1. Manufacturing
Students will differentiate between manufacturing types and production systems in order to manufacture a working prototype.

2. Scale of Production

3. Production Systems
Craft production: Small-scale production process centered on manual skills
Mechanized production: Volume production process involving machines controlled by humans
Automated Production: Volume production process involving machines controlled by production computers

4. One-Off Production
Individual product or prototype for larger-scale production
Often made with craft production techniques or combination of craft and machines
Close relationship between manufacturer and consumer due to user needs dominate
Examples: prototypes, specialist models, hand crafted items, specialist engineering, specialist architecture and just plain old one offs

5. One-off Production Advantages Disadvantages
Highly customizable to consumers needs
Flexibility for designer and consumer
Allow for testing of prototypes before continuous flow production
Can be expensive as tools or machinery needed are included in final cost
Time consuming if craft manufacturing techniques are used
Product may not be designed for disassembly (DfD); no interchangeable parts

6. Batch Production Limited production run
Manufacturing method used to produce or process any product in batches
Popular in bakeries, manufacture of sports shoes, pharmaceutical ingredients, paints, inks, etc.
Can be mechanized or automated production

7. Batch Production Advantages Disadvantages
Cheaper than one-off production
Customizable products
Easily adjust to market demands or seasonal  items
Greater consumer choice
For smaller or upstart companies that can’t afford continuous flow production
Can reduce initial capital because single production line can be used
Down time between productions runs when retooling
Products have to be stored raising cost per item

8. Continuous Flow Production
Production method used to manufacture, produce or process materials without interruption
Thousands of standardized products are continuously made 24 hours a day 7 days a week
Carried out to maximize production while reducing costs of starting and stopping production process
Can be mechanized or automated process with only a handful of workers needed

9. Continuous Flow Production
Advantages
Disadvantages
Cheaper than other production methods
Part or product needs replacing consumer is assured that it still exists
Lack of inventory which reduces storage costs
Standard products so less choice for consumer
Automated production is high in initial costs
Training of staff to run machines and CIM

10. Mass Production
Production of large amounts of standardized products on production lines, permitting very high rates of production per worker
Used when large quantities of products are needed

11. Mass Customization
CIM system that manufactures products to individual customer needs or wants
Benefits from economy of scale for single products or thousands of them
Relationship between manufacturer and customer becomes closer because individual requirements of consumer dominate

12. Mass Customization Advantages Disadvantages
Economies of scale are achieved even for small orders
Highly customizable to consumer needs or likes
Long layover time from when product is customized to reaching consumer
Very high initial capital costs
Special training for employees

13. Selecting Scale of Production
When selecting an appropriate scale of production for a product, manufacturers must consider a number of factors, including:
Product characteristics
Material characteristics
Size of market
Nature of market
Desired manufacturing processes
Desired production system.

14. Scale of Production Activity
Consider the Human Factors project. Which scale of production should Shillington Box company employ for their cardboard chairs/stools?
Post your response in Google Classroom

15. Manufacturing Processes

16. Design for Manufacture (DfM)
Designers design specifically for optimum use of existing manufacturing capability
Example: if a company has injection molders available then designer designs product with that manufacturing machine in mind
Considers material needed (thermoplastic) and its related properties and workability

17. Additive Techniques
Manufacturing techniques that add material in order to create product or component
Examples:
3D Printing
Laminated Object Manufacture
Stereolithography
Selective laser sintering

18. Subtractive Techniques
Manufacturing techniques that cut away material in order to create product or component
Examples:
Cutting
Machining
Turning
Milling
Drilling
Abrading
Cutting: Saws, scissors
Machining: drill press, mill, lathe, shaper
Turning: lathe
Abrading: sanding, grinder

19. Shaping Techniques
Manufacturing methods for modifying shape of material
Examples:
Molding
Injection, Blow, Rotational, Compression
Thermoforming
Laminating
Casting
Knitting
Weaving

20. Joining Techniques
Methods that are used to join two similar or dissimilar materials together
Examples:
Permanent
Adhering, Fusing, Fasteners
Temporary
Fasteners, Adhering

21. Selecting Manufacturing Technique
Selecting manufacturing techniques should be based on the following criteria:
Material characteristics such as form, melting/ softening point.
Cost
Scale of production
Desired properties

22. Manufacturing Processes
Assume you are manufacturing a wooden table. Describe the additive and subtractive processes you would use to build the table.
Post your response to the prompt in Google Classroom.

