MANUFACTURING PROTOTYPE How do all the aspects of manufacturing come together to make a final product?

Manufacturing the Big Picture  Essential Question:  What role does each part of manufacturing play in the final manufacturing process?

You have been contracted by your local TSA chapter to produce a product for this year’s Manufacturing Prototype event. Revisit the steps of the manufacturing process to create a production plan for a product you design. You should keep notes of each step in your design notebook. You will transfer your notes to PowerPoint to communicate your design. Manufacturing Prototype

THE DESIGN PROCESS The following is an outline of the process and steps you should complete.

The Design Process  Define the Problem  Research the Problem  Develop Possible Solutions  Choose the Best Solution  Create a Prototype  Test and Evaluate  Communicate  Redesign

Define the Problem  Define the problem and list criteria and constraints

Research the Problem  Conduct research on the problem including:  What products currently exist in this area?  What is the cost of products that currently exist?  What materials can be used?  Ergonomic factors?  Safety factors?

Research your Customer Needs  Sample Questions:  Who would purchase the product?  What is the age range of potential customers?  Like and dislikes of potential customers?  What do they want from your product?  What factors would sway them to or away from your product?  What cost would they be willing to pay?  Create a survey or data sheet and record your results in your design notebook.

Develop Possible Solutions  Create 8 solution concepts – write a detailed description of each solution  Complete thumbnail sketches of at least 4 designs.

Choose the Best Solution  Using the format to the right, answer the following questions:  Does it meet each of your criteria?  Ergonomics  Materials  Aesthetics  Construction Method  Health and Safety  Environmental  Other

Create a Prototype  Create a technical drawing using CAD software of your chosen solution. (use color to match your design)  Create a prototype using the materials given and any materials you bring from home.

Test and Evaluate  Evaluate your solution using the format below:

Communicate  You should prepare a PowerPoint presentation of your design process steps and information.  Each team will present their presentation to the class.

Redesign  Using information and feedback from the class – what do you need to redesign?  Make any modifications in your design. Changes to technical drawing Changes to materials

THE FINANCIAL COST The following is an outline of the process and steps you should complete.

The Financial Cost  Using your prototype and the internet, research your materials and figure the cost to manufacture your item.  How much is one product?  How much are 30 products?  Where can you purchase the materials most economically? (remember shipping costs)  Prepare a summary report of your findings to present to the class. Add this report to your PowerPoint presentation.

PRODUCTION PLANNING The following is an outline of the process and steps you should complete.

Production Planning - Tooling  Create the following chart in your design notebook:  Part of Product– list each part of your game  Material – what materials is each part made from  Tool Needed – what tool will you use to create that part  Tooling Needed – we will be learning about this  Create technical drawing and specifications of any tooling that needs to be built. Part of ProductMaterialTool NeededTooling Needed

Production Planning – Facility  Create a flow process chart like the one below for each part.

Production Planning – Facility PLASTICCLIP 1. Cut to width 2. Cut to length 3. Drill holes 4. Round corners 5. Assemble to clip Create an operation process chart for your entire production map.

Production Planning  Add your production planning information to your PowerPoint Presentation to present to the class.

QUALITY CONTROL The following is an outline of the process and steps you should complete.

Quality Control  Answer the following questions:  Where will you use quality control?  What methods will you use for your quality control?  Add your quality control to your PowerPoint Presentation to present to the class.

TAKING IT FURTHER - ADDING A LOGO The following is an outline of the process and steps you should complete.

Logo Design  Basic rules for a successful logo:  Simple in design  Easy to understand, even at a distance  One or two colors are normally used  Writing is simple and easy to read  A simple drawing or symbol is sometimes used.

Logos  Simple pictures can be altered easily to make logos.

Logos  Create a mockup design of 3 different logo choices for your product and put them in your design notebook.  Add these designs to your PowerPoint presentation.

TAKING IT FURTHER - PACKAGING The following is an outline of the process and steps you should complete.

Packaging  Purpose of packaging:  Protect a product from damage or contamination by micro-organisms and air, moisture, and toxins.  To keep the product together, to contain it.  To identify the product.  Protection during transport and ease of transport.  Stacking and storage.

Packaging Symbols  Polythene Terephthalate (PET) is used for widely packaging, especially for dink containers. It is 90% recyclable and the symbol reminds the consumer to recycle the container.  International recycle symbol – to remind the consumer to recycle the packaging.  Material is recyclable and made from aluminum. Look at drink cans and you may find this symbol.  Store package upright  Card packaging – materials used to make package were harvested in sustainable forests. Trees are managed and replaced when cut down.  Contents are fragile  Professional quality control and precision is used in manufacturing  Do not store package in damp conditions  Store at a particular temperature

Environmental Issues with Packaging  Waste – ensure minimum waste of materials and if possible no waste.  Why – wasted materials = wasted money Helps conserve the environment Less energy is needed to run machines  Recycle as much waste as possible to save the environment and money

Manufacturing Packaging  Use a straight edge to draw the lines of the packaging  Use design software to design the packaging appearance and attach it  Use a craft knife and straight edge to cut each of the outside pencil lines and score each of the inside lines.  Use a ruler to help fold the package into its shape

Example – Self Locking Package  Folds and holds its shape without glue

Example – Hexagonal Packages  The top folds and locks into place. The bottom has a number of tabs that must be glued.

Example – Box with Handles  Handles are part of the packaging

Example – Gift Box Small Scale

Logos  Using the packaging concepts we have discussed. create your own packaging for your product.  You will need the following:  Template for packaging  Packaging outside – logos and design  Write a rational for why you choose this type of packaging.  Include all of these items in your design notebook.  Add these designs to your PowerPoint presentation.

REVIEW OF THE PROBLEM Did you know your problem?

You have been contracted by your local TSA chapter to produce a product for this year’s Manufacturing Prototype event. Revisit the steps of the manufacturing process to create a production plan for a product you design. You should keep notes of each step in your design notebook. You will transfer your notes to PowerPoint to communicate your design. Manufacturing Prototype

Grading Rubric