Transcript Slide 1

A2 Product Design
Unit 3 Designing for the Future
Revision Notes
A2 Unit 3: Designing for the Future
Two Hour Paper Wednesday 13/06/12
In this unit you will develop your knowledge and
understanding of a range of modern design and
manufacturing practices and contemporary design
issues. You must have a good working knowledge of
the use of ICT and systems and control technology in
the design and manufacture of products. You must also
be aware of the important contributions of designers
from the past which may provide inspiration for future
design.
It is increasingly important that you develop an awareness
of the impact of design and technological activities
upon the environment because sustainable product
design is a key feature of modern design practices.
Unit 3 Designing for the
Future
3.1 Industrial and commercial practice
•Information and communication technology
•Biotechnology
(see questions handout and refer to notes from start
of year)
3.2 Systems and control
•Manufacturing systems
•Computer-integrated manufacture
•Robotics and artificial intelligence
•Flow charts
3.3 Design in context
•The effects of technological changes on society
•Influences of design history on the
developments of products
•Form and function
•Anthropometrics and ergonomics
•3.4 sustainability
•Life-cycle assessment
•Cleaner design and technology
•Minimising waste production
•Renewable and non-renewable sources of
energy
•Responsibilities of developed countries
3.1 Industrial and commercial practice
Information and communication technology (ICT)
• Characteristics, processes, application,
advantages/disadvantages of ICT in the development,
manufacture and sales of products in the global
marketplace:
Electronic communications• Email
• Electronic data interchange (EDI)
• Integrated Services Digital Network (ISDN) and
broadband
• Local Area Networks (LAN)
• Global networks 9internet)
• Videoconferencing
Electronic information handling• Market analysis
Automated stock control
• ‘just in time’ (JIT)
Production scheduling and production logistics
Flexible manufacturing systems (FMS)
• Quick response manufacturing (QRM)
Production control
Marketing, distribution and retailing of products using:
• Electronic point of sale (EPOS)
• Internet marketing
Electronic communications
E-mail:
E-mail is the simplest form of electronic communications
and has a comparatively low level of reach and range
when it is used for messaging or transferring documents.
However, it has proved invaluable in rapid
communication between designers, manufactures,
retailers and consumers due to its ease of use and
widespread access through internet connections. For
these reasons it has all but replaced the postal system.
(resulting in reduction of postal workers; the use of Ebooks has had a similar affect upon the publishing
industry, it seems ironic but Easons book stores now sell
Kindles). There are issues of security and privacy when
using e-mail and limitations on the size of attachments,
which often restrict its use, but to the majority of people it
is now their preferred way of communicating. Is it still?
What about texting?
Table 3.1 Advantages and disadvantages of e-mail
page 81
Electronic Data interchange (EDI)
This form of communication allows companies to do
‘paperless’ business using a process that transfers
business documents through a computer network, rather
than via the postal system. EDI can be formally defined
as the transfer of structured data, by agreed message
standards, from one computer system to another without
human intervention. Many modern companies use EDI
as a fast, inexpensive and secure system of sending
purchase orders, invoices, design and manufacturing
data, etc. Some manufacturers use EDI to transmit
large, complex CAD drawings and multinational
companies use EDI to communicate between locations
worldwide. EDI can also be used to transmit financial
information and payment in electronic form. However,
the transfer of files requires that the sender and receiver
agree upon a standard document format for the
document that is to be transmitted. To send a document,
EDI translation software is used to convert the document
format into the agreed standard.
Table 3.2 Advantages and disadvantages of EDI for business.
Integrated Services Digital Networks and
broadband
The development of ISDNs and broadband technology,
means that huge amounts of information can be
transferred across computer networks at far greater
speeds than ever before. The purpose of ISDN is to
provide fully integrated digital services to users
comprising digital telephony and data-transport services
through existing telephone networks.
ISDN is a set of communications standards for
simultaneous digital transmission of voice, video, data,
and other network services over the traditional circuits of
the public switched telephone network. The emergence
of ISDN represented an effort to combine subscribed
services such as Internet service provision and
telecommunications into one package.
Local Area Networks
A local area network (LAN) is a computer network that
interconnects computers in a limited area such as a
home, school, computer laboratory, or office building
using network media. The defining characteristics of
LANs, in contrast to wide area networks (WANs), include
their usually higher data-transfer rates, smaller
geographic area, and lack of a need for leased
telecommunication lines. In an office for example,
workers can log onto a computer and undertake work
and then communicate that work to any other
workstation on that particular LAN. Not only can workers
share information on the LAN but they can also share
devices such as scanners or printers.
