1. GCSE Revision (Section B) - Manufacturing Methods

2. Q What is Injection Moulding? Please turn to page 72 of the AQA product design workbook.

3. Blow Moulding Production Methods What is injection Moulding? Materials such as polystyrene, nylon, polypropylene and polythene can be used in a process called injection moulding. These are thermoplastics - this means when they are heated and then pressured in a mould they can be formed into different shapes.

4. What is Extrusion? Materials such as metals and plastics can be used in a process called extrusion. This means when they are heated and then pressured in a mould they can be formed into different shapes and sections The plastic and metals melt into a liquid which is forced through a die, forming a long 'tube like' shape. The extrusion is then cooled and forms a solid shape. The shape of the die determines the shape of the tube. Production Methods

5. Blow Moulding Production Methods Blow Moulding Blow moulding follows the same stages of manufacture as injection moulding. HDPE (high density polyethylene) is ideal for this type of manufacturing technology. The HDPE granules / powder is placed into the hopper. It drops down on to a rotating thread and travels along its distance. During this process the granules / powder is heated and becomes fluid. However, when it reaches the mould compressed air is also blown into the mould. This pushes the HDPE around the edges of the mould, forming a hollow shape, in this case the bottle.

6. Laser Cutter Laser cutting / etching machines are quite simple in the way they work. The lens system that controls the position of the laser is itself moved by a motorised slide control system. The work/material being engraved or cut by the laser is held firmly in position on a vacuum bed. The laser is deflected from it source within the machine through a series of precision lenses/mirrors and focussed accurately on the area to be cut/etched. Laser Cutter GCSE Revision

7. Production Lines GCSE Revision Production Line / Assembly Line An assembly line is a manufacturing process (most of the time called a progressive assembly) in which parts (usually interchangeable parts) are added to a product in a sequential manner to create a finished product much faster than with handcrafting-type methods.

8. GCSE Revision Standard Components Standard Component A standard component is usually an individual part or component, manufactured in thousands or millions, to the same specification (such as size, weight, material etc...). A good example is a steel bolt. Bolts are available in a vast range of standard sizes. ADVANTAGES OF USING STANDARD COMPONENTS Standard components can be manufactured in vast quantities, keeping costs down. Standard components are supplied in standard sizes. Consequently, they are easy to order. Safety / quality testing is easier when dealing with standard components. Often a number of standard components, from a batch will be tested. Faulty components can be withdrawn from sale, if detected. Manufacturers of ‘complex’ products (computers TVs, etc....), usually assemble their products from standard components. This allows them to concentrate on the development of their specialised product, rather than having to design each individual component. This speeds up product development. Setting up a mass production line is easier if standard components are used. It is easier to train staff / the workforce, as they are dealing with the same standard components, when assembling products.

9. Data Transfer Electronic data interchange Electronic Data Interchange (EDI) is the computer-to-computer exchange of data without human intervention. By moving from a paper-based exchange of business document to one that is electronic, businesses enjoy major benefits such as reduced cost, increased processing speed, reduced errors and improved relationships with business partners.

10. Production Methods Production methods The way products are manufactured depends on the quantity required. For example, cars are continually manufactured in hundreds of thousands, a prototype is a ‘one off’ (just one made) and DIY furniture is made in batches of thousands or hundreds. There are three main types of production and they are described below: What are Production methods?

11. 1. PRODUCTION LINE SET UP 2. PRODUCTION LINE SPLIT INTO SEPARATE OPERATIONS. UNSKILLED AND SEMI SKILLED WORKFORCE REQUIRED. 3. PRODUCTION LINE RUNS 24 HOURS A DAY 365 DAYS A YEAR. 4. HIGH LEVEL OF FINANCIAL INVESTMENT NEEDED AS SPECIALIST MACHINERY IS USUALLY REQUIRED. 5. QUALITY CONTROL AT EVERY STAGE. Product is made in hundred of thousands. Continuous Production Examples Cars, Food products and Petrol Production Methods Production methods

