1. Manufacturing & Design
An Introduction to the Technological World and the People who Create it…

2. Unit Overview
The purpose of this unit is for you to learn how new technologies are developed and manufactured and how they affect your way of life.
During the next several weeks you will learn about:
Developing new products
The engineering design process
How to create engineering drawings

3. Final Project
As a final project in this unit, you will design a new product, first as an individual, and then as a team.
Your final project will be a “desk organizer” made from recycled materials.

4. What Makes a Good Design Notebook?
Before you begin to design you have to setup your design notebook. So what makes a good notebook?
A good engineering design notebook is one that can be used to reconstruct your work even years after you have completed the original project.
Other engineers should be able to use the notebook to reconstruct your work.
The notebook will be used to determine the rightful owner of patents and other proprietary ideas.

5. Design Notebook Guidelines
Keep a table of contents in the front of the notebook – go to the middle of your notebook and title your page as Table of Contents
Every page of the notebook must be numbered on the outside corner – number your notebook pages
All entries should be done in ink
Make sure you record all of your information and data
Don’t crowd information on the pages
Keep your notebook and table of contents up-to-date
Include all the information favorable or unfavorable.
Errors – cross them out with a single line or an X (make sure you can still read the information)
Never tear out a page
Rough drawings and calculations should be done directly in the notebook

6. Design Notebook Guidelines
Title each page/section of the notebook and enter the information on the Table of Contents.
Sign and date the notebook page on the day you make the entry.
Information on loose sheets of paper should be entered into the notebook by:
Taping the loose paper to the next available blank page in the notebook
Taping each corner of the loose paper
Use a tape that will accept ink permanently
Place your signature on the loose paper, continue across the tape and end on the design notebook page. Sign across each corner of the taped page. Date the signature.

7. Gantt Chart
Gantt charts are used by engineers to break large projects into smaller tasks with time estimates.
Add the following Gantt Chart for unit 1 to your engineering notebook.

8. Task
Class Periods √ 5 10 15 20 25 30 35 40
1.1: What is Engineering?
1.2: Design Process
1.3: Engineering Drawing
1.4: Define the Problem
1.5: Research the Problem
1.6: Develop Possible Solutions
1.7: Choose the Best Solution
1.8: Create a Prototype
1.9: Test and Evaluate
1.10: Communicate the Solution
1.11: Redesign

9. On your Own… (Homework or otherwise)
Make a list of at least 25 different technologies that you see in a day.
Technology is…
All of the ways that people modify nature to suit human needs or wants.
Do not include specific objects on your list, but rather kinds of objects or processes.
Chevrolets, Cadillacs, and Jeeps are not three different technologies; they are all cars with internal combustion engines. An electric car is a different technology because it works on different principles.
When talking about the definition of technology…explain that technology refers both to products, like clothing, buildings, and most of our foods, and processes, such as the methods of weaving cloth, cooking food, or constructing buildings 9

10. Class Discussion: Technologies What were some of the technologies you listed?
Ask students to name some of the technologies they listed. The main purpose of this exercise is to help students expand their understanding of “technology.”
Don’t be too critical of cases in which they list a particular object…point out that an individual object is an example of technology.

11. What do you know? What is Engineering?

12. What do you know? What is Engineering?

13. Task 1.1: What is Engineering?
Essential Questions:
How and why do industrial designers work in diverse teams?
How do industrial designers improve current technologies?

14. A design story featuring IDEO and a talented
Nightline: Deep Dive
A design story featuring IDEO and a talented
team of designers…
(Video length - 22 min.)

15. Let’s Discuss What were the different team member roles in the video?
Did everyone in the team have an engineering background?
What steps did the team follow?
How did they make sure that everyone’s idea was considered?
Is this what you thought engineers did?
Sample answers:
Human factors experts, designers, artists, etc.
No, one was a marketing person, one had a medical background…
Define the problem, observe how people actually use grocery carts, generate lots of ideas, sketch, vote for the best ideas, combine ideas, build prototype.
Have a leader, mutual respect, posting ideas on the wall.
Answers will vary.