Table 3.3 Advantages and disadvantages of LANs.
page 83
Global networks (Internet)
What is Internet?
The Internet is an arrangement of connected computers,
which lets computer users all over the globe exchange
data. At the present time, approximately 33% of the
world population has accessibility to the Internet. The
Internet is an extraordinary entertainment and learning
tool that may be utilized in a number of modes to
increase the ability of a user to collect information. The
principal components of the Internet are the World Wide
Web (WWW) and e-mail. With the passage of time, the
Internet has become the most effective business tool in
the contemporary world. Where LAN systems are
limited to a particular company or location, the Internet
has opened up worldwide possibilities. It can be
described as a global meeting place where people from
every corner of the world can come simultaneously.
It allows information and data to be passed
around instantly, opening up the
possibilities of things like design being
undertaken in Europe and manufacturing
in Asia. However LAN systems can be
almost totally secure (firewalls) but with
the Internet security is weaker and there is
always a danger that hackers could get
into what appear to be secure installations
and gain confidential information.
Table 3.4 Advantages and disadvantages of global
networks.
page 83
Exam paper June 2011
1. Electronic communication is an essential element of modern
business practice.
(a) Give three advantages to a business of using email compared with
telephone
communication systems.
(3)
(b) Describe four benefits to a business of using the internet as a
marketing tool.
(4)
(Total for Question 1 = 7 marks)
Answer Mark
1(a) Any three of the following :• Easier to contact groups of people. (1)
• Message content is stored for reference purposes. (1)
• Attachments can be easily sent. (1)
• Person does not have to be available to immediately
answer
the phone. (1)
• Emails give you more thinking time. (1)
• Less expensive. (1)
• Easier to filter / prioritise messages. (1)
• More secure / private than audible phone calls. (1)
(3 x 1)
(3)
1(b) Any four of the following :• Cheap method of advertising / facilitating sales (1)
• Focussed marketing / can be targeted at specific consumers.
(1)
• Has a global reach expanding customer base. (1)
• Provides a direct link to customers for sales / follow-up. (1)
• Wide range of information made available (Multimedia,
interactive presentations, detailed information, customer
reviews). (1)
• Faster processing of transactions resulting in increased
efficiency. (1)
• Allows customers to customise product. (1)
• Business can directly monitor sales and respond to trends
quickly.(1)
• Advertisements generated /edited /distributed quickly and
easily. (1)
• Websites available 24/7 encourage sales.(1)
Do not accept just ‘Efficient’.
(4 x 1)
(4)
Total for question
7
Videoconferencing
With the introduction of relatively low cost, high capacity
broadband telecommunication services in the late 1990s,
coupled with powerful computing processors and video
compression techniques, videoconferencing usage has
made significant inroads in business, education, medicine
and media. Like all long distance communications
technologies (such as phone and Internet), by reducing
the need to travel to bring people together the technology
also contributes to reductions in carbon emissions, thereby
helping to reduce global warming.
Videoconferencing uses audio and video telecommunications
to bring people at different sites together. This can be as
simple as a conversation between people in private offices
(point-to-point) or involve several (multipoint) sites in large
rooms at multiple locations. Besides the audio and visual
transmission of meeting activities, allied videoconferencing
technologies can be used to share documents and display
There are two types of videoconferencing systems:
• Dedicated systems have all the required
components packaged into a single console,
including a high-quality remote-controlled video
camera.
• Desktop systems are add-ons to normal
personal computers such as webcams and
microphones, transforming them into
videoconferencing devices.
Multipoint videoconferencing allows for
simultaneous videoconferencing among three or
more remote points using a multipoint control
unit (MCU) as a bridge that interconnects calls
from several sources. This enables three or
Electronic information handling
Market analysis (consider the market analysis for your
product)
Market analysis is an investigation of a market that is used
by a company when planning future activities. It can be
used to look at the available market for a product or it
may be used to predict expansion or contraction the
workforce. It can influence issues ranging from how a
product is advertised through estimates on capital outlay.
The raw can be collected in a number of ways e.g.