12. 1. FLEXIBLE PRODUCTION LINE SET UP - MUST BE ABLE TO CHANGE WHEN THE PRODUCT CHANGES 2. PRODUCTION LINE SPLIT INTO SEPARATE OPERATIONS UNSKILLED AND SEMI SKILLED. 3. PRODUCTION LINE RUNS FOR A SPECIFIED AMOUNT OF TIME UNTIL THE CORRECT NUMBER OF PRODUCTS HAVE BEEN MANUFACTURED. 4. WORKFORCE FLEXIBILITY REQUIRED. WORKERS MUST BE ABLE TO SWITCH FROM ONE JOB TO ANOTHER. 5. OFTEN COMPONENTS ARE BOUGHT FROM OTHER COMPANIES AND ASSEMBLED INTO THE NEW PRODUCT. Examples Furniture, Electrical goods, Newspapers and clothing Product is made in thousands and hundreds. Batch Production Production Methods Production methods

13. 1.SMALL SPECIALIST COMPANIES. 2. A SKILLED WORKFORCE - SPECIALIST SKILLS eg. ENGINEERING. 3. SPECIALIST MATERIALS OFTEN REQUIRED eg. SPECIALIST MODELLING MATERIALS. 4. HIGH QUALITY PRODUCTS MANUFACTURED. 5. FINAL PRODUCTS OFTEN EXPENSIVE DUE LEVEL OF SKILL REQUIRED TO MANUFACTURE THEM AND COST OF SPECIALIST MATERIALS. 6. A HIGH STANDARD OF QUALITY CONTROL 7. PRODUCTS MANUFACTURED FOR AS SPECIALIST MARKET / CLIENTELE. Examples PROTOTYPES, SPECIALIST MODELS, HANDMADE ITEMS, SPECIALIST ENGINEERING, ONE OFFS Product is prototype ‘one off’. Single item Production Production Methods Production methods

14. Continuous production Information about continuous production 1. PRODUCTION LINE SET UP 2. PRODUCTION LINE SPLIT INTO SEPARATE OPERATIONS. UNSKILLED AND SEMI SKILLED WORKFORCE REQUIRED. 3. PRODUCTION LINE RUNS 24 HOURS A DAY 365 DAYS A YEAR. 4. HIGH LEVEL OF FINANCIAL INVESTMENT NEEDED AS SPECIALIST MACHINERY IS USUALLY REQUIRED. 5. QUALITY CONTROL AT EVERY STAGE. Batch production Single item/one off production Information about one off production 1.SMALL SPECIALIST COMPANIES. 2. A SKILLED WORKFORCE - SPECIALIST SKILLS eg. ENGINEERING. 3. SPECIALIST MATERIALS OFTEN REQUIRED eg. SPECIALIST MODELLING MATERIALS. 4. HIGH QUALITY PRODUCTS MANUFACTURED. 5. FINAL PRODUCTS OFTEN EXPENSIVE DUE LEVEL OFSKILL REQUIRED TO MANUFACTURE THEM AND COST OF SPECIALIST MATERIALS. 6. A HIGH STANDARD OF QUALITY CONTROL 7. PRODUCTS MANUFACTURED FOR AS SPECIALIST MARKET / CLIENTELE. Information about batch production 1. FLEXIBLE PRODUCTION LINE SET UP - MUST BE ABLE TO CHANGE WHEN THE PRODUCT CHANGES 2. PRODUCTION LINE SPLIT INTO SEPARATE OPERATIONS UNSKILLED AND SEMI SKILLED. 3. PRODUCTION LINE RUNS FOR A SPECIFIED AMOUNT OF TIME UNTIL THE CORRECT NUMBER OF PRODUCTS HAVE BEEN MANUFACTURED. 4. WORKFORCE FLEXIBILITY REQUIRED. WORKERS MUST BE ABLE TO SWITCH FROM ONE JOB TO ANOTHER. 5. OFTEN COMPONENTS ARE BOUGHT FROM OTHER COMPANIES AND ASSEMBLED INTO THE NEW PRODUCT. Production Methods Production methods

15. GCSE Revision Jigs, Moulds and Templates