Analysis of Manufacturing Processes and Automation at Consol Company

This project report analyzes the manufacturing processes of Consol Company, focusing on its production of glass bottles. It examines the design process, process flow, and various manufacturing techniques, including polymer, welding, powder metallurgy, and hot metal forming. The report delves into the machines used, work analysis, and the levels of automation implemented by the company, including its approach to Industry 4.0. Furthermore, it explores design considerations, material handling, and costing procedures. The project also includes an analysis of potential workplace injuries and safety measures. The report highlights the company's adherence to international manufacturing standards and its efforts to efficiently utilize raw materials and resources. The project also explores the integration of technologies to enhance quality and productivity, and improve the financial condition of the company.

ENGINEERING MANUFACTURING TECHNOLOGY
STUDENT NAME:
STUDENT ID:
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Summary
The purpose of this report is to examine different technologies related to manufacturing so that
available raw material and resources can be utilized efficiently. Industry 4.0 is looking to
transform the picture of the industrial workforce. Internet of things (IoT) has made
communication easy and fast. It helps people to connect easily with each other. Management can
easily connect with workers from any place at any time. A range of products has been produced
under Consol’s manufacturing plant through different manufacturing process such a polymer,
welding, powder metallurgy and hot meal forming that facilitate in giving strength to the final
product. International manufacturing standard has been critically followed that helps in meeting
needs and demands of the consumers positively.
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Acknowledgement
The research sheds light on different manufacturing process adopted by CONSOL to
manufacture range of glass bottle for drinking. I want to thank my professor and colleague for
supporting me in completing the research within strict deadline. Apart from professor, I want to
thank my family and friends who always support me to conduct this research and motivates me
to tackle potential risk and challenges. I would like to take this opportunity to thank my
supervisor ----------------------- for the constant guidance and support provided to me during the
process of this research. It would not be justified if I did not thank my academic guides for their
important and valuable assistance and encouragement throughout the research process. I would
also like to thank my friends who had provided me with help and encouragement for collecting
primary data and valuable resources. Finally, I would like to thank the professionals from the
retail industry who have participated in the research survey and provided with valuable inputs
into the subject
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Table of Contents
Chapter 1: Introduction....................................................................................................................5
Chapter 2: Manufacturing process...................................................................................................5
2.1 Design process.......................................................................................................................5
2.2 Process flow...........................................................................................................................5
2.3 Manufacturing process...........................................................................................................8
2.4 Machine used.........................................................................................................................9
Chapter 3: Work Analysis.............................................................................................................11
Chapter 4: Technologies................................................................................................................13
4.1 Level of automation.............................................................................................................14
Reference list.................................................................................................................................17
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Chapter 1: Introduction
Engineering manufacturing technologies is an important to improve the quality and productivity
of the products such as joining in manufacturing, molding and forming manufacturing. The
purpose of this report is to examine different technologies related to manufacturing so that
available raw material and resources can be utilized efficiently. Consol company has been
selected that help in understanding the process of manufacturing along with relevant tools and
techniques for finite product. The company process glass bottle for drinking water, which is of
different category such as pharmaceutical, spirit and food. The report focuses on different type of
different type of manufacturing process that facilitates in developing quality bottle that
eventually upsurge financial condition of the company.
Chapter 2: Manufacturing process
2.1 Design process
Design process is considered as one of the essential aspects of manufacturing in which desired
products have been designed, which is called Design for Manufacturing (DFM). In this process,
the thickness and texture of glass are measured vividly to assure that each task and activity can
be accomplished within strict deadline. A range of features and components have been closely
monitored including wall thickness, simple transition and texture. Hence, design process helps in
determining all respective issues and challenges that may occurred during manufacturing glass.
Figure 1: Manufacturing flow diagram
2.2 Process flow
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RAW MATERIAL
LaminateDie Cut
Coating and
slitting
Adhesive

