BTEC First Engineering Learning aim C Understand how engineering contributes to a sustainable future Learning aim C is concerned with reducing the impacts of engineering on society and the environment. 1

Starter On your mini white boards write down what you think happens to a product when it’s no longer used

Starter Swap your 2 homework questions with the person to your right, then answer those 2 questions. Mark using the mark schemes once completed

To be able to design exam questions and mark schemes which demonstrate your knowledge. To be able to identify how engineering contributes to a sustainable future by investigating the life cycle of a product.

Life Cycle Assessment raw material extraction material production BTEC First Engineering Life Cycle Assessment raw material extraction material production product disposal / recycling production of parts the product use Teacher notes (PS 9): Learners should be aware of the cyclical nature of LCA. Depending on the product, raw materials may be needed and then disposed off at the end of the cycle, such as foodstuffs or oil, while other products, such as plastic (PET) bottles or aluminium cans, can be recycled and the loop can continue almost indefinitely. assembly of products © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 5

Raw Material Extraction BTEC First Engineering Material Production Production of Parts Assembly of Product Raw Material Extraction Recycle Re Use Teacher notes (PS 9): Learners should be aware of the cyclical nature of LCA. Depending on the product, raw materials may be needed and then disposed off at the end of the cycle, such as foodstuffs or oil, while other products, such as plastic (PET) bottles or aluminium cans, can be recycled and the loop can continue almost indefinitely. Disposal Use © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 6

Life Cycle Analysis: Handy Videos BTEC First Engineering Life Cycle Analysis: Handy Videos Life Cycle Analysis: https://youtu.be/7u5mQwREN6Y Plastic Water bottle example: https://youtu.be/UlG1Yd66_lI Refining Plastics: https://youtu.be/gYnGgre83CI Chopping down trees: https://youtu.be/WQIbFx4xc-M Processing wooden boards: https://youtu.be/-DJypFyptRY Steel – from start to finish: https://youtu.be/9l7JqonyoKA Land-fill – (least sustainable) https://youtu.be/18FLfQDInI8 Teacher notes (PS 9): Learners should be aware of the cyclical nature of LCA. Depending on the product, raw materials may be needed and then disposed off at the end of the cycle, such as foodstuffs or oil, while other products, such as plastic (PET) bottles or aluminium cans, can be recycled and the loop can continue almost indefinitely. © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 7

Raw materials extraction BTEC First Engineering Raw materials extraction Metal: Metal OREs found beneath the ground. Excavated in open pit mines   Wood: Trees are logged using chainsaws and vegetation removed before being loaded onto lorries Plastic: Crude oil is extracted from deep below the ground using oil wells Material production Metal: Rocks containing the Ore are Smelted: Heated to melt the metal inside so it flows out. (Alloys: Combined with other metals)   Wood: Logs are sawn and planed into various sizes as well as being processed into manufactured boards Plastic: Crude oil is refined to remove the relevant chemicals from the ore. Pigments are added to make them colourful Teacher notes (PS 9): Learners should be aware of the cyclical nature of LCA. Depending on the product, raw materials may be needed and then disposed off at the end of the cycle, such as foodstuffs or oil, while other products, such as plastic (PET) bottles or aluminium cans, can be recycled and the loop can continue almost indefinitely. © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 8

Metal: Casting, Forging and Machining(milling/turning/drilling) BTEC First Engineering Production of parts Metal: Casting, Forging and Machining(milling/turning/drilling)   Wood: Parts are cut using saws, routers. Also drilled and sanded Plastic: Injection Moulding and other industrial moulding techniques. Assembly Metal: Welding, screws, rivets   Wood: Wood joints, adhesives, fixings (screws, nails, brackets) Plastic: Self tapping screws, adhesives, moulded clips Teacher notes (PS 9): Learners should be aware of the cyclical nature of LCA. Depending on the product, raw materials may be needed and then disposed off at the end of the cycle, such as foodstuffs or oil, while other products, such as plastic (PET) bottles or aluminium cans, can be recycled and the loop can continue almost indefinitely. © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 9