23. Production Systems

24. Craft Production Production process based on manual skills
Small-scale production
Design Contexts include: one-off products such as custom made furniture, pottery, art and crafts,

25. Craft Production Advantages Disadvantages
Quality tends to be considerably higher than mass-produced products
Customized to fit personal needs
Flexibility for designer, customer and craftsman
Craftsman able to charge more for manufacturing of product
Takes great amount of time and effort
Much more expensive for buyer
Not possible to produce on larger scale
Product not designed for disassembly; no interchangeable parts

26. Mechanized Production
Volume production process involving machines controlled by humans

27. Mechanized Production
Advantages
Disadvantages
Product is cheaper than craft production
Quality of product is improved as fewer human errors will occur, finish of product will also be improved
Increased wages due to training and becoming skilled
Efficiency of production: less time is taken to produce goods
Health and safety. Work conditions are usually poor in factories, lack of safety standards can be issue in some cases. Repetitive strain injury.
Cost of energy, training and capital machinery. Increased wages due to highly skilled operators needed.
Environmental pollution.
Boredom for workers
Low job satisfaction for workers

28. Automated Production
Volume production process involving machines controlled by computers
Systems such as CAD, CAM and CNC can contribute to automated production system by linking to manufacturing equipment which is likewise controlled by computer

29. Assembly Line Production
Volume production process where products and components are moved continuously along conveyor
Product goes from one work station to another and components are added until final product is assembled
Design Contexts include: automobile manufacture, computer or laptops, most electronic consumer products

30. Impact of Automation on Workforce and Environment
Positive
Negative
Tedious and time-consuming jobs performed by machines rather than workers
Improved health and safety due to improved work conditions
Improved job satisfaction due to improved work conditions
Replaces unskilled workers with skilled workers or upscaling of existing workers. Results in better pay
Less social interaction due to fewer employees
Loss of worker expertise and overtime pay
Makes life dependent on new technology
Training in new areas of electronics, computer engineering and maintenance of systems is needed
Huge negative affect on environment due to heavy industrialization

31. Impact of Mechanization and Assembly Line on Workforce and Environment
Positive
Negative
More labor is performed by machines
More social interaction since workers are under one roof
Upscaling from craft to learn new machines results in better pay
Health and Safety may decrease due to pollution from industrialization
Loss of master craftsman
Huge negative affect on environment due to heavy industrialization

32. Impact of Craft Production on Workforce and Environment
Positive
Negative
High job satisfaction, prestige as master craftsman
Good health and safety due to control over work environment
Minimal negative affect on environment
Minimal social interaction usually working on their own

33. Design for Manufacture (DfM)
Design for materials: designing in relation to materials during processing
Design for process: designing to enable product to be manufactured using specific manufacturing process
For example: injection molding
Designers design specifically for optimum use of existing manufacturing capability. There are four aspects of DfM.

34. Design for Manufacture (DfM)
Design for assembly: designing taking account of assembly at various levels
For example: component to component, components into sub-assemblies and sub-assemblies into complete products
Design for disassembly: designing product so that when it becomes obsolete it can easily and economically be taken apart, components reused or repaired, and materials repurposed or recycled
Designers design specifically for optimum use of existing manufacturing capability. There are four aspects of DfM.

35. Production Systems Activity
Making connections to Theory of Knowledge answer the following question:
The increased dependency on automation and robots has affected craftsmanship. How has technology affected traditional ways of knowing?
Post your answer to the prompt on Google Classroom.

36. Robots in Automated Production

37. Robotics Applications

38. Primary Characteristics of Robots
Work envelope: 3D space a robot can operate within, considering clearance and reach
Load capacity: Within this context, the weight a robot can manipulate

39. Robot Types Single-task robots: can only carry out one task at a time
Multi-task robots: can carry out more than one task at a time
Teams of robots: groups of robots carry out similar tasks
Machine to machine (M2M): refers to wired and wireless communication between similar devices.

40. Robotic Systems in Production
Advantages
Disadvantages
Improve health and safety of workforce
High accuracy of work – reduced errors and waste
Perform repetitive and dangerous tasks
Work in confined spaces
Perform functions 24/7 leading to higher production
Re-programmability or flexible
Expertise needed to operate such systems
Training of workers required in both operation and maintenance
High initial capital cost

41. Robot Generations First-generation robots: Second-generation robots:
simple mechanical arm that has ability to make precise motions at high speed
Need constant supervision by human operator
Second-generation robots:
equipped with sensors that can provide information about their surroundings
Can synchronize with each other and do not require constant supervision by human
Controlled by external control unit
Third-generation robots:
autonomous and can operate largely without supervision from human
Have their own central control unit
Swarms of smaller autonomous robots also fit in this category

42. Robots in Production Activity
Describe some of the advantages and disadvantages of using robots in automated production. Which design contexts would robots be preferred? Which design contexts would robots not be preferred?