Key Terms Manufacturing ICT Robotics Industry Continuous Bespoke Production Line Volume

Scales of Manufacture Mass Production Quantity of 10,000+ Cars Electronic goods – phones, kitchen electrical Flat-pack furniture Batch Production Quantity low 100’s, maybe low 1000’s Pottery Bread Furniture (sofas) One-Off Production (Bespoke) Quantity of 1 Jewellery Made to measure suit Specialist equipment for elite sportsman

Bespoke Production One-off production is where you make a single product. This is often made to an individual design for one customer, such as ‘custom-made’ furniture. One-off products are often made by hand by skilled craftsmen. One-off products are normally expensive, because of the amount of time taken to make them. Summary: Products are highly specialised, custom built High level of skill required Costs extremely high Can reliability ensure very high quality of build and finish

Batch Production Batch production makes small quantities, from a few hundred to a few thousand, depending on the type of product. Each batch of products will have the same design. However, different batches might be customised in some way. For example, the same design might be made in a different colour or size. Batch production normally uses machine tools, and costs less to make products than with one-off manufacture, because you don’t have to spend as much time setting up machines to make each product. Summary: Products are produced intermittently – with gaps between production Relatively small volume produced Uses some industrial methods, and makes good use of CAD/CAM Responds to demand from consumer Systems are often flexible (make more than one version or type)

Mass Production Mass production makes very large quantities of the same product. Most things that you use every day are mass produced. Mass production is usually carried out on an assembly line. This is a collection of machines, often robots, that are just used to make that product. Each machine will just do one thing to the product, before passing it on to the next one. The cost of setting up a production line is very high, so you have to make large quantities of a product to pay for it. Machinery and tooling is often very expensive and specialist. Summary: Products are produced at high volume, cheaply. Increased automated systems Huge investment needed. Initial set up costs high…long term cost low

Continuous Production Continuous production is used to make products like steel, oil or chemicals. Many of these products are used as the materials to make other products. Factories that operate continuous production often run 24 hours a day, seven days a week. The process needs to be continuous because it would be very expensive to stop it and then turn it on again.

CAD Benefits: Drawbacks CAD stands for Computer Aided Design and uses a range of software to help develop a product using virtual 2D and 3D “drawing”. Used in conjunction with FEA (Finite Element Analysis) where we can analyse stresses and strains, it helps to assess quality before manufacture. Examples include: 2D Design 3D Studio Max Pro/Engineer Solid-Works Benefits: Virtual Reality Modelling Communication Low Cost Files can be saved and altered with ease Can rapidly product detailed engineering spec. to reduce lead times Drawbacks High demand of initial training/High cost of set up Not ideal for initial concept generation

CAM CAM (Computer Aided Manufacture) is a series of processes and equipment that allow products to be manufactured via machines governed by PC’s not us. Equipment includes: CNC Routers Laser Cutters CNC Lathes Vinyl (Plotter) Cutters RPT (Rapid Prototyping) Benefits Cost effective and relatively fast Removal of human error In-built Quality Control Drawbacks Loss of traditional skills Loss of jobs High initial set up costs http://www.esacorp.com/animations/prototype-animation.gif

Manufacturing Concepts CIM Computer Integrated Manufacture is the process whereby every single step in the manufacture of a product incorporates the use of computers. For example: Designing using a CAD drawing program Testing via Virtual Simulation Prototyping models using CNC machines (3D Printing) Controlling stock by scanning codes on parts Using Robots to manufacture components Intermediate scanning/testing using sensors for Quality Control http://www.technologystudent.com/rmprp07/intman1.html

Manufacturing Concepts JIT (Just In Time) This is a Japanese based concept whereby all the parts needed for a product arrive at the factory at the last minute. The factory estimates how long a process will take to manufacture, and orders the parts to arrive just before needed, in small batches. They are not stored at the factory. Benefits: No storage/warehouse costs to the company Efficiency Easy monitoring of stocks/parts Increased jobs/scope for companies to supply parts Drawbacks Relies on punctuality of delivery Relies on effective ICT systems (and fully operational!) Risk of wrong parts arriving Environmental concerns due to number of deliveries. More info… JIT involves an ICT dependent system that tells the factory and its supplier how many of a product is needed and when by. The factory will have a logistics division that are responsible for getting the part from the supplier just in time for it to be assembled into the final product.

QRM and e-POS QRM (Quick Response Manufacturing) Most manufacturers cannot afford to manufacture products into stock or storage before sale. QRM means you save on storage costs too. Companies that manufacture like this risk not being able to sell their products as their may have been a sudden change in the market. Jaguar opt for a ‘Made to order’ system. Customers are allowed to choose various options before manufacturing on their product starts. Of course, this means a longer wait time! e-POS (Electronic Point of Sale) Barcodes are an essential part of QRM. They allow the JIT ordering of components and products and re-stocking. For example when ASDA gets close to running out of Walkers crisps the computer will automatically place an order with the factory for the quantity required.

