2.2e Relationship between material cost, form, manufacturing processes and scale of production

Question 1

Relationship between factors
that affect products

Answer 1

• Material cost: the expense generated by selecting a
  particular material.
• Form: the shape that a design takes.
• Manufacturing processes: the way materials are
  manipulated to form the product.
• Scale of production: the number of products
  produced can vary, this dictates the way the
  manufacturer sets about making this number.
• Disposal of waste: every process generates waste,
  in different forms, and how waste is dealt with
  responsibly

Question 2

Factors that influence material cost

Answer 2

Material selection is considered at the design stage
because the performance of the product relies on the
materials used to construct it.
Material selection is influenced by factors such
as manufacturing processes, assembly, service,
environmental impact of material, use and disposal and
recycling.
Other factors may include:
* strength
* availability
* durability
* workability
* ease of transportation
* cost
* aesthetic values
* resistance to fire.

Question 3

Manufacturing products

Answer 3

During design and development, it is essential that
materials and processes are tested fully to ensure that
the eventual form of a product is achievable.
Some materials and manufacturing processes have
limitations, and so this needs to be explored and
understood before the final production commences.
* There are limitations when using all types of
materials.
* The energy required and pollution generated, and
overall cost and efficiency.
* The source of the material and transporting this
material for production.

Question 4

Costs

Answer 4

The biggest single factor affecting the cost price of
a product is the amount being made. The scale of
production will be dictated by the number required.
Other cost factors include:
* wage costs for manual workers
* labour productivity
* exchange rates
* raw materials
* taxes
* bureaucracy and administration
* transportation
* interest rates

Question 5

Environmental factors

Answer 5

Industrial factories are a major contributor to water
pollution. The dumping of contaminated water, gases,
chemicals, heavy metals or radioactive materials causes
damage to marine life and the environment as a whole.
* Reducing carbon footprint: all manufacturing will
have some negative impact on the environment but
decreasing or limiting this is important.
* Selecting materials that are sustainably sourced,
and where possible, you should reuse or recycle
waste materials rather than deplete natural
resources further.
* Many industrial and commercial settings now
harness green energy using solar or wind power
to contribute towards the energy required for
manufacturing.

Question 6

Scales of production

Answer 6

One off production will be used when making single
products. This will be reliant on manual labour as no
automated machinery would be set up. Labour costs
will be high, and production will be slower than if
machinery were being used.
Batch production will see a limited number of similar
products manufactured. There may be less manual
work and more automated machinery employed, and
rates could be faster.
Mass production would be thousands of identical
products with the use of automation. This would be
quick and efficient but set up costs would be high.
Continuous flow production would be a 24/7
approach constantly manufacturing identical items with
high levels of automation and quality control.