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 i...Read More

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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field trips.
Chapter 4: Technologies
Manufacturing technology provides new and innovative tools that allow individual to change the
approach of manufacturing approach to reduce the overall costing. Presently, there are range of
technologies that can be applied to increase production and quality of product. It includes power-
driven manufacturing machinery, non- portable and automation technology that help in
improving quality and production. Advance manufacturing technologies have been implemented
such as medical pharmaceutical, aerospace and car manufacturing.
Structural Parts
Chassis Wheels Suspension Seat Assembly
This is the outer
portion of bike that
help in giving shape
and frame of electric
bike that eventually
help in reducing the
cost of electrical bike.
It is made up of
aluminum alloy, which
is lighter in weight and
cost effective.
The wheels are main
components of vehicles
that eventually
strengthen its mobility.
The spokes on the
wheels is comparatively
stronger than the thin
spokes on a traditional
bicycle.
Suspension helps in
giving confortable
ride to people, which
is a key element of
bike. It facilitates in
enhancing the
efficiency and
reliability of
electrical bike
positively.
The seat of
electrical vehicles
get assembles in a
systematic way to
assure that
respective
passengers get
comfortable ride.
All components of electrical bike are interconnected which is also a part of life cycle
methods that stated that material and techniques to manufacture this material is essential. This
approach facilitates in improving the life cycle of each component. On the contrary, there are
several issues and challenges in finding the right raw material and tool to form the right
products that gradually reduce the effectiveness of manufacture components. Reduce, reuse, and
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recycle of materials are three principles that have been implemented in the manufacturing
process to assure that maximum possible result can be gathered effectively (Deng et al. 2016).
This approach will help in reducing the adverse effect on environment by encouraging eco-
friendly materials positively in addition, utilization of available resources is important to
minimize the risk of failure. Just in Time (JIT) manufacturing process plays a significant role in
assessing the needs and demands of the consumers, which reduce the consumption of resources
in a manufacturing process.
4.1 Level of automation
In the era of digitalization, Industry 4.0 is a new milestone for the Consol in all sectors and is
marked the fourth industrial revolution. Advanced systems and software are being incorporated
to simplify communication with modern trends and facilities. Adapting new technology not only
gives a state of the art industry but achieves the desired goal by meeting the engagements.
Industry 4.0 is the end of traditional methods of application of various tools in industries and
switching to modern technology for changing the trend, making business modules, developing
better ways for the manufacturing process, to cost of labor, and stay ahead in business in terms of
competitiveness. From the advanced lab to well-managed warehouses, technology is playing a
vital role in every step in manufacturing firms. The trend of this new change is already
underway.
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. This reduces the
communication gap between the workforce and the management which helps in improving the
quality of work. Console is one of the leading manufacturers of glass bottles and international
clients spread worldwide. The company has a wide and established a loyal customer base.
Considering the advancement of technology in this firm, reports tend to show that with
advancement and modern skillset more people will be employed than losing jobs. More use of
robotics and IT features will increase job opportunities related to the IT and the database sector.
Console is committed to adapting to new technology advancement for delivering the best to its
customers by maintaining the highest quality and international standard. With multiple plants
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scattered all around the country, the company is capable of manufacturing glass products with
efficiency using complex processes. All glass bottles made by this company go under assurance
tests so that the quality complies with the global standards.
The day isn’t far way when robots will take over the physical labor done by the manpower. The
requirement in the other departments in the industry will increase as the demand for the new
skillsets will rise. Understanding how Industry is going to impact the business scenario one must
consider the effects that it is said to bring (Kafara et al. 2017). The sole goal of this revolution is
to increase productivity, production, and efficiency. By adopting this revolution industry as
Console will be able to increase productivity. With increased productivity, competitiveness with
also increase which no doubt will increase the job opportunities for the workforce to meet the
demand of the increasing market. For implementing Industry 4.0 successfully in industries,
companies must retain the existing workforce, develop and redesign the current strategies of the
firm, and design more strategies for future workforce planning. Automation solutions help from
designing, operation, to service. The application of advanced technology will help in increasing
the number of data scientists.
