1. Planning/Production Record P17 Date/ Time Work carried outQuality control checks Health and Safety issues Name:

2. Planning/Production Record P17 Date/ Time Work carried outQuality control checks Health and Safety issues Name:

3. Planning Task Bank Work carried outQuality control checksHealth & Safety Issues Produce final idea on 2D design. Change cut lines to red. Cut out using the laser cutter Make sure measurements are accurate & size of the speakers are correct. Use gridlock. Material selection for laser cutter matches material used. Correct depth selected. Laminate MDF to make up the thickness of MP3 docking station. Glue together with PVA and clamp in vice. Check that layers are lined up and not too much glue Safe use of PVA glue application Cut out docking station outer shape with scroll saw Ensure it is sanded after to ensure a smooth finish Goggles & Apron for Linisher. Clamped in vice Glue acrylic and MDF pieces together with Epoxy resin Small amount of glue used. Pieces lined up accurately. Mix glue correctly using a stick Glue HIPs over curved edge of docking station Ensure the HIP’s is glued properly. Hold in place/ clamp until dry Safe use of glue. Apply filler to fill in gaps and defects between pieces. Check that all defects are filled in for high quality finish before priming. Use in a well ventilated space, ensure lid properly secured. Sand the docking station using the Linishing machine. For a smooth finish before the pieces are primed. Don’t over sand. Goggles & apron. Safe use of the machine with Apply sanding seal to MDF to seal MDF Then rub down with wet & dry. Good quality finish and paint not absorbed into the MDF. Wet & Dry – smooth surface. Well ventilated space and lid properly secured. Spray with filler primer spray. Even layer of primer spray on the docking station. Build up in thin layers. Rub down with Wet & dry. Repeat step as needed. Well ventilated space. Protective mask, goggles and gloves worn. Apply top coat of spray paint. Shake can well and test on scrap material to avoid dripping Even layer sprayed. Well ventilated space. Protective mask, goggles and gloves worn.

4. Planning Task Bank Work carried outQuality control checksHealth & Safety Issues Grille design/ pattern on 2D design and cut out on Laser cutter. Check dimension are correct on laser cutter. Small amount of glue so it is not visible Mix glue correctly using a stick Phone holder cut pieces to size and shape Masked evenly for cutting and measured with tri-square Goggles & apron. Guard lowered for material thickness. Acrylic pieces shaped using the strip heater. Marked accurately with tri- square and steel rule. Jig used to shape for accuracy. Care taken when using Strip Heater. Protective plastic removed. Gloves worn for smaller panels. Speakers mounted to a piece of material. -Circle cut using the scroll saw or coping saw. -Holes drilled on pillar drill/ hand drill for screws. Actual speaker used to mark and measure accurate placement. Holes must be 100% accurate so that speaker fits. This will keep the speakers secure inside the unit. Goggles & apron. Guard lowered for material thickness if scroll saw being used. Door made to access the speaker components. – Plastic door component used. Can be sprayed a different colour. Can be laser engraved or design cut onto it e.g. company name. Door Component – measured onto material and cut out accurately by drilling hole first. Hole cut out in material to be mounted with door with small amount of glue. If spray used- mask, well ventilated space, goggles. Scroll saw- Goggle and Apron Door made to access the speaker components. – Sliding door Groove measured out on side panels - Or separate MDF pieces- groove created with chisel and glued onto back. Mark and measure the grooves accurately with Tri- Square and steel rule. Use a marking gauge for accuracy. Safe working of chisel- Clamped in Vice, mallet used. Goggles. Door made to access the speaker components. – Rotating door Large hole cut in back panel of docking station. Hole drilled above the corner of the door. Door panel cut larger than hole. Hole drilled in corner. Door panel must be larger than hole on back panel. Holes on two panels must line up perfectly. Panels are screwed together loosely enough for front panel to be able to be rotated for access to inside. Goggle and apron for drilling.

