2.7, 2.4&2.6, 2.9, 1.11&2.8

Question 1

What do Project Management systems aim to do

Answer 1

Project management systems aim to ensure waste is reduced and all activities are efficient

Question 2

What are the 3 project management techniques

Answer 2

SCRUM, Six Sigma, CPA(Critical Path Analysis)

Question 3

What are the 2 features of SCRUM and its advantage

Answer 3

A method where teams work together to reach goals in a short timescale “sprints”

The team attends daily scrum updates where progress and possible issues are shared

The team can quickly respond to changing demand due to the regular nature of the meetings

Question 4

What is Six Sigma and what procedures does it use

Answer 4

A set of techniques and tools for process improvement to minimise defects

The system uses the DMAIC(Define, measure, analyse, improve and control) procedure to assess and improve design stages

Question 5

What is CPA (Critical Path Analysis)

Answer 5

A project management method used to plan the completion of a project in the shortest possible time through identification of wasted time and opportunities for parallel/simultaneous working practices.

Question 6

What are the 4 steps for CPA(Critical Path Analysis)

Answer 6

Sequential ordering and estimated timing for each task

Identification of whether a task depends upon the completion of other tasks or is non-dependant

Appreciation of time required for sequential (‘one by one’) completion of stages

Determination of critical path (the longest timed route which is also the quickest time the project could realistically be completed in) by rearranging tasks to make best use of any slack time

Question 7

List some forms investigation you have not used in your project

Answer 7

Looking at current trends or styles

Using British Standards

Investigating historical influences

Investigating the safe use of materials

Using internet forums to gain public opinions on the projects development

Question 8

What are the 3 methods of Ideas generation

Answer 8

Mind maps can give a idea of what factors to consider during development of the project

SCAMPER is a way of developing ideas that includes (Substituting materials, Combining ideas, Adapting the design… )

Thinking hats are a way of improving creative discussion by making a group wear different hats with different colours that indicate different ways of thinking e.g facts and essentials, feeling and emotion …

Question 9

When developing ideas in industry what is a good design practice

Answer 9

In industry, designers tend to work collaboratively within teams (designers, engineers, ergonomists, manufacturing specialists and project managers) to best utilise their expertise and skills. This is more commonplace when working on demanding and complex projects.

Question 10

What are the 4 adv and 1 disadv of working collaboratively when designing

Answer 10

+ Cloud based files allow designers to work on the same project at different times remotely

+ Video conferencing allows real time face to face meetings remotely

+ Innovative solutions can be generated to address complex problems

+ Sharing of best practice

• Personal conflicts can occur and coordinating can be difficult due to remote working

Question 10

Give a description of Entrepreneurs

Answer 10

Entrepreneurs have initiative, new ideas and are willing to take risks but they will also work with designers and engineers to turn their ideas into reality.

Question 11

What are some methods of evaluating and testing products /7

Answer 11

Products are tested and evaluated to ensure that the product is safe, attractive and comply with the UCD

It is much more expensive and brand damaging to recall and repair products rather than removing faults of the product at the design stage which can be done by careful testing and evaluations of products

Certain products are subject to scrutiny by independent companies in order to reduce the likelihood of problems to comply with legislation and receive appropriate certification

The British Standards Institution (BSI) publishes a range of standards that are used in the design and manufacturing of products

The BSI kitemark indicates that a product has been certified with testing and are in compliance with standards

Independent market research organisations obtain objective information on competitors’ products, the current state of the market, retailing constraints and brand identity

Market research organisations use targeted questionnaires and focus groups in which members of the public, from appropriate demographic groups, are asked to express their views on existing and proposed products

Question 12

What is the idea behind iterative and cyclical design

Answer 12

Feedback from clients and potential users is analysed prior to creating iterations of design proposals.
Feedback is again sought and analysed but this time maybe from focus groups and production staff.

Question 13

What is accuracy and why is it important

Answer 13

The level of conformity of a measurement to the required value

To ensure that parts fit and function correctly

Question 14

What is tolerance and why do the metal gears in a watch movement have very high or close tolerances?

Answer 14

The allowed upper and lower accuracy limits

As to make sure that the gears perfectly fit together

Question 15

What are datum surfaces or edges and why work from datum surfaces or edges

Answer 15

Datum surfaces are ones that other measurements references are made from

To reduce cumulative error

Question 16

Why do the wooden parts of a homemade rabbit hutch have relatively low or wide tolerances?