The advancement of technology with industry 4.0 will help in reframing and reshaping the
business and most importantly, the economic landscape. The digitalization with forecasted
strategies and improved business models will bring new opportunities for businesses for small
and medium-size. The four characteristics of Industry 4.0 that should be considered are:
 Vertical Networking: This system helps the logistics department to quickly understand
the change in the stock or the demand cycle. It helps to monitor the goods and resources
which are scattered everywhere.
 Horizontal integration: With the installation of real-time systems, horizontal integration
offers more flexibility and helps to provide a quicker response to issues and problems
(White et al. 2016). Businesses and as well as the customer can develop business
strategies and advanced models for cooperating.
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 Through engineering: The third characteristic of this revolution is through engineering
for the seamless operation through designing, development, and manufacturing. From the
production to the development of new products can be integrated with new engineering
synergies.
 Exponential technologies: This final characteristic helps in customization, cutting costs,
and flexibility. An exponential technology helps to increase flexibility in 3D printing,
quality assurance and provides advanced solutions for the supply chain.
Manufacturing companies that function worldwide harmonize new features to their existing IT
infrastructure. The demand is high in transforming the R&D department of the firms as Consol.
With cost-effective plants, the operating cost and product efficiency are reported to be high.
Deploying artificial intelligence will help to enhance the customer’s aftersale service and also
help in developing new services. Manufacturing industries are prone to frequent and dangerous
accidents. Introducing robots to carry out the activities that are risky for manpower will
definitely improve the quality of work and reduce the rate of accidents. Convectional
manufacturing of one product increases the price of the product high as a whole. Increasing the
units of production will cut down the per-unit cost. Investment can be recouped easily with mass
production to meet the demand. It is often impossible for human eyes to detect a tiny device that
hampers the quality of the output. Material engineering helps to detect even a tiniest of particles
(Faludi et al. 2015). Companies across all sectors have started relying on advanced technology,
automation, and robotics for enhancing product and workforce quality and optimize usage.
Companies need to ready to adapt to the change to create more opportunities to keep the business
safe from risk. This revolution is said to create big opportunities for the manufacturing firm’s
thereby boosting national income with fully boosted manpower management. A detailed
understanding of technology development and effective action related to it will definitely
contribute to the success of this revolution.
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Reference list
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2019]
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submicron particle emissions from a desktop 3D printer in the perspective of emission
reduction. Building and Environment, 104, pp.311-319.
Faludi, J., Bayley, C., Bhogal, S. and Iribarne, M., 2015. Comparing environmental impacts of
additive manufacturing vs traditional machining via life-cycle assessment. Rapid Prototyping
Journal, 21(1), pp.14-33.
Hadidi, H., Mailand, B., Sundermann, T., Johnson, E., Madireddy, G., Negahban, M., Delbreilh,
L. and Sealy, M., 2019. Low velocity impact of ABS after shot peening predefined layers during
additive manufacturing. Procedia Manufacturing, 34, pp.594-602.
Kafara, M., Süchting, M., Kemnitzer, J., Westermann, H.H. and Steinhilper, R., 2017.
Comparative life cycle assessment of conventional and additive manufacturing in mold core
making for CFRP production. Procedia Manufacturing, 8, pp.223-230.
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[Retrieved on 20 August 2019]
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Theberge, N. (2015). Danger zone: Men, masculinity and occupational health and safety in high
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Unnikrishnan, S., Iqbal, R., Singh, A., & Nimkar, I. M. (2015). Safety management practices in
small and medium enterprises in India. Safety and health at work, 6(1), 46-55.
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White, K. M., Jimmieson, N. L., Obst, P. L., Gee, P., Haneman, L., O’Brien-McInally, B., &
Cockshaw, W. (2016). Identifying safety beliefs among Australian electrical workers. Safety
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