16. Key Points to Remember
Engineers work in teams with a variety of expertise in order to come up with different solutions.
All suggestions are respected and evaluated fairly in order to develop a good solution.
You will be working as a part of a design team similar to the one you saw in the video today.

17. So far, we have…
asked ourselves some questions about engineering, technology, design, and team work.
seen the design process first hand through IDEO’s shopping cart project.
identified some key components of team work.
defined technology and thought of various different technologies.

18. 1.1 Essential Questions Revisited
How and why do industrial designers work in diverse teams?
How do industrial designers improve current technologies?

19. Task 1.2: Design a Coffee Cup Sleeve The Design Process
Essential Questions:
How do people use a given technology?
How are technologies redesigned to meet people’s needs?
What is a mock-up and how does it help the design process?
How is mathematics used to determine costs and feasibility?
What do industrial designers, engineers, and scientists do?

20. Your challenge…
Throughout this activity, using a manila folder and tape, you will build a mock-up (model) of a new kind of coffee cup sleeve. Think about new features or improve some old ones.
You’ll have to design the coffee cup sleeve and calculate how much you can sell them for based on the cost of manufacturing and distributing the new product.

21. Engineering Design Define the Problem Research the Problem
Develop Possible Solutions
Choose the Best Solution
Create a Prototype
Test and Evaluate
Communicate
Redesign
Have student sketch this Engineering Design graphic in their engineering notebook. They should continue recording each step in their notebook as we work through the following slides…

22. Define the Problem
This stage includes the problem statement and also a list of Criteria/Constraints.
Criteria (desired features)
Constraints (limitations)
Your Task:
Design a coffee cup sleeve
Must fold up for storage.
Must open and be ready to use.
Must have a handle.
Only the provided materials may be used
Setting criteria sometimes helps when defining the problem. Some examples in this problem might be:
Protect the cell phone
Be easy to get to
Inexpensive
Etc.

23. Research the Problem Research comes in many forms: Internet Interviews
Observations
Library
In the interest of time, we’ll conduct limited research by letting you interview one-another about platform design as well as shoe aesthetics.
Your Task:
Gather information about:
how to make a structure that will fold.
What types of coffee sleeves already exist.
Have students work in pairs. Remind them about the part of the Nightline video in which the team members observed how people actually used a shopping cart. Observation is one way, interviews are another…

24. Develop Possible Solutions
Brainstorming – think of as many solutions as possible.
This stage almost always entails quick design sketches
Your Task:
Sketch at least two different ideas
Label the different parts of your design
Think about which components are the most important to you?
Develop Possible Solutions
Sketches need not be done in a specific way…we’ll learn about engineering drawing soon enough.

25. Choose the Best Solution
Be careful not to pick a solution based solely on just if you “like it.” At this point you need to compare each solution with the criteria you set in the identify the problem step.
Choose the Best Solution
Create a Pugh Chart
Which solution will you make a mock-up of with manila folders?
Can you combine various aspects of different solutions into one final solution?
How will you cut the material and construct the design?
Design
Folds flat - 5
Easy to use - 5
Handle - 5
Total 1 5 4 3 12 2 6
Urge students to look back at their definition of the problem before deciding on their final solution

26. Before committing to a particular solution, engineers create a prototype.
Prototype: full scale working model that tests whether the technology meets the requirements.
Prototypes rarely work as expected.
Your Task:
Build a mock-up with the available materials.
Pay attention to detail and try to produce a quality model.
Grading – accomplishes task (4), appearance (6)
Create a Prototype
Explain that a “mock-up” is a rough model showing what a design will look like in three dimensions. While students are working, circulate around the room and:
ask students to describe the purpose of their design
Provide tips to help students with cutting, joining, and drawing
Have students clean up when they are finished

27. Test the solutions to see if it meets the design criteria.
Your Task:
Test your design and record your results.
Does it fit?
Does it fold flat?
Can you open it and start using it easily?
Test and Evaluate

28. Communicate the solution to the people who might use the product.
Explain your solution
Communicate the solution to the people who might use the product.
Your Task:
Why should someone buy your holder?
What makes it worth it?
If you had enough time and materials, what would you do differently?
Communicate
Have each student stand and show off his or her cell phone holder, explaining what it does, and how it’s different.