Questionnaires, e-mails etc. Once the data has been
collected , special software processes it. Once the data
has been processed it can be sorted so that companies
can interpret the results. On the basis of the results,
decisions are taken about the nature of the marketing
plan and about how best to satisfy the needs of the
intended customers. Market analysis is essential in
6 (a) Explain the benefits to a business of
using electronic methods of market
analysis.
(6)
Exam paper June 2010
6(a) Any three of the following points with a valid linked explanation:• Fast data transmission/ collection (1) so business is working
with up to date data / reduces lead time / enables QRM . (1)
• Data collected is accurate (1) providing the basis for good
decision making / allowing accurate prediction of future trends
/increasing competitiveness (1)
• Costs of information gathering are reduced (1) as fewer
personnel are needed / less postage costs. (1)
• More detailed information can be collected (1) allowing
businesses to better match products to market needs. (1)
• Allows large volume of data to be quickly analysed or
interrogated in different ways (quantative, qualative, trend)
(1) identifying patterns upon which immediate action can be
taken. (1)
• Efficient storage of data (1)so minimal space needed / makes
archiving and retrieval easier (1)
(3 x 2)
NB. The points above may lead to explanations given for the other
points. If it is a valid link then award the mark, but be aware of
repetition.
Quantitative and Qualitative Data
• Some methods provide data which are quantitative and
some methods data which are qualitative. Quantitative
methods are those which focus on numbers and
frequencies rather than on meaning and experience.
Quantitative methods (e.g. experiments, questionnaires
and psychometric tests) provide information which is
easy to analyse statistically and fairly reliable.
Quantitative methods are associated with the scientific
and experimental approach and are criticised for not
providing an in depth description.
• Qualitative methods are ways of collecting data which
are concerned with describing meaning, rather than with
drawing statistical inferences. What qualitative methods
(e.g. case studies and interviews) lose on reliability they
gain in terms of validity. They provide a more in depth
and rich description.
Specification development
When developing a specification for a new product, a whole
range of factors need to be taken into account.
Issues such as:
• Form
• Function
• User requirements
• Performance requirements
• Materials
• Processes
• Scale of production
• Cost
These are all factors which you are familiar with from your
own practical project. In an industrial situation, the
issues involved will be much more complex and
therefore computer programs are used to help produce
The process of specification development involves defining
all the parameters which relate to the product. Using
information such as:
• Anthropometric data
• Material limitation
• Market research data
A computer can establish factors such as components
required for a particular product, materials,
measurements and even building and construction data.
The advantage of such a system is that the process is
swift, thus reducing lead time for a product. It also
means that, as information is held on a computer, all
those who have need of the most up-to-date
specification can gain easy access.
There are two situations where
specifications are used in the design
process:
• Design specification
• Manufacturing specification
Both of which can be generated with the aid
of computers.
Table 3.6 Types of specifications that can be generated
using computer technology
Automated stock control
‘Just in time’
‘Just in time’ (JIT) manufacturing is a system used by
companies to reduce costs. Just In Time is a phrase that
originated at Toyota. Originally, it described how material
should be processed and moved in order to arrive "Just
In Time" for the next operation.
Lean Manufacturing means "manufacturing without
waste."
By only producing items when they are actually needed the
quality and efficiency of the manufacturing are improved.
It can also lead to higher returns for the company itself.
The idea is that a re-order level is set within stock control
and new stock is only ordered when that level is
reached. There is therefore no overordering which
saves space and again increases efficiency. An example
of JIT can be seen in the manufacture of cars.
Manufacturers only buy in materials for the immediate
use of the manufacturing process. As a consequence
the process of manufacturing is smooth, with just the
right amount of materials being delivered to the factory at
the correct time. The turnover is rapid and the amount of
money tied up in raw materials and components is
reduced. The main downside to this however is that if
the supply is interrupted (as happened in Japan after the
tsunami) the factory will face downtime as there are no
materials/components stockpiled.
Exam paper June 2011
Question: 4(b) Explain three reasons
why the operation of a just in time
(JIT) system leads to ‘lean
manufacturing.’
(6)
4(b) Any three of the following with a relevant explanation :• No wasted storage (1) as materials / products are
delivered /
dispatched just when needed. (1)
• No wasted time (1) as production delays are eliminated.
(1)
• No wasted energy (1) movement of materials is
minimized.
(1)
• No wasted materials / components / products (1) as only
amount needed are ordered /products are made to order.
