Homework 1 Section A

Design & Engineering

1. The products shown below have been designed and manufactured for use in pre-school, early years and primary schools.

Design & Engineering

Question 1 (continued ) (a) Explain why the materials chosen for each of these products are suitable. You should make six valid points. You do not need to cover all materials but should cover both products in your answer.

(b) Name three appropriate mass manufacturing processes used in the production of these lawnmowers and explain why they are suitable. You should cover both products in your answer but may refer to different processes for each.

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(c) Describe the aesthetic appeal of each coat rack. Your answer should cover four different aesthetic aspects.

(d) Describe five functional issues that will have influenced the design of each of these products.

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(e) Explain how any four production and planning systems can be used to improve production efficiency.

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Design & Engineering

1a. Justify the choice of materials used to produce both coat racks. In this question, which comes up without fail, take a few moments to plan your answer. Try to place yourself in a situation with the product. Consider the following Design Factors… • Environment. What type of environment will the lawnmower be used?

• Safety. Think about the safety aspects relating to the user and the machine.

• Aesthetics. Think about how the product looks to it’s intended target market.

• Sustainability. Can we recycle the materials when the product is at its life's end?

• Manufacturing. Think about the different types of manufacturing processes used to manufacture the coat rack. • Performance. How is the coat rack expected to perform? Consider weight, stability, strength.

Design & Engineering

1a. Justify the choice of materials used to produce both coat rack. •Try to conduct a thought shower/brainstorming activity to quickly generate some ideas regarding materials.

•Statements which justify issues such as: •durability of material/impact resistance (non corrosion) •strength to weight issues •readily available materials •Nylon – self lubricating gears •HSS/tool steel – hardness •rubber – excellent grip •chemical resistance •comfort of foam •foam gives excellent grip •suitability for production methods •function of component parts •aesthetic properties •ease of cleaning •re-cycling Design & Engineering

1b. Name and Justify the mass production methods used to produce both coat racks. This question comes up regularly. Take a few moments to jot down all of the plastic and metal (or wood if it’s appropriate) processes that you know.

Metal- Pressure Die casting; Sand casting; Extrusion; Press Forming; Piercing & Blanking; Drop Forging; Sheet and Tube forming etc.

Plastic- Injection Moulding; Extrusion; Vacuum Forming; Rotational Moulding; Blow Moulding; Compression Moulding etc.

Once you’ve done that try to imagine how each part of the product has been manufactured, in other words match the part up with the production method.

Finally, you must justify you’re answer. You must provide robust reasons as to why you believe your correct in your answer. Design & Engineering

1b. Name and Justify the mass production methods used to produce both coat racks. Standard answers appear each year in the shape of the following… Standardisation of sizes, component parts all the same size. No further finishing required. Shapes suitable for process.

Standardisation of components and materials chosen because they are easily sourced/formed.

Suitable for mass/batch production – injection moulding.

Economy of scale – mass/continuous production/JIT.

Design & Engineering

1c. Explain the ergonomic issues associated with both coat racks.

Any four issues explained in the context of ergonomics: Remember Ergonomics is the study of Anthropometrics, Physiology and Psychology.

Design & Engineering

(d) Describe five functional issues that will have influenced the design of each of these products.

In this question you are expected to describe any five functional issues discussing the merits of both products.

Consider the following… • Ease of Maintenance- Is cleaning the product going to be easier for one over the other?

• Function- What benefits do they provide? Do they posses any special features? Is the product easy to use?

• Safety- What are the safety features when in use?

• Build Quality- How well built is the product? Difficult to judge maybe from a photograph. Design & Engineering

(e) Explain how any four production and planning systems can be used to improve production efficiency.

• • • • • • • • • • • You are expected to explain how any four planning systems can be used to improve production efficiency.

There are a number of stock answers that can be used time and time again. use of correct production type (batch/mass/flow) Gantt charts flowcharts use of CNC, CAD/CAM jigs/patterns JIT standard components sub-contracting or any other appropriate planning system and efficiency explanation.

Design & Engineering