5. Planning Task Bank Work carried outQuality control checksHealth & Safety Issues Creating the mould for vacuum forming (blobjects). 1 st Step Negative mould made from coiling method for clay ready for plaster of paris cast for the positive mould. Allow to fully dry Clay must be smoothed out so that the plaster mould is has a high quality finish. Clay in air tight bag between sessions to stop drying out. Must have sloped edges so HIPS can be removed. Big enough for speakers to go inside. Care taken with Clay and tools to work the material such as knifes. Safe working practice on a flat surface. Creating the mould for vacuum forming (blobjects). 2 nd Step Mix plaster of paris. Fill the clay mould with plaster of paris and allow to set. Clay mould must be smooth for plaster of paris to create a smooth mould for the Vacuum Former. Sloped edges for Vacuum Former Size smaller than vacuum former bed. Safe use of plaster of paris. Hands at a safe distance once poured into mould. Safe space to set. Creating the mould for vacuum forming (blobjects). 3 rd Step Fully dried Plaster of Paris placed on Vacuum Former and HIPS formed around the mould. Lightly sprinkled with talcum powder for easier removal. Care taken when using Vacuum Former. Protective plastic removed. Allow to cool. Creating the mould for vacuum forming (blobjects). 4 th Step HIPS cut to size from around the mould. Sand edges lightly by hand. A little extra left on HIPS. Can be lightly sanded down to achieve a high quality finish. Cutting Mat, Stanley knife with blade clicked away Marking out the wood for the finger joints for boxes marking out with a marking gauge and ruler accurately so joints are all the same size Flat surface and safe use of marking gauge. Cut out the finger joints for the boxes Chisel out any parts of the finger joints that are too big Keeping to marked out lines so the fit is high quality. Do not chisel too far and keep checking with the piece of wood it will slot together with. Safe use of chisel, mallet. Clamped securely in vice. Drill a hole in the panel where the AUX part will fit in to connect to the phone. Mark out and cut the phone holder material. Glue together if required. Measure the AUX cable to make sure that the drill is the right size so that it is accurate and secure. Check universal phone measurements. Goggles and apron. Work clamped securely.

6. Planning Task Bank Work carried outQuality control checksHealth & Safety Issues Drill a hole for the switch is going to be. Pull through the wires out of the switch hole and solder the switch to the wires and push the switch into the hole. Select the correct switch and measure the switch to ensure that it fits accurately Goggles and apron, work clamped securely. Care taken when soldering using the soldering iron stand in a well ventilated space. Screw the circuit board inside my docking station. Ensure that the screws won’t come through on the outside of the docking station. Measure the screws and the thickness of the material. Careful handling of circuit board to ensure circuit stays connected. Attach the battery to the circuit board. Rewire and solder the speakers and pull wires through to the circuit and solder securely. Test the battery to make sure it works. Ensure negative and positive are soldered in the right place. Careful with electrical components. Care taken when soldering using the soldering iron Mark out and measure docking station pieces for cutting. Label each part. Ensure pieces are measured accurately with steel rule, tri- square. Careful use of equipment on a flat workbench Finishing the acrylic parts cut out on scroll saw or by hand by hand filing, wet & dry and using the polishing machine. Work clamped carefully but protective plastic on to stop work from being marked. Safe operation of hand tools, Goggles and apron on. Using 2D Design to design branding for company logo onto vinyl sticker/ baser. Using the laser cutter to cut the design to be applied to docking station. Commercially viable logo, zoom feature and gridlock used for high quality design work. Careful application to the docking station. Safe operation of Laser cutter. Check the speaker and circuit board are wired correctly and connect to a phone and battery Check the quality of soldering, no overlapping on circuit, wires snipped. Careful whilst handling the electronic components.

7. Making Timeline SingleDoubleTime Used Mon 9th NovThurs 12 th Nov3 hours Thurs 19 th Nov5 hours Mon 23rd NovThurs 26 th Nov (Community Day) 6 hours Thurs 3rd Dec8 hours Mon 7 th Dec MOCK WEEK Thurs 10 th Dec MOCK WEEK - Thursday 17 th Dec Controlled Assessment week 10 hours Mon 4 th JanThurs 7 th Jan13 hours Thurs 14 th Jan15 hours Mon 11 th JanThurs 14 th Jan Product Design Controlled Assessment Day 11:10 – 5:10pm 20 hours FINAL Practical deadline Wed 20 th Jan Year 11 Parents Evening