(1)
• Minimized faulty products (1) as rigorous quality
assurance
systems are established. (1)
• No wasted labour (1) as work tasks are carefully planned
/systems automated where possible / so minimizing labour
costs.(1)
Production scheduling and production
logistics
When undertaking the manufacture of any product
it is important that all the resources and the
sequencing of tasks are allocated in the correct
way to ensure efficient production. This process
can be very complex.
Computer-based production scheduling and
production logistics (the planning, implementation,
and coordination of the details of a business or other
operation ) help make the production process
smooth. The idea is that if there are small
issues or hiccups in the process the computer
can iron them out. By producing a production
schedule a company can determine whether or
not a delivery promise can be met. It gives the
workers undertaking the manufacturing process
itself a statement of what should be done so that
their productivity might be measured, therefore
The advantages of computer-based
scheduling and production:
• Flexible and easily adaptable if product
mix or quantity changes
• Minimise work in progress and reduce
inventory
• Maintain balance on production line
• Raise productivity levels
Flexible manufacturing systems
Flexible manufacturing systems (FMS) are manufacturing
systems that have been set up to allow a company some
degree of flexibility to enable it to react to, and instigate,
changes fairly rapidly to the manufacturing process.
These changes might be either predicted or unpredicted.
This flexibility falls into two main categories:
Machine flexibility:
• System’s ability to change to produce new product types
• Ability to change order of operations
Routing flexibility:
• Ability to use multiple machines
• Ability to absorb changes such as capacity and capability
Such flexible manufacturing systems are usually linked with
CAM systems which are in turn linked to material
handling and ASRS systems.
The main advantages of FMS are:
• Better productivity
• Quicker machinery set-up times
• Lower labour costs
• Reduced down time on machinery
As a result, production and productivity are
increased.
Quick response manufacturing (QRM)
The main aim of quick response
manufacturing (QRM) is essentially to
reduce the lead time in all aspects of the
manufacturing process. From outside a
company, QRM is seen by the client as
responding rapidly in the designing and
making of products that are customised to
their needs. From the company’s point of
view, QRM is geared to the improvement
of the quality of the final product and to the
reduction in costs.
Production control
All the activities involved in manufacturing; handling
materials, parts, assemblies, and subassemblies, from
their raw or initial stage to the finished product stage
have to be carefully controlled in an organized and
efficient manner. It may also include activities such as
planning, scheduling, routing, dispatching, storage, etc.
This means that at various stages during manufacture
the quality of the work is checked. If problems are
found, relevant procedures need to be activated. In
modern industrial situations production control is
undertaken using computer technology. Depending on
the sophistication of the software there are a number of
ways in which production can be monitored and
controlled. All involve monitoring and testing at various
stages during production.
One method of quality control (QC) uses
coordinate measuring . In this case, a sensor
connected to a computer comes in physical
contact with the object under scrutiny. The
probe is able to check various parts of the
component. If the original coordinates of the
probe are known, then as the probe is moved
around the work, the dimensions can be
checked for accuracy. One method of checking
for accuracy is to have an optical based system.
The advantage of such a system is that there is
no direct contact with the work-large objects can
be checked and the response time is only limited
by the electronics in the system.
The problem with visual inspection of
products is that an element of human error
can creep in. ‘Intelligent cameras’ can be
programmed to view selected elements of
the component and flag up any issues
electronically. The advantage of this
system is that instead of sampling, the
camera can check all components passing
in front of it.
Advantages of computer-aided
inspection methods:
• Measurable quality throughout the entire
process.
• Inspection time can be speeded up.
• Any issues can be instantly identified and
rectified early.
• Large 3D objects can be tested.
• Can be made to adhere to up-to-date and
relevant standards.
• Information can be transferred digitally
instantly.
Marketing, distribution and retail
Electronic point of sale
Information lies at the centre of any business and, if used
properly, it ensures the business stays one step ahead of
its competitors. By using electronic point of sale (EPOS)
systems, a business is able to supply and deliver its
products and services faster by reducing the time
between placing the order and delivery of a product (lead
time). Each product is identified using its unique
barcode. When passed over a barcode reader, or
scanner, the barcode is read by a laser beam. The laser
scans the barcode and reflects back onto a photoelectric
cell. The bars are detected because they reflect less
light than the background on which they are printed.
