1. BTEC First Engineering
Learning aim A Know about engineering processes used to produce modern engineered products

2. Surface mount
Surface-mount technology (SMT) is a method for producing electronic circuits in which the components are mounted or placed directly onto the surface of printed circuit boards (PCBs). An electronic device so made is called a surface-mount device (SMD). In the industry it has largely replaced the through-hole technology construction method of fitting components with wire leads into holes in the circuit board. Both technologies can be used on the same board for components not suited to surface mounting such as large transformers and heat-sinked power semiconductors.

3. Printed circuit board
Electronic circuits in schools and industry are normally manufactured through the use of PCBs (Printed Circuit Boards). The boards are made from glass reinforced plastic with copper tracks in the place of wires Components are fixed in position by drilling holes through the board, locating the components and then soldering them in place. The copper tracks link the components together forming a circuit.

4. Process of manufacturing a PCB and SMT
Printed circuit board (PCB) manufacture
The Surface Mount Technology (SMT) process 1. 1. 2. 2. 3. 3. 4. 4. 5. 5. 6.

5. Process of manufacturing a PCB and SMT
Printed circuit board (PCB) manufacture
The Surface Mount Technology (SMT) process
Components are soldered to the surface of the board
Producing the artwork
The finished board is then inspected for imperfections
Designing the layout
Conveyor belts are used to transport the boards to the reflow soldering oven
PCB etching
Populating the board and soldering
The board is heated to a temperature that melts the solder plate
Drilling the board
Place components using pick and place robot
Apply solder paste to copper pads

6. 4 Scales of production One-off Batch Mass Continuous
BTEC First Engineering
4 Scales of production
One-off
Batch
Mass
Continuous
Teacher notes (PS 4):
One-off – designs are made individually (bespoke) for the customer. They are often craftsman made, using hand tools and light equipment. High-cost, high-value products.
Batch – a set number are produced, but with flexibility to increase production or individualise designs (e.g. cars produced with different trim levels). Also, a requirement for a repeat amount made at another time, on a regular or irregular basis, time, and quantity.
Mass – products made in large numbers, possibly until demand ceases to exist. Little human involvement in production as much is done by automated equipment.
Continuous (or flow) – production is indefinite. Commonly associated with liquid products (oil, fizzy drinks etc.) but could be for high-demand items (bottle tops, nails etc.). As with mass production, little to no human involvement in manufacture.
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7. One off Batch Mass Continuous
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8. Scales of production One-off
BTEC First Engineering
Scales of production
One-off
Where just one product is made for a customer.
Could be a prototype.
Batch
A set number of identical products.
Some flexibility to individualise designs.
Mass
Products produced in large quantities.
Often involves automation.
Continuous
Automated production can continue for months.
Often produces low-cost products.
Teacher notes (PS 4):
One-off – designs are made individually (bespoke) for the customer. They are often craftsman made, using hand tools and light equipment. High-cost, high-value products.
Batch – a set number are produced, but with flexibility to increase production or individualise designs (e.g. cars produced with different trim levels). Also, a requirement for a repeat amount made at another time, on a regular or irregular basis, time, and quantity.
Mass – products made in large numbers, possibly until demand ceases to exist. Little human involvement in production as much is done by automated equipment.
Continuous (or flow) – production is indefinite. Commonly associated with liquid products (oil, fizzy drinks etc.) but could be for high-demand items (bottle tops, nails etc.). As with mass production, little to no human involvement in manufacture.
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9. Characteristics of different scales of production
ONE OFF
BATCH
MASS
 CONTINUOUS
Unit Cost
High 
Medium
Low
Tools & equipment
General
Specialised
Specialised and dedicated
Initial investments
High
Production efficiency
Medium/high
Very high
Labour type
Skilled
Skilled/semi skilled
Semi-skilled/unskilled
Unskilled
Labour costs
Low 
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