Topic 5:
Product
development (11
hours)
5.1 Manufacturing
Techniques
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Assessment statement |
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Notes |
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5.1.1 |
Define manufacturing technique |
1 |
A
specific manufacturing term, sometimes relating to one material group only. |
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Outline the techniques
of moulding, casting, weaving, fusing, stitching,
cutting, machining, abrading, using adhesives and using fasteners. |
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The principles of each
technique are required. |
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Describe how the
techniques in 5.1.2 relate to different materials. |
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For example, casting relates to metals, plastics, food, ceramics
and some composites, but not to timber or textiles. |
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Discuss advantages and disadvantages of using the
techniques to manufacture products. |
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Refer to the viewpoints
of the manufacturer and the user. |
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5.2 Craft
production
1.5 hours
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Assessment statement |
Obj |
Notes |
References |
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Define craft
production and one-off production. |
1 |
A
small-scale production process centred on manual
skills. An
individual (often craft-produced) article or a prototype for larger-scale production |
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5.2.2 |
Describe why most products were manufactured
by craft techniques prior to the Industrial Revolution. |
2 |
Refer to the development of skills; sources of
materials and energy; sales and distribution; relationship of craftsman or
designer with client or consumer. |
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5.2.3 |
Explain the advantages and disadvantages of
craft production. |
3 |
Consider economies of scale, value of the product, labour, market forces and flexibility of manufacture. |
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5.2.4 |
Discuss the importance of craft production
for developed and developing countries. |
3 |
Economic development, infrastructure and market needs should be
considered, but also the rise of the “master craftsman” in industrialized
countries |
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5.2 Craft
production
1.5 hours
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Assessment statement |
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Notes |
References |
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5.3.1 |
Define mechanization. |
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A volume production process involving
machines controlled by humans |
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5.3.2 |
Describe how the availability of new sources of power in the
Industrial Revolution led to the
introduction of mechanization. |
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Refer to water and steam power. |
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5.3.3 |
Define assembly-line production |
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The mass production of a
product via a flow line based on the interchangeability
of parts, pre-processing of materials, standardization and work division. |
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5.3.4 |
Explain the relevance of assembly-line
production to mechanization |
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Refer to economics, design of products, effect
on the workforce and consumer choice. |
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5.3.5 |
Outline two advantages
and two disadvantages of mechanizing a production process. |
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Consider cost, quality of product, social conditions and labour |
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5.3.6 |
Define batch production and mass
production. |
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Limited
volume production (a set number of items to be produced). The
production of large amounts of standardized products on production lines, permitting very high rates of production per
worker. |
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5.3.7 |
Compare batch
production and mass production in a mechanized production system. |
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Consider market needs, consumer choice, product differentiation
and economies of scale. |
5.4 automation
2 hours
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Assessment statement |
Obj |
Notes |
References |
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5.4.1 |
5.4.1 Define automation. |
1 |
A volume
production process involving machines controlled by computers. |
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5.4.2 |
5.4.2 Describe how the
development of computer and information technology in the “technological
revolution” led to the introduction of automation. |
2 |
Refer also to the importance of electricity |
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5.4.3 Define computer-aided
manufacture ( (CNC). |
1 |
The use
of computers to aid manufacturing. Refers
specifically to the computer control of machines for the purpose of manufacturing complex parts in metals and other
materials. Machines are controlled by a program commonly called a “G
code”. Each code is assigned to a particular operation or process. The codes
control X,Y,Z movements and feed speeds. |
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5.4.4 |
5.4.4 Explain how CAD, |
3 |
Consider the wide variety of systems available |
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5.4.5 |
5.4.5 Define just-in-time
(JIT) and just-incase (JIC). |
1 |
A
situation where a firm does not allocate space to the storage of
components or completed items, but instead orders them (or manufactures them) when required. Large storage areas
are not needed and items that are not ordered are not made. A
situation where a company keeps a small stock of components (or complete
items) or ones that take a long time to make, just in case of a rush order. |
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5.4.6 |
5.4.6 Explain the advantages of JIT
and JIC to manufacturing. |
3 |
Refer to reliability, efficiency,
distribution, workforce, storage, capital
investment, stock control and traditions. |
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5.4.7 |
5.4.7 Define mass customization.
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1 |
A
sophisticated CIM system that manufactures products to individual customer orders. The benefits of economy of scale are
gained whether the order is for a single item or for thousands. |
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5.4.8 |
Outline how mass
customization is changing the relationship between the manufacturer and the
consumer. |
2 |
The relationship is
akin to craft production, where the individual requirements of the consumer
dominate. |
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5.4.9 |
Discuss the impact of
automation on working conditions. |
3 |
Consider nature and type of employment, healthand
safety issues, social interaction and job satisfaction. |
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5.4.10 |
Outline how automation
has improved the type and range of products available to consumers. |
2 |
Many products require
such precision in their manufacture that, without
automation, it would not be possible to produce them at an affordable price. |
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5.5
Economic considerations
2 hours
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Assessment statement |
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Notes |
References |
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5.5.1 |
List the costs that contribute to the final cost of a product. |
1 |
Take into account scale of production,
complexity of product, resources, skills, quality control, size and weight of
product for storage and distribution, type of advertising and marketing,
profits and taxes. Include costs relating to availability and procurement of
materials, R&D, labour, manufacturing costs, capitalcosts, overheads, distribution and sales. |
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5.5.2 |
Define fixed costs and variable
costs. |
1 |
The
costs that must be paid out before production starts, for example, machinery. These costs do not change with the level of
production. Costs that vary with output, for example, fuel or raw
materials. |
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5.5.3 |
Identify the factors in 5.5.1 as fixed costs or variable costs |
2 |
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5.5.4 |
Explain how the costs in 5.5.1 relate to
craft production, mechanization and automation. |
3 |
For example, raw materials and labour
costs will be significant for an individually crafted mahogany table, but for
an injection-moulded plastic component these costs
would be low and the capital cost of machinery high. |
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5.5.5 |
Explain the concept of “break-even point” in
relation to fixed and variable costs |
3 |
Once “break-even” point
is reached, profits can be made, because fixed costs have been covered. Variable costs will continue to rise with increased production |
Clean
manufacturing
2 hours
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Assessment statement |
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