Each product has its unique 13-digit number:
• First two numbers indicate where the product was made
• The next five numbers are the brand owner’s number
• The next five numbers are given by the manufacturer to
identify the type of product
• The final digit is the check digit, which confirms that the
whole number has been scanned correctly
It is important to note that information regarding
the price of the product is not contained on the
barcode (why?). Instead, the scanner (for
example at a supermarket checkout) transmits
the product code number to an in-store
computer that relays the product’s description
and price back to the checkout, where it is
displayed electronically and printed on the till
receipt. The in-store computer then deducts the
item purchased from the stock list so that it can
be re-ordered when stock is low (JIT).
http://teachertube.com/viewVideo.php?video_id=172944&title=IDAutomation_USB_Barcode_Scanner_Tutorial
Data matrices, also known as 2D barcodes, are
visual codes that can be read and decoded by
machine vision systems. The increasing use of
data matrix codes arises from the
manufacturer’s requirements for tracking their
products or components. The intention is that
batch or serial numbers can be permanently
marked onto components, which is useful for
tracking defective batches and identifying
counterfeit parts. 2D barcodes contain more
information because they use not only the width
of lines but also the height of them.
Electronic point of sale (EPOS) and associated
management software provide manufacturers with:
The electronic point of sale
(EPOS) system
Internet marketing and sales
The internet has revolutionised the marketing and sales of
products and services. Through the global networking of
computers, the internet provides an effective means of
accessing a wealth of information and entertainment.
The dramatic rise in e-commerce has led to the
formation of virtual communities, which businesses are
eager to explore.
The possibilities for innovative marketing techniques are
endless due to the simple identification of target market
groups by user preferences. Marketing can be ‘tailor
made’ to suit these markets, so a marketing message
can be sent directly to potential customers as opposed to
‘blanket’ advertising in traditional media.
Advantages and disadvantages of Internet sales and
marketing
Biotechnology
Genetic engineering in relation to wood
production
In recent years,
Lamination
Lamination is where material has been produced
by gluing together thin sheets, or veneers, to
make up that material. The most common form
of laminate material is plywood. Plywood is
made up of a number of thin layers of wood that
are called veneers. There are always an odd
number of veneers and they are always
arranged so that the grain on each layer is
positioned at 90⁰ to the layer above and below.
This is the strongest arrangement and plywood is
very stable and very strong. The layers are
bonded together with strong glues, usually epoxy
–resins.
There are a vast number of applications for plywood:
• Interior uses- cupboards and furniture.
• Exterior uses- boat building and shuttering.
Other wood laminates include:
• Laminboard
• Blockboard
Lamination can also be used to give a protective surface to sheet
material. For example a kitchen worktop made from MDF or
particle board is kept easily cleaned by gluing (with a contact
adhesive) a laminate material such as Formica®.
Lamination can also be used for shaping material. This is where
sheets or strips of veneer, are glued together and clamped in a
former. When the glue dries and the work is removed from the
former the work retains the shape of the former. This process is
used in the production of products such as chairs where sweeping
curves might be required. The advantage of this type of production
is that it is much less time consuming than trying to bend a solid
piece of wood into the desired shape. It also means that the former
can be used as a jig for batch production.
Advantages and Disadvantages
of using lamination:
Manufacturing systems
This is a period of rapid technological
development with more products than ever
being offered to the public especially in
electronics. These products change in
complexity and style very quickly, think of the
new models of products like mobile phones,
televisions, computers and gaming consoles
that you have experienced in the last ten
years. Companies involved in producing
these products use the latest complex
automated manufacturing systems. You must
have an understanding of these systems and
the effect they have on employment now and
in the future.
Advanced manufacturing
technology
(AMT)
AMT describes the massive impact computers have
had on manufacturing. Computer –integrated
technology (CIM) is the term used to describe the
incorporation of computer technology into all
aspects of manufacturing e. g. CAD for design and
modelling to CAM for production involving
robotics, materials-handling devices and
automated machinery.
ICT has also led to manufacturing management
becoming more integrated into all aspects of
production from design, production and
distribution.
Quick response manufacturing (QRM) has enabled companies
to be more efficient and respond more quickly to changes in
consumer demand. QRM incorporates total quality
management (TQM) and just in time (JIT) systems to enable
companies to :
• Reduce costs and waste
• Increase sales by responding quicker to customer demand
• Increase turnover (units sold)
• Improve quality by placing responsibility on specific
production teams or cells.