29. Redesign Find a way to improve the initial design. Your Task:
Go back to the first steps in the process and add some ideas about the problem you are trying to solve.
The engineering design process is more like a wheel than a series of steps…it’s a constant cycle.
Redesign
Explain that the Redesign step often will occur after a product has been used for a while and people come up with ways to improve it…like the shopping cart…

30. The design process is a continuous cycle.
Engineering Design
Define the Problem
Research the Problem
Develop Possible Solutions
Choose the Best Solution
Create a Prototype
Test and Evaluate
Communicate
Redesign
The design process is a
continuous cycle.

31. The Cost of Manufacturing How much would your cost be to manufacture?
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
Cost of Materials – a materials engineer has decided you will use a material that costs $30 for each square yard (yd²).
$30/1 yd² material
1 yd
1 yd

32. The Cost of Manufacturing How much would your cost be to manufacture?
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
As a manufacturing engineer you don’t want to waste materials because that increases the cost of the product. Try to create as many items as possible out of the $30 sheet.
Start by figuring out how much material you will need to make one. If you can, unfold your mock-up so that it creates a pattern (also called a template).
Lay it out on a clean sheet of your design notebook and draw a rectangle around the outside to show how much material you will need to make another. You will probably have some waste.
Measure the length and width of the rectangle then calculate the area:
Area=length x width = ______ inches x ______ inches
= _______ inches²

33. The Cost of Manufacturing How much would your cost be to manufacture?
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
In order to determine how many patterns you can fit onto one square yard of material, you will need to convert the area from square yards to square inches.
Calculate the number of square inches in a square yard. Remember:
Area (A) is length (l) multiplied by width (w).
A=l x w(how many inches are in a yard?)
1 yd²= ______ in²

34. The Cost of Manufacturing How much would your cost be to manufacture?
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
If you were to lay out your shoe template onto a square yard and trace it so the patterns are easy to cut out, how many items could you fit on one square yard?
What would the material cost be for one item?
Remember one square yard of material cost $30.
Use the following formula to help:
Material cost =
cost for 1 yd² / # of holders on 1 yd² = ________

35. The Cost of Manufacturing How much would your cost be to manufacture?
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
Can you reduce the cost by further reducing the waste? Try making two or three templates and fitting them together in different ways to minimize waste. Sketch a pattern that results in minimum waste with at least 2 templates together in your notebook.
How many templates can you fit on one square yard? Calculate the lowest material cost for one item. Use this information and the fact that 1 yard of material is $30.
Material cost = cost for 1 yd² / # of items on 1 yd² = ________

36. The Cost of Manufacturing The Cost of Labor…
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
In addition to buying the materials, the manufacturer needs to pay the employees.
If the factory worker is paid $15 per hour, how much will he earn in an 8-hour day?
Earnings for a 5 day work week?
Earning for a 52-week year?
If he can make 1 item every 10 minutes, how many can he make in an 8 hour day?
Using the daily pay rate you calculated above, what would the labor cost be to make each item?
$15x8=$120 per day
$120 x 5 days = $600 per week
$600 x 52 weeks = $31200
6 per hour x 8 hours = 48
$120 /48 phones = $2.5

37. The Cost of Manufacturing Overhead Cost…
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
The cost to rent the factory, pay the utility bills, and other business maintenance costs are grouped together as the cost of overhead.
The easiest way to estimate manufacturing overhead on a single product is to determine plant overhead during a year and divide by the total number of products produced in that time.
Assume your factory can produce 100,000 items per year, and the overhead costs are $200, What is the overhead cost per item?
$200000/100000= $2.00

38. The Cost of Manufacturing Total Production Cost…
Material Cost
______________
How many products will fit on 1 yd² of material?
Material cost
per item
Labor cost
Overhead cost
Total Production Cost
Using all of your figures, calculate the cost to produce one item.
material cost + labor cost + overhead = total production cost
Material costs will differ
Labor costs = $2.5
Overhead = $2.5

