Objective: To understand about scales of production.

Objective: To understand about scales of production.

Scales of production:

Products are made in a variety of different quantities and these are known as scales of production. There are four different types::

One off production

Batch production

Mass production

Continuous production


One off production

Only one of the product is made for a specific purpose, e.g a wedding cake. All the costs for designing, manufacturing and transportation are charged for this one product so costs are high and production is slow.

Batch production

These products are identical and are made in batches of pre determined numbers. Once the first batch has been produced a second batch is manufactured using the same tools and equipment. E.g Magazines, pasties. Employees may carry out a variety of tasks in manufacture and the use of Jigs and templates would be used to speed processes up.

Mass production

The product goes through many stages of a production line. The workers and the machines are responsible for only certain parts. Cost of the plant is high.

Continuous production

Products are produced over periods of hours, days, weeks or even years. The production line never stops. Few workers required and skill range is low.

Cut these out and stick ‘em in


Arrange the pictures to the descriptions

Objective: To understand about organising production.


Just in time production:

With lots of options available for products the manufacture has to be organised so that all the parts come together when they are required this also means that the company doesn’t have to store lots of goods.

Jit involves working closely with the suppliers. The leather company making the seats need to know what colour is needed and when for. Each company needs to match their manufacture and delivery to the order time, this is called logistics. Ict is used to help information be shared.

E.G if you order an Oak Green Golf, with a 2l 16v petrol engine and a grey leather interior then all the parts have to be ordered to the production line in time as the rest of the construction starts. After all the production line cant stop just because the engine hasn’t arrived yet.

Copy this into your book.



Advantages of JIT:

Less money tied up in storage.

Disadvantage:

Late delivery of goods stops the production line.




All these parts have to come together at one time


EDI (Electronic data interchange)

This is the transfer of structured data with out human interference.

This can shorten the supply chain by speeding up the time given to initiate and agree customer orders.

A tee shirt is sold in a shop, a stock order goes direct to the manufacturer, the items are totalled up and collected by a delivery firm and delivered to the shop.


Managing stock:

This is very important to commercial production:

If there is not enough stock available, products cant be sold. There will also be a delay on ordering and receiving new stock. This can man that the customer might go elsewhere rather than wait..

Too much stock and it takes up space waiting to be sold and the risk of damage is increased. This is particularly important with food.

http://www.youtube.com/watch?v=R4pN50yYI5k

What does a warehouse look like, think of ikea.

Cut out and stick in the image from pg 60. Copy this into your book.

Objective: To understand how ICT is used in production

CAD CAM

CADAdvantages

Disadvantages


CAD CAM

CAMAdvantages

Disadvantages


CAD CAM

How else could ICT be used in industry beyond CAD CAM?

Video conferencing

Why are products manufactured in the far east?

What are the issues with this?


Automating large scale production.

Take a photocopy of 66-67 and glue it into your book.

Objective: To understand how to shape metals by casting

Sand casting:http://www.youtube.com/watch?v=7BI4v0Gqc7k&feature=related

Cut out photocopied page 69, and glue in.

Objective: To understand about plastic moulding processes

Choose one of the three products on the table.

Pick a suitable manufacturing process:

Rotational Moulding injection moulding Blow moulding 1 mark

Describe the process to make this product:

3 Marks


Injection moulding:

http://www.youtube.com/watch?v=WHwTHarf8Ck&feature=related

http://www.youtube.com/watch?v=eUthHS3MTdA&feature=related

Rotational moulding:

http://www.youtube.com/watch?v=VPLaUzMh3Rw

Blow moulding:

http://www.youtube.com/watch?v=ZfyPCujUPms

Cut out the plastic products on the next slide and arrange them into types of plastic process






Objective: To understand how to manufacture traditional wood joints

Traditional wood joints

You may be asked to identify a traditional wood joint, or possibly suggest how you might construct a wooden object. As a result you will need to know about these.

Cut out the paragraphs about the wood joint and put the picture next to it, Then move onto the next one.

Objective: To understand how to join metals.

Research at home page, 84-85 and page 93-94.

Objective: To understand about mechanical properties

Plasticity: The ability of a material to be perminently changed in shape. An example is melting a material into liquid form and pouring it into a mould.

Elasticity: this is the ability of the material to bend and flex when force is applied and then return to shape.

Strength: The ability to withstand force without breaking or deforming.

Hardness: How resistant a material is to wear. Often specified for high wear areas like public places.

Toughness: A materials ability to resist sudden impacts before breaking.

Durability: A materials resistance to wear and tear and its resistant to corrosion and deterioration.

All resistant or compliant materials share these properties but in different combinations. A designer will choose a material that is high in the property they require.