Some disadvantages of QRM are:
• Disruption to supply can lead to not meeting targets e.g.
Japanese companies suffered badly after the tsunami as new
stock could not be delivered leading to increased downtime.
• Inability to meet increase and change in customer demands.
• Problems within companies as regard to who is responsible
for what?
• A change in company philosophy and roles may be required
leading to personnel problems.
Concurrent manufacturing
Concurrent engineering is a work methodology based
on the parallelization of tasks (i.e. performing tasks
concurrently). It refers to an approach used in product
development in which functions of design engineering,
manufacturing engineering and other functions are
integrated to reduce the elapsed time required to bring
a new product to the market. A concurrent
manufacturing system brings together a wide range of
teams such as manufacturing (making), project
management (planning), technical support and
marketing to form multi-disciplinary teams to make the
design and manufacture process quicker. ‘Time is
money’ therefore the quicker you get a product to
market the less costs you experience. The information
flow between these groups has been facilitated by the
use of ICT systems.
Quality function deployment
QFD
This is a strategy developed by companies
to keep ‘in touch’ with customer
requirements in order to create a more
successful product. It is a quality
assurance method that factors in customer
satisfaction whilst developing design
ideas. The main feature of QFD is its
focus on customer requirements and its
use of multi-disciplinary teams that use a
‘House of Quality’ matrix.
House of Quality Matrix
House of Quality is a diagram, resembling
a house, used for defining the relationship
between customer desires and the
firm/product capabilities. It is a part of the
Quality Function Deployment (QFD) and it
utilizes a planning matrix to relate what the
customer wants to how a firm (that
produces the products) is going to meet
those wants.
House of Quality matrix
Some of the advantages of using
QFD/’House of Quality’ matrix as
part of concurrent manufacturing
are:
• Reduced time to market
• Reduction in design modifications
• Decreased design and manufacturing
costs
• Improved product quality
• Enhanced customer satisfaction
Flexible manufacturing systems
(FMS)
• A flexible manufacturing system (FMS) is a manufacturing system in
which there is some amount of flexibility that allows the system to react
in the case of changes, whether predicted or unpredicted. This
flexibility is generally considered to fall into two categories, which both
contain numerous subcategories.
• The first category, machine flexibility, covers the system's ability to be
changed to produce new product types, and ability to change the order
of operations executed on a part. The second category is called
routing flexibility, which consists of the ability to use multiple machines
to perform the same operation on a part, as well as the system's ability
to absorb large-scale changes, such as in volume, capacity, or
capability.
• Most FMS consist of three main systems. The work machines which
are often automated CNC machines are connected by a material
handling system to optimize parts flow and the central control
computer which controls material movements and machine flow.
• The main advantages of an FMS is its high flexibility in managing
manufacturing resources like time and effort in order to manufacture a
new product. Increase productivity, lower labour costs due to
automation and shorter lead times.
Lead Time
The amount of time that elapses between when a
process starts and when it is completed. Lead
time is examined closely in manufacturing,
supply chain management and project
management, as companies want to reduce the
amount of time it takes to deliver products to the
market.
For example, the lead time between the
placement of an order and delivery of a new car
from a manufacturer may be anywhere from 2
weeks to 6 months. In industry, lead time
reduction is an important part of lean
Product data management systems
(PDM)
The main drawback of advanced manufacturing
technology (ATM) and computer-integrated
manufacturing systems is their dependence upon
computer data to integrate fully all operations.
The cost of managing data is a key issue within
CIM. This is because if data becomes corrupted it
may cause machinery to malfunction. In order to
prevent these problems companies often use a
product data management system. PDM is an
information system used to manage data for a
product as it passes from design to manufacture.
The data includes plans, 3D models, CAD
drawings, CNC programs as well as all related
project data and documents.
Product data management (PDM) is the use of
software or other tools to track and control data
related to a particular product. The data tracked
usually involves the technical specifications of the
product, specifications for manufacture and
development, and the types of materials that will
be required to produce goods. The use of product
data management allows a company to track the
various costs associated with the creation and
launch of a product. Product data management is
part of product life cycle management, and is
primarily used by engineers. The main
advantages of PDM are:
• Reduced time to market (eliminates bottlenecks)
• Improved productivity (reduces data retrieval time)
• Improved control (data is up to date and does
need constant changing).