39. The Cost of Manufacturing Manufacturer’s Markup…
Total Production Cost
______________
Wholesale Cost
Item Volume
Items per box
Wholesale $ per case
Cost per case with shipping
You can’t sell a product for the same amount it costs you to produce it and make money (profit), but you can’t mark it up too much or the customer might go elsewhere.
The markup is a percentage added to the cost of production. For example, to make a 10% profit you would add 10% of the total production cost to the total cost of production.
To find 10% of the total production cost multiply the cost by To make 25% profit, the manufacturer multiples the production cost by .25 and adds that value to the cost of production. The final sum is the wholesale cost.
prod cost + (manufacturer’s markup x prod cost) = wholesale cost

40. The Cost of Manufacturing Packing for Shipment…
Total Production Cost
______________
Wholesale Cost
Item Volume
Items per box
Wholesale $ per case
Cost per case with shipping
Factories do not sell products individually, but instead in full boxes, called cases to stores that sell to individual customers. Assume your holders will be tightly packed in a shipping box with cardboard packaging to protect them.
To find the volume of one item in cubic inches, measure the overall volume of the assembled mock-up, adding about ¼” on all sides to allow for the cardboard packaging.
Volume (V) is length (l) multiplied by width (w) multiplied by height (h). What is the volume packaging? Volume = l x w x h
V packaging = _____ in. x _____ in. x _____ in. = _____in³
Length (in)
Width (in)
Height (in)
Items Measurements
Packaging Measure = item +.25

41. The Cost of Manufacturing Packing for Shipment…
Total Production Cost
______________
Wholesale Cost
Item Volume
Items per box
Wholesale $ per case
Cost per case with shipping
The company has a big supply of shipping boxes, or cases, that are 18in. long, 12 in wide, and 10 in high. What is the volume of one shipping box.
How many items could you fit inside one case? Show how you calculated your answer.
Length x width x height = volume

42. The Cost of Manufacturing What you will charge per case…
Total Production Cost
______________
Wholesale Cost
Item Volume
Items per box
Wholesale $ per case
Cost per case with shipping
Calculate the price your manufacturing plant will need to charge for a case.
Wholesale Cost Per Item x Items per box = wholesale cost per box
Shipping and handling is $25 per box
Wholesale Cost Per box + Shipping and Handling = total store cost
Look back to see how many items you could fit per box when we calculated the shipping information

43. The Cost of Manufacturing Retail Pricing…
Total Production Cost
______________
Wholesale Cost
Item Volume
Items per box
Wholesale $ per case
Cost per case with shipping
When a store buys items, it pays a “wholesale price.” The store then sales the product for a higher “retail price” that is usually 50% more than the wholesale price.
When setting the wholesale price per unit, your must consider all of the following:
costs it takes to produce one unit
The amount of money you want to make beyond your costs (your “profit”)
Whether people will buy your product at the final “retail price”

44. The Cost of Manufacturing Retail Price…
Total Production Cost
______________
Wholesale Cost
Item Volume
Items per box
Wholesale $ per case
Cost per case with shipping
Manufacture’s Markup
The Cost of Manufacturing Retail Price…
Calculate the retail price. Assume the store owner would need to charge a markup of 50% to cover salaries, rent, overhead, and profit.
Total Store Cost / Items per box = Store Cost per Item
Store Cost of Each Item + (store’s cost markup x store cost of each item) = Retail price
Store’s markup is 50%

45. The Cost of Manufacturing What are the trade-offs…
Competition often means that the manufacturer has to find a way reduce the cost of the product or go out of business. The last step is to think about how you might reduce costs.
Reducing the cost almost always involves trade-offs.
Trade-off is a design choice in which one benefit is chosen at the expense of another.

46. The Cost of Manufacturing What are the trade-offs…
Write about one trade-off that would make the product less expensive. Do you think this is a good trade-off?
Write about one trade-off you think would help sell more products.

47. 1.2 Essential Questions Revisited
How are technologies redesigned to meet people’s needs?
What is a mock-up and how does it help the design process?
How is mathematics used to determine costs and feasibility?
What do industrial designers, engineers, and scientists do?