Copy these into your book

Objective: To understand about physical properties

Print out page 102-103.

Cut the sections out and stick them in.

Objective: To understand about different types of paper and card.

Layout and Tracing paper

Has a translucent version. Used during development stages of designing as previous drawings can be used as underlay.

Cartridge paper

A tough lightly textured paper. Traditionally used for general drawings and sketching.

CardboardHeavy form of paper, often made from recycled material. Can be laminated together to create thicker boards.

Solid white board

Made from wood pulp strong and high in quality, this is used for book covers and expensive packaging.

Duplex board Made from pure wood pulp with bleached liner on one side, mainly used in food packaging.

Foil lined board

Aluminium foil is laminated to one side of any paper or board.

Corrugated board

Made from liner board and the medium (corrugated sheet in the middle). Cheap ad often used for large cartons and boxes, strong and not too heavy.

Which is which?


Layout and Tracing paperHas a translucent version. Used during development stages of designing as previous drawings can be used as underlay.

Cartridge paperA tough lightly textured paper. Traditionally used for general drawings and sketching.

CardboardHeavy form of paper, often made from recycled material. Can be laminated together to create thicker boards.

Solid white boardMade from wood pulp strong and high in quality, this is used for book covers and expensive packaging.

Duplex boardMade from pure wood pulp with bleached liner on one side, mainly used in food packaging.

Foil lined boardAluminium foil is laminated to one side of any paper or board.

Corrugated boardMade from liner board and the medium (corrugated sheet in the middle). Cheap ad often used for large cartons and boxes, strong and not too heavy.


Layout and Tracing paperCartridge paper

Cardboard

Solid white board

Duplex board

Foil lined board

Corrugated board

Can you think of how these might be used in a product?

Objective: To understand about different types of wood

Wood comes in two main types and then split off from there:

Natural Wood

Comes in two types. Hardwood and soft wood.

Hardwood trees loose their leaves in the winter generally and grow more slowly. This makes them more expensive

Softwood (like Christmas trees) don’t loose their leaves in the winter and grow more quickly.

Designers choose the type of wood on colour and pattern of the grain as this varies dramatically.


Manufactured wood.

Manmade and consists of woods being glued together either in layers or fibres. As a result of this they can be manufactured in very large sheets.

Offer consistency in strength and workability.

MDF: Wood dust and resin pressed together

Plywood: Thin layers of wood glued at right angles.

Chipboard: Made from small chips glued with resins and compressed.

Blockboard: Core soft wood strips clued and covered with plywood on both sides.

Hardboard: wood fibres that have been pulped and compressed.


FSC:

Forestry Stewadship Council

The wood comes from a sustainable source.

http://www.youtube.com/watch?v=wnDkXWNDsDE

http://www.youtube.com/watch?v=51AwOL0He4c&feature=related

Objective: To understand about different types of metals

Metals:

Ferrous Metals:

Contain Iron. Common forms are, cast iron, mild steel, high carbon steel and stainless steel.

Steel is the most important metal we use.

Ferrous metals are prone to rusting.

Objective: To understand about different types of metals

Metals:

Non ferrous metals:

Do not include iron, but do include aluminium, copper, lead, zinc, tin, gold and silver.

Alloys and alloying:

Pure metals have limited range of properties. By combining its possible to create and alloy that has a better range of properties or characteristics.

Objective: To understand about different types of plastics

There are two main types of Plastics. However these then split again into different types.

1. Natural Plastics- Occur naturally

2. Synthetic plastics- Man made



1. Natural Plastics- Occur naturally

The most common form of this is Amber



2. Synthetic plastics.

These split into three main types which have specific properties:

Thermoplastic- Can be reshaped if heated.

Thermosetting plastic- Once it has been shaped it cannot be remoulded, it is SET.

Reinforced Plastic: Both thermo and thermoset can be reinforced by adding fibres such as glass or carbon.


Quiz time:

1. What plastic started the film ‘Jurassic Park’?

2. What was Delboy and Rodneys three wheeled Reliant Robin made from?

3. If you were making a handle for a Frying pan would you use Thermo or Thermo setting plastic and why?

4. In Vacuum forming the most common plastic used is High Impact Polystyrene (HIPS). What sort of plastic is this?

5. What plastic is the body of Mr Browns future Lotus Exige (in White) made from?


1.

2.

3.

Amber

Glass reinforced plastic

Thermosetting plastic resists heat better


4.

5.

Thermoplastic, because it can be re heated and re moulded

Glass reinforced plastic

Objective: To understand about manipulating and combining materials

Paper and board:

Paper and board is very easy to manufacture and is very versatile. Combining this with different materials produces packaging for a variety of things e.g: Aseptic cartons.

