ad'ust speed/depth and/or mechanical order of cutting #epetition though pressure through software or hardware controls repeating process (rder wrong: reset though software controls !lectronic or Speed/depth of cut; rotational speed of &utting incorrect: ad'ust speed/depth, through mechanical cutter; type/si e of cutting tool; order of software or hardware controls(rder wrong: cutting#epetition though repeating reset though software controls process

4ua ity contro

*uality control is a specialised type of system control designed to check that a product meets the design specification and is of the prescribed &uality. +efore making a product, the designer should decide what &uality checks need to be done, and at what stage in the making process they should be carried out. A high-&uality product will#

meet the specification do what it is supposed to do be free of defects satisfy customer re&uirements
*uality control checklist#

check against the specification# does the product meet all aspects of the specification, is the te t accurate, spelt correctly, with correct grammar and layout, ha"e the correct shades of colours been used, are the registration marks correct and do they line up, ha"e correct desktop publishing -DT./ layout templates been used, check measurements# are they within the tolerances specified, for products such as pop-up books, check the cut and fit of different parts# do they fit accurately and neatly without gaps, for products such as pop-up books and cards, check to see if the product works properly and as intended# do parts mo"e as re&uired,

Production methods
There are four main types of production system used in manufacturing graphic products, each one suitable for a different scale of production.

0ne)off production is when only one of the product is made. It is labour-intensi"e, because e"ery product is different. 0ne-off graphic products might include a presentation book as a sou"enir of a special e"ent, or a model of a theatre set.

5atch production is when a set &uantity of the product is made. It may also use a lot of labour, but $igs and templates are used to aid production. 0ften the machines can be easily changed to produce a batch of a different product. +atch-produced graphic products include programmes for a play or concert, or posters to ad"ertise a play or concert.

-ass production is when a "ery large number of the product is made, usually on a production line - but the process cannot be continuous because the product regularly changes. 1 amples of mass-produced graphic products are newspapers and maga2ines.

+ontinuous)f o$ production is when many thousands of products are made. The difference between this and mass production is that the production line is kept running 34 hours a day, se"en days a week, to eliminate the e pense of stopping and restarting the production process. The process is often automated and few workers are re&uired. Continuous-flow production is used for graphics products which sell "ery large numbers throughout the year, and do not need to be fre&uently changed - such as cereal packaging.

/+( in industry
Information and communications technology is widely used in manufacturing graphics products. Its benefits are that#

it makes it easy to produce accurate, comple , standardised drawings It allows comple shapes to be made with ease and precision it enables changes to be made &uickly and easily, and it greatly simplifies batch or mass production +omputer aided manufacturing ,+A-.
CA! machines are good for batch or mass production, and they are also useful for one-off products that are complicated to make. There are two types of CA! machine#

26 +A- machines
.lotter5cutters can be used either for cutting of card and "inyl, or -by replacing the blade with a pen/ to produce drawings and lettering prior to cutting. Cutter5printers are more comple CA! machines which allow full-colour printing before cutting is done.

36 +A- machines
These are mainly used for cutting plastics, hard wa , soft metals and wood-based materials such as !D6. They are particularly useful for making prototype models and moulds for "acuum-forming. Some of these machines can ha"e a scanner head fitted in place of the cutting tool, allowing 7D scanning to be done. No$ try a (est 5ite

(est 5ite
1. (he four main e ements of a system that p ans manufacturing are: Design, inspection, operation and mo"ement Design, storage, inspection and operation Storage, inspection, operation and planning Storage, inspection, operation and mo"ement

2. A 'ua ity graphics product $i : !eet the specification Do what it is supposed to do

8ot ha"e defects Satisfy customers All of the abo"e

3. 7hich is the most a%our)intensi!e form of production8 Continuous-flow production +atch production 0ne-off production !ass production

4. Nationa ne$spapers and maga9ines are i&e y to %e produced using $hich form of production8 Continuous-flow production +atch production 0ne-off production !ass production

5. Programmes for a p ay or concert and the posters that ad!ertise it are i&e y to %e produced using $hich form of production8 Continuous-flow production +atch production 0ne-off production !ass production

6. (he pac&aging for a %est)se ing %rea&fast cerea is i&e y to %e produced using $hich form of production8 Continuous-flow production +atch production 0ne-off production !ass production

:. 7hich of the fo o$ing is N0( an ad!antage of using /+( $hen designing and ma&ing graphic products8

Difficult drawings can be produced easily and accurately. Comple shapes can be made easily and accurately. If a computer crashes, work might be lost. Changes can be made &uickly and easily. The product can easily be batch or mass produced.