Answer 16

Because the rabbit hutch doesn’t have complicated or moving parts that need high precision

Question 17

What are 6 methods for planning to make accurate prototypes

Answer 17

A clear PDS is required in order to give a clear list of the clients essential and desirable requirements

The development must allow the concept to be tested against

Ideas will be modelled as CAD to check systems

The manufacturing procedures must be evaluated for suitability to achieve a level of accuracy

The manufacturing requires a clear schedule of production with one off products being able to be checked at every stage of production

During production many QC checks must be carried out in order to ensure that the product meets the PDS

Question 18

What are 2 methods for planning to make accurate products at various scales of production

Answer 18

During development a wide variety of techniques are used to ensure the product is accurate due to the cost of any errors during manufacturing e.g. CAD processes, working drawings with tolerances, sample prototypes, templates, jigs, fixtures, NDT & DT …

During manufacturing, accuracy is tested against a range of QC checks to compare the product to the PDS e.g. Visual Aesthetic checks, sample dimension checks, Tolerance dimension checks …

Question 19

What are the 3 production aids

Answer 19

Jigs

Templates

Fixtures

Question 20

What are Fixtures, Jigs and Templates

Answer 20

Fixtures – clamping devices used to hold the workpiece in place. For example a welding or machining fixture.

Jigs – devices used to hold the workpiece and guide the tool. For example a drilling jig.

Templates – a thin sheet of material which acts as a pattern to be traced.

Question 21

What are the benefits of creating production aids (Fixtures, Jigs and Templates)

Answer 21

Save time measuring or marking out (jigs and templates).
Maintain accuracy and consistency
Reduce likelihood of human error occurring.

Question 22

What are the importance of QA procedures and policies and some examples of them

Answer 22

QA is the procedures and policies to reduce waste and ensure products are within acceptable tolerances

Some QA policies include e.g. Only sourcing ISO 9001 Quality standard materials, Setting temperature ranges for moulds to ensure effective filling and cooling, Setting rigid maintenance schedules for machinery, …

Some QA procedures include e.g. CAD and CAE models, FEA, CFD, …

Question 23

When must QA checks be carried out

Answer 23

QA checks must be carried out within the production process

Question 24

What is a method of QA checks for glass bottles

Answer 24

The design of components can be modified as well such as numbers embossed on products to trace any issues back to the moulds or cavities

Question 25

What are QC checks, when is it used and what are some examples of QC checks

Answer 25

QC refers to the monitoring, checking and testing of materials to ensure they comply to acceptable tolerances within the QA

QC checks take place during production and in conjunction with guidance documents to ensure the product meets the PDS

QC checks include e.g. Material checks, Visual inspection, Dimension checks, Finish checks, Chemical analysis …

Question 26

What is the aim of TQM(Total quality management) and what 2 features help it achieve this

Answer 26

TQM is the ambition to remove waste and produce products on time

TQM involves customer focused improvement

TQM companies strive for continuous improvement and value the views of their workforce and encourage them to participate in teams where individuals can solve problems

Question 27

What is CMM(Co-ordinate Measuring Machines) useful for and what is its adv and disadv

Answer 27

The use of CMM e.g. a probe scanner allows the manufacturer to check a range of predefined measurements on finished products due to the data automatically compared to a 3D CAD model and logged on a computer system

CMM can be used to check tooling for dimensional accuracy and update QA procedures

Very accurate but quite slow

Question 28

What does Non contact laser scanning do and what can it be used to create

Answer 28

Non Contact laser scanning allows thousands of readings a second for a true comparison with a CAD model and can create new 3D CAD models from the scan itself due to reflections from a laser of the surface of the product

Question 29

What is 2 adv of Non contact laser scanning and what 3 things can it be used to check

Answer 29

Accurate and less costly

Used to check prototypes, large surfaces and non rigid parts

Question 30

What is NDT(Non destructive testing) and its 2 main methods

Answer 30

NDT refers to methods to check internal structures often after joining processes

The 2 main methods of NDT are Xray and Ultrasound analysis

Question 31

What is the material subject to in NDT (Non destructive testing) and when it it essential

Answer 31

The material is subject to radiation or ultrasound to check refraction of signals to indicate any not visible faults

This form of testing is essential where a joint failure could be a major issue

Question 32

What is sustainable development

Answer 32

Development that meets the needs of current generations without compromising future generations abilities

Question 33

What are the 3 ways to make sustainable use of resources

Answer 33

The use of finite resources must be stopped as it hinders future demand

Trees must be replanted to reduce risk of soil erosion, flash flooding and C02 entering the atmosphere

Many companies consider their CO2 levels(Carbon footprint) by both their Primary carbon footprint (Direct emissions e.g. transport, energy consumption) and Secondary carbon footprint (Indirect emissions from products we use )

Question 34

What are the 3 adv and 4 disadv of sustainable energy sources

Answer 34

+ Is sustainable and will never run out

+ Requires less maintenance (Operational costs are lower)

+ Little or no waste e.g. CO2 or pollutants meaning minimal environmental impact

• Renewable energy is not reliable as it often relies on the weather for sources of power
• Large number of facilities
• Renewable energy is hard to store and is generally less practical
• Renewable energy is currently a lot more expensive than fossil fuels - Costs of developing new technologies