Process flow in manufacturing process Description
Flow of raw materials In this step, project manager monitors all the
requisite raw material based on respective
standard to utilize the available resources in a
systematic way. Different types and size of
containers are used for transportation to
understand the quantity and grade of raw
material that reduce the risk of failure
positively.
Work in process flow A range of products has been produced under
Consol’s manufacturing plant through different
manufacturing process such a polymer,
welding, powder metallurgy and hot meal
forming that facilitate in giving strength to the
final product. International manufacturing
standard has been critically followed that helps
in meeting needs and demands of the
consumers positively.
Flow of finished goods The final products have been transferred with
the help of conveyors forklifts and carts to
deliver the order on time. It offers a variety of
high- quality glass packaging solution that
supports company in up surging its financial
and economic condition.
Operator flow There are several departments and team
members under manufacturing process that
facilitates in enhancing superior supply chain
management and optimization. It includes
comprehensive bottle service and a glass
analytical laboratory. The technical team are
available 24 hours a day for glass filling line
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support, providing critical spares, overhaul and
glass equipment to ensure that all the vital
information can be shared hierarchy.
Machine flow Different machines have been used to
manufacture plastic such as beveling machine,
plastic glass making, polishing wheel and
forming machine that are majorly used to
strengthen plastic quality.
Engineering flow Hot meal forming and cold metal forming
engineering flows have been used for
manufacturing pressure sensitive labeling and
applied ceramic labeling. The major reason to
use different engineering process is to check
the quality of glass.
2.3 Manufacturing process
Manufacturing process can be defined as the process of transforming raw material into finished
product with the help of proper tools and techniques so that maximum positive result. It is
essential of developing short- term and long term goal for different manufacturing components to
accomplish the manufacturing within strict timeline (Hadidi et al. 2019). There are ranges of
manufacturing processes that have been used in developing respective products including
machining manufacturing, joining in manufacturing, molding and forming manufacturing.
Products Short- term Long- term
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Structural parts The associate employees
are needed to give proper
training about utilization
of resources and
techniques to make sure
each task can be completed
within fixed time scale
Advanced equipment’s
and technologies are
needed to implement
within manufacturing
process to make sure
maximum benefit can be
gathered positively
Electrical parts The manufactured
components are required to
validate properly to avoid
risk of failure.
All electrical safety
measures are needed to
consider ensuring the
quality of the every
electrical component.
Miscellaneous parts JIT manufacturing process
is required to implement
that facilitates in assessing
the needs and demands of
the consumers positively.
This approach helps in
enhancing feasibility and
reliability of
manufacturing process.
A legitimate policies and
regulations are needed to
implement within
organization for
sustainable development
through elimination
potential issues and
challenges vigilantly.
2.4 Machine used
Product life cycle plays a significant role in improving the reliability and feasibility of the
product by utilizing the available resources and raw material systematically. The possibility of
each electrical component can be determined through four stages of the product life cycle, which
have been listed below:
Introduction
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Introduction phase asserted that promotion and advertisement are essential to gain maximum
benefit through selling the products. It enforced company to invest capital in promotional
activities to make product familiar to the consumers. Also, the cost of the products needs to be
high to compete with top electrical companies.
Growth
This is a crucial phase of product where the growth of products can be determined through
selling performance that shows the success of the promotional activity. In this stage, the
company starts gaining profit in lesser available resources positively. The principle of the
circular economy is essential to implement in this phase to make sure the maximum possible
result can be gathered expertly.
Maturity
Maturity stage of product life cycle asserted that the company needs to focus on cost and
volume of products to make sure maximum possible result can be gathered positively. In this
stage, sales volume is maxed out at a particular saturation pointy that demand for some
innovative ideas and advanced technologies in order to meet the needs and requirements of the
consumers positively.
Decline
Decline stage of a product implies that sales performance may reduce due to the change in the
demands of the consumers for sustainable development. It stated that the needs and requirements
of the consumers are required for analysis to develop an effective strategy for a maximum
possible result.
Hence, the product life cycle is required to consider the success of products from manufacturing
to sales of products. Each stage of the product life cycle stated that available resources need to
use in a systematic way that increases the financial performance of the company positively.
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Figure 2: Future sustainable System
(Source: Created By the Researcher)
Proper training needs to be provided to all the associate employees so that they can
accomplish the task with appropriate techniques and system. On the contrary, workplace ethic
helps a company in encouraging employees to improve the sustainability and flexibility of the
project. Electric vehicles can able to integrate different business operations that help in assessing
the needs and reliability of the project vigilantly (Kafara et al. 2017). This approach enables a
company to monitoring all kinds of activities within an organization that eventually reduce
potential risks. The working culture within the organization gets automatically changed through
these approaches and the National Electric Code that support the company in achieving
sustainable development. Therefore, it can be stated that this researches required in conducting
for sustainable development.
Chapter 3: Work Analysis
In manufacturing process, the chance of accident and cause of death is high that demand for
proper safety and tools to make sure associate team member can able to perform their task
vigilantly. Consol adheres to international standard of manufacturing to make sure raw material
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Raw
material
Manufact
uring
DistributionUse
End of life

can be utilized in an effective way. The role of employer under Consol manufacturing workplace
has been clearly defined that helps in completing the task within limited period of time.
Role of employer
Project Sponsor
Project Sponsor Role
Martin Mathews A project sponsor plays a crucial role in a project management
task. He looks after the ongoing task of the project, resources,
and capital assigned for the project work.
Project team members
Project Team Role
Roselin Parker Responsible for assigning tasks to each individual and takes
the report from the team member who looks after the tasks
assigned.
Sarah Parker Responsible for looking after the data collection related to the
assignment.
John Smith Responsible for looking after the task assigned to each team
member on a day to day basis and maintain the work report.
Amelia Sampayo Responsible for creating study material related to the project.
Thomas Alberto Responsible for data mining and validating the data for the
final write up.
Rose Cook Responsible for collecting information from on-site locations,
converse with people related to the project.
Tim Cook Responsible for creating reports from the data gathered from
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