These contain:

Cardboard 70%- A stable material with good heat resistance, light protection and can be easily printed.

Polythene Film 24%- Waterproof and seals well.

Aluminium foil 6%- Excellent gas, water and light barrier (particularly when laminated between plastic layers).

The combination of these properties makes Aseptic cartons very popular for products such as Fruit Juice, Milk and Soups. However it is hard to recycle.

Copy this into your book



Timber based products:

Timber is very versatile but it does have limitations. The biggest one being the sizes that it comes in. As a result manufactured boards have been and are being developed to address these issues whilst retaining the appearance of natural wood.



Manufactured board comes in very large sheets and is generally from recycled materials. However they are unattractive and so they have a decorative layer of ‘veneer’ on top. The use of veneers makes the wood cheaper as the quantity of ‘real’ wood is greatly reduced.

A veneer is term given to thin layers of wood approximately 0.8mm thick. This is widely used by companies like IKEA.

A plastic laminate can also be used particularly for kitchen worktops. These are layers of paper in a plastic resin. The paper gives a decorative finish and the resin makes it hardwearing, heat resistant coating.

Objective: To understand about metal and plastic based products and composite materials.


Metal based materials:

Non ferrous metals have a protective layer to prevent corrosion. Ferrous metals, with the exception of stainless steel, rust. There are several methods that can be used to stop this:

Link these products to the process on the next slide:

• Cans of Tomato soup• Mk2 VW Golf bodies• Bathroom taps• Outdoor bracket• Jewellery



Electroplating:

Chrome. Another metal is used to coat the base metal. The coating material as well as preventing corrosion gives the base material a more attractive appearance.

Tin Plating:

Steel sheets are passed through tanks of molten tin. The food industry use this.

Zinc plating:

Steel is dipped into molten zinc. This is called galvanising.

Enamelling:

This is the process of coating ferrous and non ferrous metal with a layer of ground glass. It creates a hard and decorative and coloured coating that when used with steel, is hard and scratch resistant. Often used for coating cookers.

Plastic coating:

Applying a thermoplastic coating to the surface of a metal item to provide long term corrosion, impact and chemical resistance


What process would you choose for these products?



Plastic based materials

Plastic are largely synthetic or manufactured materials so can be easily processed to provide a wide range of different properties.

Plasticisers can be used to improve the flow properties when injection moulding.

Flame retardants are often used to produce a plastic that is resistant to combustion.

Additives can be added to make plastic more biodegradable.

Bio plastics are also available and these are made entirely out of renewable materials, wheat, corn and potatoes.

Objective: To understand about smart materials and smart systems.

Cut these out.

Photo chromic:Materials change colour in response to light. Some glasses use reactive lenses which become darker as the light levels increase.

Thermo chromic:These materials change colour in response to temperature. This has been used to manufacture bath plugs that show you when the bath temperature is too hot.

Electroluminescent:Produces light of different colours when an electric current is passed through them. Used to illuminate emergency exits in buildings.

Fluorescent:Materials produce light when exposed to uv rays. When uv is removed the light goes out.

Shape memory alloys:After being strained they revert back to their original shape at a certain temperature. Example would be memoflex glasses.

Quantum tunnelling composites:These have been used to create touch sensitive switches for electronic devices in clothing.


Cut these out.

Thermo electric materials:When a current is applied one side of the material cools whilst the other side heats up. A plate has been developed that uses this material to keep food either hot or cold depending on the polarity of the power source.

Magneto-Rheological fluids:These become solid when placed in a magnetic field. They can be used to construct dampers that suppress vibrations in buildings during earth quakes or high winds.


Write these titles in your book and arrange the boxes you have just cut out to the correct titles:

1. Colour changing materials

2. Light emitting materials

3. Moving materials

4. Temperature changing materials

5. Thickness changing materials.

Once you think you have them right, check page 128-129 and glue them in the correct places.

After this read ‘the future of smart materials and smart systems, and nanotechnology page 129. What are your thoughts?

Objective: To understand about modern materials

Take page 130-131 and stick in the individual pictures and explanations.

Answer question 1 and 2 at the bottom of 131.

Do the same with 132 and 133

Objective: To understand about standard components

Standard components:

These are pre manufactured parts brought in by individuals or commercial manufacturers usually as part of a batch or mass production system.

This brings many benefits to the producer and the consumer, including, re direction in manufacturing costs, standard sizing, consistent quality.

For example an mp3 player uses a standard mini usb socket to connect to a computer. The mini usb socket would be made by a factory who specialise in this component and would be then brought in by other mp3 player manufacturing companies.

VW own, Volkswagen, Audi, Seat and Skoda. Although they appear different there are many shared parts between these ranges.


Objective: To understand about scales of production.

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