Lean manufacturing
• What is Lean Manufacturing?
• Lean is the term used to describe the
production systems and methods developed
by the Toyota Company in the post war
years. Lean comes about by focusing on the
reduction of the non-valued activities within
the organisation. Lean is all about achieving
more value by applying fewer resources more
effectively and efficiently through the
continuous elimination of non-valued added
activities or waste. Eliminating ‘fat’ anything
that is superfluous or waste.
Define the following
manufacturing systems: (page
101)
• Pull tools – Kanban
• Perfection tools – Kaizen
Just in time
JIT
• JIT is derived from a Japanese manufacturing
philosophy. Quite simply, JIT ensures that the right
materials, components and products arrive at the right
time, at the right place and in the exact amount. This
reduces waste and overstocking as new stock is only
ordered when it is needed, so saving warehouse space
and storage costs.
Major disadvantage any disruption to supply can lead to not
meeting targets e.g. Japanese companies suffered badly
after the tsunami as new stock could not be delivered
leading to increased downtime. If companies are not
correct in their predictions for stock needed they may run
out thus halting production till new stock is ordered.
Exam Exercise
Describe what Automated materialshandling, Automated storage and
retrieval systems (ASRS) and
Automated guided vehicles (AGV)
systems are?
(pages 103-104)
Question 3 (a) (b) paper June 2010
Sample Exam Question
Evaluate the impact of advanced
manufacturing technologies (AMT) on
employment.
See page 105 of Text Book
4 (a) Artificial intelligence (AI) is being increasingly
developed for use in the manufacturing industry.
(i) State what is meant by the term ‘artificial intelligence’
(AI).
• Any aspect of the following answer :• • Computers that can think / make
decisions / problem solve /
• learn / adapt / simultaneously process
large amounts of
• information .(1)
• (1 x 1)
Flow Charts
• A flowchart is a type of diagram that represents
an algorithm or process, showing the steps as
boxes of various kinds, and their order by
connecting these with arrows. This diagrammatic
representation can give a step-by-step solution to
a given problem. Process operations are
represented in these boxes, and arrows
connecting them represent flow of control. Data
flows are not typically represented in a flowchart,
in contrast with data flow diagrams; rather, they
are implied by the sequencing of operations.
Flowcharts are used in analyzing, designing,
documenting or managing a process or program in
various fields.
Open and
Closed loop
control system.
Closed-loop
has some form
of feedback.
A simple flowchart
representing a process for
dealing with a nonfunctioning lamp.
Design in context
In this section you will investigate a wide
range of design-related issues throughout
history. As designers you need to be
aware and informed about current and
future applications of technology as well
as what has gone before.
The effects of technological changes on
society
Design and technology has improved the lives of millions of
people worldwide. But the changes brought about by
developments in technology have resulted in farreaching social consequences.
Mass production and the consumer
society
With the advent of modern industrialisation brought about
by the invention of the steam engine (James Watt, 1765)
massive social changes have taken place. The
‘industrial revolution’ and industrialisation fundamentally
changed life worldwide. Many new fields of design were
needed to accommodate this and the professional
designer came into being. Population explosions
occurred in towns and cities where production was
centred and a new urban way of life was created. More
people needed more products and mass production
responded to this need. Expensive and time-consuming
crafted work could now be replaced by machine work.
Products once exclusively for the rich could now be
made at an affordable price for ordinary working people.
The modern mass-consumer society is a feature of the
affluent developed world where people’s ‘wants’ are
satisfied by a continual stream of new products. It is
also referred to as a ‘throw –away’ culture with an
increasing demand for convenience products such as
fast food and over-packaged goods. From the 1960s an
emerging teenage market has emerged. Some of the
strategies adopted by advertising companies are:
Built-in obsolescence
Built-in or planned obsolescence is a
method of stimulating consumer demand
by designing products that wear out or
become outmoded after limited use. This
has been adopted by a range of industries,
most notably by developed countries in
motor, domestic appliance and electrical
goods.
Mass production and its effect
upon employment
The industrial revolution and mass consumerism
meant that the craftsperson was replaced by
low-skilled workers in highly mechanised
factories. Although working conditions have
generally improved modern mass production still
has some social consequences:
• Reduced workforce
• High -skilled workforce required to set up and
maintain machinery
• Low-skilled workforce for more menial repetitive
jobs