Does the product use energy or create any kind of waste or pollution? BTEC First Engineering Use Does the product use energy or create any kind of waste or pollution? How many times can the product be used before it comes to the end of it’s useful life? Disposal/recycling Metal: Melted down and re-cast into new products or parts but this uses a lot of ENERGY   Wood: Can be re-claimed (used intact), can also be chipped to form manufactured boards like chipboard or MDF Plastic: TheromoPlastics and be melted down and re-moulded into new products or parts but this uses a lot of ENERGY. (ThermoSETTING plastics can’t be recycled) OR, they will end up on LANDFILL Teacher notes (PS 9): Learners should be aware of the cyclical nature of LCA. Depending on the product, raw materials may be needed and then disposed off at the end of the cycle, such as foodstuffs or oil, while other products, such as plastic (PET) bottles or aluminium cans, can be recycled and the loop can continue almost indefinitely. © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 10

Reducing waste Reduce Reuse BTEC First Engineering Reducing waste Reduce Reuse Engineers should think about using less materials and energy to manufacture products. If a product can be used again, this reduces the amount of materials going to landfill. Recover Recycle Waste materials can be treated to generate heat or power for other uses. Products can be broken down into materials that can then be re-manufactured to make new items. Teacher notes (PS 10): Reduce – Linked with LCA. Designers should reduce the materials needed to make products and also the need to replace them frequently. It is not appropriate to have built-in obsolescence (no longer being useful) if the desire is to reduce waste in this way. Reuse – Sometimes it is possible to reuse all or part of a product. This is an effective way of reducing wastage. Examples could include reusing boxes for storage or cannibalising vehicles for spare parts to keep others working. Recover – Waste and offcuts can be treated to generate energy. The simplest form would be burning offcuts of timber for water heating and central heating in a factory. Recycle – If a product cannot be reused it should, where possible, be recycled. In many areas waste is sorted and materials that can be recycled are separated from general waste. Materials such as glass and aluminium can potentially be recycled infinitely, while paper and card can only be recycled a limited amount of times. © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 11

Lean manufacturing Just-in-Time Kaizan Poka-yoke BTEC First Engineering Lean manufacturing Just-in-Time Kaizan Poka-yoke Materials and components are delivered to a production line when they are needed, thus reducing cost and time. Many well-planned manufacturing systems are based on Just-in-Time. To make things better, a company needs to improve continuously. Kaizan is a system where ideas that are suggested by workers that can be used to make production better. Mistakes often happen in engineering. Poka-yoke is a method that can be used to eliminate human error where tasks are repeated. The benefit to staff is that jobs become less boring. Teacher notes (PS 11): Lean manufacturing improves the efficiency of an engineering business. Many methods were developed in Japan and have spread worldwide. The overall aim of lean manufacturing is to reduce wastage, either by reducing the amount of stock held, or by reducing mistakes/faulty products. © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 12

Renewable sources of energy BTEC First Engineering Renewable sources of energy Wind Solar Turbines are used to convert wind energy into electricity. They cause no air or water pollution, but are only efficient when it is windy. Photovoltaic cells use the light of the sun to produce electricity. They work most efficiently when they are south-facing. Hydro Geothermal Moving water can be used to generate electricity via a turbine. The water can be stored in a reservoir to make sure there is always a supply. Steam naturally heated by the earth can be used to turn a turbine. This then generates electricity. There is no pollution from geothermal energy. Teacher notes (PS 12): Each type of renewable energy has benefits and disadvantages. Wind energy is only viable if there sufficient wind, hence the location of wind farms in upland areas or out to sea. Wind farms significantly alter the appearance of the environment. They produce no air or water pollution, but can be noisy if there are many. Land used for wind farms can, however, still be used for agriculture. Solar energy is most efficient where panels are south-facing. Energy can be stored in batteries for use overnight, and despite the name, only need daylight, rather than direct sunlight, to operate. Hydro energy often involves building a dam, through which pipes allow water to pass through the turbine to create electricity. Energy from hydro plants can be brought online instantly if there is a high demand for power. In times of lower demand, water can be pumped from a lower reservoir back to the upper reservoir. Geothermal energy is not common in the UK, but the principle involves pumping water into the ground. The heat from the ground turns this to steam which then turns a turbine to generate electricity. © Pearson Education Ltd 2012. Copying permitted for purchasing institution only. 13