BTEC First Engineering Unit 1: The Engineered World Learning aim C Understand how engineering contributes to a sustainable future BTEC First Engineering

Unit 1: The Engineered World Life Cycle Assessment © Pearson Education Ltd Copying permitted for purchasing institution only. material production production of parts raw material extraction assembly of products the product use product disposal / recycling BTEC First Engineering

Unit 1: The Engineered World © Pearson Education Ltd Copying permitted for purchasing institution only. BTEC First Engineering Disposal Raw Material Extraction Material Production Use Re Use Recycle Assembly of Product Production of Parts

BTEC First Engineering Unit 1: The Engineered World © Pearson Education Ltd Copying permitted for purchasing institution only. BTEC First Engineering Life Cycle Analysis: Handy Videos Life Cycle Analysis: Plastic Water bottle example: Refining Plastics: Chopping down trees: Processing wooden boards: Steel – from start to finish: Land-fill – (least sustainable)

BTEC First Engineering Unit 1: The Engineered World © Pearson Education Ltd Copying permitted for purchasing institution only. 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

BTEC First Engineering Unit 1: The Engineered World © Pearson Education Ltd Copying permitted for purchasing institution only. 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

BTEC First Engineering Unit 1: The Engineered World © Pearson Education Ltd Copying permitted for purchasing institution only. 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

BTEC First Engineering Unit 1: The Engineered World Reducing waste Reduce Engineers should think about using less materials and energy to manufacture products. Reuse If a product can be used again, this reduces the amount of materials going to landfill. © Pearson Education Ltd Copying permitted for purchasing institution only. RecoverRecycle 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. BTEC First Engineering

Unit 1: The Engineered World Lean manufacturing Just-in-Time 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. © Pearson Education Ltd Copying permitted for purchasing institution only. Kaizan 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. Poka-yoke 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. BTEC First Engineering

Unit 1: The Engineered World Renewable sources of energy Wind Turbines are used to convert wind energy into electricity. They cause no air or water pollution, but are only efficient when it is windy. Solar Photovoltaic cells use the light of the sun to produce electricity. They work most efficiently when they are south-facing. © Pearson Education Ltd Copying permitted for purchasing institution only. HydroGeothermal 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. BTEC First Engineering