48. Task 1.3: Engineering Drawing
Essential Questions:
Why are engineering drawings important?
What kinds of drawings are most useful to engineers and why? 48

49. Drawing Game
Sit across from your partner with a manila folder between you
Arrange your blocks any way you’d like and make a drawing to show how they are positioned (you have 2 minutes).
Give your drawing to your partner and have him/her arrange their blocks just as you have drawn them. Watch this process, but do not help. (you have 2 minutes).
Remove the folder so your partner can compare his or her blocks with yours…Are they the same?
Switch and follow the same process with your partner drawing.
When finished discuss what you learned with your partner. 49

50. What did you learn?
How easy or difficult would this task be if they you were restricted to describing only in writing how to arrange the blocks rather than using drawings?
How difficult would it be to create something really complicated, like an entire house, skyscraper, or an airplane?
Emphasize that drawings are a helpful way to show how to make something, but only if they are drawn in a way that is very clear, and if the person looking at the drawing knows how to interpret it.

51. Measurement
The first step in creating and understanding engineering drawings is accurate measurement.

52. Reading a Ruler
When reading a ruler, you want to find out how far the item is from zero. When reading a ruler, you must locate the zero marking, this may vary depending on the ruler. On some rulers, the zeros start at the end, but on others it starts about 1/4 of an inch from the end. If you do not check your ruler beforehand you will not be getting an accurate measurement.

53. Types of Measurements Standard – inches, feet, yards, and miles
Metric – millimeters, centimeters, decimeters, meters, decameters, kilometers, etc.

54. Reading a Standard Ruler

55. The Standard MeasurementB C D

56. Scale
Scale is a ratio of a length used in a drawing to portray the actual length of the object.
In the drawing below, 1 inch represents 2 inches on the actual box so the scale is 1/2 or 1:2. 1”
Drawing 2”

57. Practicing Scale
Keeping with the 1:2 scale from the last slide, what would the scaled dimensions be in a drawing of the actual block shown below? Sketch the drawing and record the 1:2 scale in your design notebook.
What would the scale be
if you wanted to make it
3 times bigger?
H=2”
L=3”
W=2”
1:2 scale
H= ____ W= ____ L= ____
H=1” W=1” L=1.5”
3 times bigger would be 3:1 or 3/1

58. Practicing Scale
The actual gear represented on the card at your desk has an outside diameter (including gear teeth) of 16”. Measure the drawing on the card, sketch the gear in your notebook and record the correct scale (see below)
Actual Size = 16 inches
Scale: ______ : ______
model actual
1:8

59. Practicing Scale
When writing scale as a ratio, use the same units on both sides of the colon. Do not mix units! For example:
1:4 means 1 inch: 4 inches, or 1 foot: 4 feet – not 1inch: 4 feet
What is the scale if a 4 inch length on a drawing corresponds to a 4-foot length on the actual object?
A building has a wall of windows that is 12 feet across. If a scale of 1:24 is used, how wide is the wall of windows on the drawing in inches?
1:12
6 inches

60. Practicing Scale
Car designers build models of new designs because, unlike a drawing, a model can be seen from all sides.
If you build a 1:10 model of a car that is 15 feet long, how long would the model be? Give your answer in inches.
18 inches

61. Practicing Scale
If you are a carpenter following a 1:20 blueprint for a house and you measure one wall on the blueprint to be 8 inches long, how long should you build the wall for the house? Give your answer in inches.
If you discovered that the architect who made the blueprint made a mistake, and the scale should really have been 1:25, how would you need to change the length of the wall of the house?
160 inches
It should be 200 inches. You would need to increase the wall length by 40 inches

62. 4 Types of Drawings 1. Orthographic Drawings
Shows the top, sides, and bottom of an object
Also called multi-view drawings
Should be drawn to scale

63. 4 Types of Drawings 2. Isometric Drawings
Isometric is from greek meaning “equal measure”
Depth is shown by slanting the edges up at a 30 degree angle from the horizontal
Especially useful to engineers because it shows depth, and each line is drawn to scale

64. 4 Types of Drawings 3. Oblique Drawings
Show the front, top, and one side of an object.
Front drawn as front view and horizontal edges drawn at a 45 degree angle to give the impression of depth.
Not drawn to scale, therefore not as useful to engineers

