1.11 Design for Manufacture, Maintenance, Repair and Disposal

Question 1

what are the 6 Rs?

Answer 1

Reduce
Reuse
Recycle
Rethink
Refuse
Repair

Question 2

reduce- definition

Answer 2

• minimising waste by less material/eliminating excessive packaging

Question 3

reuse- definition

Answer 3

• make it possible for products to be used again rather than discarded

Question 4

recycle- definition

Answer 4

• recover parts & materials to be reused once product reach the end of their useful life

Question 5

rethink- definition

Answer 5

• consider if there may be alternatives to materials/products etc

Question 6

refuse- definition

Answer 6

• avoid designs, products & materials which are harmful to the environment or a re difficult to recycle

Question 7

repair- definition

Answer 7

• design products that can be repaired rather than those that have to be thrown away when damaged

Question 8

EASE OF MANUFACTURE STRATEGIES

Injection moulding of parts that are needed in large quantities rather than machining them from solid material

Answer 8

• highly efficient
• automated to save manufacturing costs
• can have highly detailed moulds with high quality outcome

Question 9

EASE OF MANUFACTURE STRATEGIES

using modular approach to design

Answer 9

• sub-systems easier to track & fault find

Question 10

EASE OF MANUFACTURE STRATEGIES

using standardised parts & sizes across versions/models

Answer 10

• reduce overall number of parts required

Question 11

EASE OF MANUFACTURE STRATEGIES

use of advanced soldering techniques (eg wave, reflow)

Answer 11

• much faster & simpler than manual soldering

Question 12

EASE OF MANUFACTURE STRATEGIES

use of self-finishing materials (eg polymers)

Answer 12

• avoid need for coating (eg painting)

- saves time

Question 13

EASE OF MANUFACTURE STRATEGIES

use of redistribution techniques rather than fabrication/wastage techniques

Answer 13

• more efficient for large production runs- processes reduced

Question 14

EASE OF MANUFACTURE STRATEGIES

use of factory planning & layout simulation software

Answer 14

• ensures optimal layout of machines, robots, etc

Question 15

EASE OF MANUFACTURE STRATEGIES

use of adhesives (instead of mechanical fasteners)

Answer 15

• quicker, more efficient
• cheaper
• less parts used

Question 16

EASE OF MANUFACTURE STRATEGIES

use of ribs & webbing for moulded parts

Answer 16

• reduces thickness but maintains strength

Question 17

EASE OF MANUFACTURE STRATEGIES

use of integral snap fittings in polymer products

Answer 17

• can be designed to be separable or fixed
• reduced manufacturing processes (no need for adhesives/fixings)
• easy to incorporate into mould

Question 18

EASE OF MANUFACTURE STRATEGIES

use of moulding posts into which self-taping screws can be secured

Answer 18

• improves efficiency (no need to incorporate more complex fittings)

Question 19

EASE OF MANUFACTURE STRATEGIES

moulding texture into surface of polymer

Answer 19

• add tactile features
• mask blemishes
• enhance aesthetic

Question 20

EASE OF MANUFACTURE STRATEGIES

buy pre-made components

Answer 20

• more efficient than producing in-house

Question 21

importance of ease of disassembly to enhance sustainability of a product (2)

Answer 21

• allows materials to be recycled
• easier to disassemble = faster, more efficient & cheaper to do- less waste produced
  > reduces material costs as less raw materials need to be bought