Protect Inform Display/Promote Store/Transport Preserve

Printing card Typically offset lithographic or gravure process used 4 process colours – yellow, magenta, cyan, black Varnishing, foil blocking, embossing are common

A few exam tips Offset lithography is the best answer for any questions relating to the printing of card packaging Flexography is the best answer for any question relating to the printing of plastic film (such as carrier bags) Printing is a finishing technique suitable for card and some other materials

Adhesives Wood Wood Metals Plastics Fabric Fabric Plastics Metals PVA: Polyvinyl Acetate is a white water-based adhesive. The PVA soaks into the surface and sets once the water is absorbed into the wood. It is often regarded as being stronger than wood fibres themselves and so makes a strong bond. Adhesives Synthetic Resin: A waterproof adhesive which needs to be mixed into a creamy consistency with water. Chemical hardening takes place. Very hard and very brittle. Will set in the plumbing outlet so do not wash residue down the sink. Fabric Plastics Metals Wood Solvent Cement: There are several types available. The most common is Dichloromethane which works by dissolving the surface of hard plastics such as Acrylic and High Impact Polystyrene. Very dangerous fumes are given off so ventilation is essential. Wood Contact Adhesive Contact Adhesive PVA or Synthetic resin PVA Contact Adhesive Metals Contact Adhesive Contact Adhesive Epoxy Resin Hot Melt Glue: The use of glue guns are common in schools. Hot melt is useful for quick modelling but can rarely be used in final products. Plastics Contact Adhesive Solvent Cement Epoxy Resin Contact Adhesive Epoxy Resin: Avery versatile but expensive adhesive which will stick most dry clean materials. Equal amounts of resin and hardener are mixed together. Chemically sets to a hard material. Fabric Latex Adhesive Contact Adhesive Contact Adhesive PVA Contact Adhesive: Both surfaces are coated and allowed to become touch-dry. Adhesion takes place as soon as the two surfaces meet. The solvent fumes are very dangerous and good ventilation is essential. Latex Adhesive: A rubber solution which is cheap and very safe. Does not give any dangerous fumes although the smell is not pleasant.

Consumer protection keeps us safe from poor quality products Manufacturers who produce unsafe or unreliable products ts may find themselves being prosecuted under several different laws. * The Trade Descriptions Act – this ensures that any claims made about a product must be true. * The Consumer Safety Act legislates over fire regulations and specifications for clothing, toys and electrical goods. * The Sale of Goods Act ensures that the products perform as you would expect and that goods last a reasonable length of time. * Fire Safety regulations cover new and second hand furniture, stuffed furnishings and fabrics, to ensure resistance to ignition and low toxicity fumes. As well as the law, consumers can get help from: These places will give consumers advice: The office of fair trading The Citizens Advice Bureau Local Authority Trading Standards The British Standards Institute The Consumers Advice Council The environmental Health Dept. The National Consumer Council Local Authority Trading Standards

Drill a hole for the ring START Put on goggles Drill a hole for the ring Attach the ring END

Reduce Refuse Rethink Design & Technology Objective 3: To introduce the 6 Rs focussing on Reduce, Rethink and Refuse. Consumers need to look to reduce the number of products they buy, or consider buying products that use less energy. Manufacturers are looking to design products that are: Have less materials in the product Take less energy to manufacture Need less packaging during transport Retailers can reduce carbon emissions by transporting products straight tot he consumer from the place of manufacture, instead of via warehouses and shops. Reduce The consumer has the choice as to whether they buy a product or not. They can ask the following questions: Should they refuse the product because it is too inefficient Should the refuse the product because its packaging creates to much waste? The designer and manufacturer have an increasing need to think about how the consumer will react to their products. Will they refuse them? Refuse Design & Technology Rethink Consumers can ask the question “ Do I really need this product? Designers and manufacturers can make products that do the same job more efficiently. They can design the packaging so that it’s easier to recycle.

Re-use Repair Recycle Design & Technology Objective 4: To introduce the 6 Rs focussing on Reuse, Repair and Recycle.. Glass milk bottles area classic product that is reused. A more recent products that can be reused is a printer cartridge, which can be refilled. Some products have filters that can be washed rather than using disposable, single use filters. Consumers could sell or donate products they no longer use themselves, so that someone else can use them. Re-use Designers have a responsibility to design products that can be repaired more easily. It takes fewer resources to replace a part of a product, than to replace the whole item. Repair Products are converted back to their basic materials and remade into new products. Examples include: Glass crushed, melted and made into new bottles. Aluminium cans melted down to make new products Designers and manufacturers of products need to design products for recycling. Car manufacturers are obliged to label all plastic parts in new cars to aid recycling of all those parts. Electrical and electronic products now have to include recycling instructions for the consumer. These state that products should be taken to special recycling points at the end of their life. Recycle Design & Technology

Identify these symbols – what do they mean and where would they be used.

Design & Technology GCSE Product Design Symbols Safety symbols Standards symbols

CAD CAM CNC CIM What do these initials stand for? What do they mean?

Objectives: To revise random topics that may occur in the exam. What are standard components (give examples)? What are the advantages of using standard components? What are knock down fittings? When are they used? What are smart materials? Name a smart material and a product using this material? Name a design era. Name an iconic product. Name 3 thermoplastics. Name 3 hardwoods Name 3 non ferrous metals What is a tolerance in industry. What does FSC stand for? Explain 3 ways to reduce your carbon footprint. Choose a product and describe how it has developed over time? What is anthropometric data? What is inclusive design? What do the following abbreviations stand for CAD, CAM, CNC, CIM, JIT, FMS? What is blister packaging? What is the difference between quality control and quality assurance? What does BSI stand for?. What are patents, copyright and registered designs? What is market pull and technology push? What is continuous improvement? Resources you could use. CD ROM player, AQA revision guides, www.technologystudent.com