65. 4 Types of Drawings 4. Perspective Drawings
Show objects as they would appear to the naked eye, or as they would appear in a photograph
Lines showing depth converge toward an imaginary vanishing point, creating the appearance of distance

66. Orthographic Drawing
Typically, you only need the front, top, and side view in an orthographic drawing
These views are two dimensional and do not show any depth…pay attention only to the faces of the object that can be seen from the side of the object you are drawing
Let’s practice identifying views…

67. Orthographic Drawing Practice
Practice identifying the views of the following objects by shading the corresponding sides with matching colors or patterns:

68. Orthographic Drawing Practice
Practice identifying the views of the following objects by shading the corresponding sides with matching colors or patterns:

69. Creating your 1st Orthographic Drawing
Step 1: Draw the front view – starting in lower left corner of the paper
Measure the length & height of the drawing and decide on the scale for the drawing
Draw light construction lines to frame the front view then make any other relevant measurements and draw the shape using the construction lines as a guide.
Have students color front, top, and side view…then demonstrate drawing front view on board.
Color in the front, top, and side view of the diagram above 69

70. Creating your 1st Orthographic Drawing
Step 2: Prepare to draw the top and side views
Draw construction lines extending upward and to the right from the front view (as shown below) 70

71. 71

72. Creating your 1st Orthographic Drawing
Step 3: Draw the top view
Use the construction lines you drew to place the top view
Measure the width of the object to ensure you have the correct size
Go to next slide and draw top view on promethean board 72

73. Draw top view here 73

74. Creating your 1st Orthographic Drawing
Step 4: Draw the right side view
Use the construction lines you drew to place the right side view
Teacher 74

75. Draw top view here 75

76. Creating your 1st Orthographic Drawing
Step 5: Verify correctness and erase construction lines
Teacher 76

77. Orthographic Drawing Practice
Draw a multi-view drawing of the following block: 1. 2.

78. Orthographic Drawing Practice
Solution

79. Orthographic Drawing Practice
Solution

80. Orthographic Drawing Practice
Draw a multi-view drawing of the following block: 3. 4.

81. Orthographic Drawing Practice
Solution

82. Orthographic Drawing Practice
Solution

83. Orthographic Drawing Practice
Draw a multi-view drawing of the following block: 5.

84. Orthographic Drawing Practice
Solution

85. Hidden Lines
Hidden lines are drawn as dashed lines and show hidden features of the object (ie. Holes, false ledges, etc)
They show things you could see if you could look through objects with “X-ray vision”

86. Dimensioning
All engineering drawings should indicate dimensions - the distances and locations on the actual object
Dimensions usually consist of a dimension line, capped by two arrowheads and broken in the middle for the measured distance
Two extension lines may extend from the edges of the object to show clearly where the dimension line begins and ends
Note: dimension and extension lines
should be drawn lighter than object lines

87. Dimensioning

88. Title Blocks
Title blocks are used to give essential information on technical drawings
Located on the lower-right side of the engineering drawing and typically include:
Name of the drafter
Title of drawing
Scale
Date

89. Final Orthographic Practice
Create orthographic drawings for the following blocks. Include a Title Block and dimensions.
Scale is 1: 12
1” = 12”

90. Do Now…
Complete the missing view of the object below.

91. Review
Remember…
Orthographic Drawings are drawn to scale
Draw Top, Front, and Right Side as follows:
Let’s review worksheet problems 5-7, 5-8, 5-9, 5-10, and 5-17

92. Creating Isometric Drawings
Step 1 – Draw front corner, slanting lines at 30 degrees
Step 2 – Keeping the lines parallel to your initial corner sketch lines and using a ruler to maintain correct size, draw the front view shape
Step 3 – Complete drawing, ensuring lines stay parallel

93. Another way to create isometric drawings…
Step 1 – Draw front corner, slanting lines at 30 degrees
Step 2 – Lightly draw an isometric box that the entire shape will fit in
Step 3 – sketch details of the shape on the front, top, and side
Step 4 – Erase lines that are not needed

94. Practice
Create Isometric drawings of the following part:

95. Practice
Create Isometric drawings of the following part:

96. For Homework…