Question 35

What are the six Rs of sustainable product design

Answer 35

Recycle

Reduce

Refuse

Rethink

Reuse

Repairs & Maintenance

Question 36

What is “Recycling” and what are the 3 main ways in which it happens

Answer 36

Convert waste products into new materials for new products

End of life disposal is a key area for designers to consider and many manufacturers actively advertise the use of recycled waste in their products

Recycling happens in 3 main ways :
Primary recycling (The use of functioning second hand products)
Secondary recycling (At the end of a products life the materials are recycled to make different products)
Tertiary recycling (The complete breakdown of a product via a chemical process)

Question 37

What is “Reduce” and what are 2 examples of how it can be implemented

Answer 37

Cut down on the amount of material and energy used to make and package the product

For example bottled water companies constantly strive to use as little polymer as possible while keeping integral strength

Reductions can reduce energy consumption by making it easier to reach blow moulding temperature

Question 38

What is “Refuse”

Answer 38

Exercise consumer choice as to whether to buy a product or not

The consumer may choose to not buy a product if they consider the product to be bad for the environment or if it is a product they do not need

Question 39

What is “Rethink”, what does it help with and what design features does it involve

Answer 39

Rethink the way products are designed and manufactured so that they carry out the same function more efficiently)

This could include making products more energy efficient in manufacturing and running costs

It also includes design aspect such as fittings and SMAs

Question 40

What is “Repairs & Maintenance” and what problem does it adress

Answer 40

When a product or component fails fix it rather than throwing it away

Designers have a responsibilities to consider the use of resources and address the throw away culture

Question 41

What is “Reuse”, What is required to make effective use of “Reuse” and Who needs to consider it

Answer 41

At the end of a products life reuse the product for the same or another purpose

Reusable products may need to be cleaned or reconditioned before they can be used

Designers need to consider the reuse potential of their product or product components which may influence decisions such as ease if disassembly when designing

Question 42

What is “Upcycling” and what scale is it used at and what scale is becoming more viable

Answer 42

This is the creative reuse of unwanted products and materials resulting in outcomes with a higher quality or environmental worth than the original

This activity is often at a domestic level and creates items such as e.g. personalised designs using Scrabble letters, decorations from old jigsaw pieces, glass jars used as vases …

It is becoming increasingly viable to upcycle at a commercial scale such as re-using tons of unwanted tents at music festivals and converting them into showerproof clothing and accessories

Question 43

Why is packaging important and why do designers need to consider their packaging

Answer 43

Packing is an important aspect of any product design. Without packaging some goods would not reach the consumer. Packaging can help prevent items getting lost, prolong shelf life of food products, protect and promote products and make products easier and safer to handle

Designers need to consider the optimum amount of packaging to protect the product and prevent waste

Factors such as making the packaging lightweight, using recycled content and making the packaging recyclable should be considered

Question 44

For sustainable manufacturing what must designers consider, how should products be designed and an example of this

Answer 44

Designers must also consider energy use in manufacture and processing

Products should be designed so that there is minimal waste material and ideally the waste can be reused/recycled

Water-cooled machinery can use rainwater harvesting and recovery of waste water

Question 45

What are product and food miles and what are ways of reducing them and emissions

Answer 45

Product miles are the total lifetime distance that a product travels from place of production to place of use (Linked to C02 emissions)

Food miles are often used in the food industry to try and push consumers to purchase locally sourced products

One way of reducing product miles and CO2 emissions is cutting out the middleman and shipping product from manufacturing directly to the consumer. This reduces the journeys and results in fewer emissions

Another way of reducing emissions is by avoiding the store of products in distribution centres which require energy and also additional product miles

Question 46

What is the traditional economy?

What is a circular economy?

What methods should be considered for a circular economy?

What are the 2 nutrient types for a circular economy?

Answer 46

The traditional approach is for a linear economy (Take, make, dispose)

A circular economy aims to use materials that ensures a cycle of reuse and remanufacture without utilising wasteful resources or having products end up in landfills

Manufacturers can adopt several methods to support a circular economy such as (Product leasing, take-back and optimising their approach to the products lifecycle)

The circular economy considers 2 nutrient types for continual product disassembly and reuse, Biological nutrients (Organic materials that can simply be composted and safely disposed of) and Technical nutrients (Man Made materials designed to be used repeatedly at the same high quality and minimal energy)

Question 46

What are the 4 circular economy principals

Answer 46

Preserve and enhance natural capital
(The control of finite resources and the use of processes that use renewable or more efficient resources)

Optimise resource yields
(Designing for refurbishment, effective disassembly, remanufacture, reuse and recycling with an aim to keep the highest quality and value in all resources so that there is a continuous cycle)

Foster systems effectiveness
(Considering, assessing and rethinking design to reduce negative impacts on factors that could directly affect population such as land use and the use of fossil fuels)

Retain a competitive economy with opportunities for growth