Manufacturing Methods

Question 1

What is the process of vacuum forming?

Answer 1

1) A sheet of thermoplastic is placed over the mould (former with suitable draft angles)

2) The lid/ heater is lowered over the sheet of plastic

3) Wait for the plastic to become malleable and close to melting

4) Remove the air in the former below the sheet so the plastic moulds to it.

5) Take the moulded plastic sheet out and leave to cool

Question 2

What are the advantages and disadvantages of vacuum forming?

Answer 2

Advantages
- Moulds are cost effective
- Moulds are quick to make

Disadvantages
- You need a draft angle
- Complex shapes cant be produced
- Products can only be hollow and may lack strength

Question 3

What are the advantages and disadvantages of knock down fittings

Answer 3

Advantages
- Much easier and cheaper for the user to construct with no need for expensive tools/ machinery
- Product can be taken apart easily making them portable
- Provides good strength and stability due to interlocking design
- Reusable
- More cost effective for the user

Disadvantages
- More expensive for the manufacturer
- Normally shipped separately which increases the carbon footprint
- The user may not assemble the fittings correctly leading to frustration and possible complaints
- The fixings are usually visible and take up space which could give the idea of lower quality

Question 4

What is a former?

Answer 4

An tool or mould to used to shape a material into a desired shape (Usually metal)

Question 5

What is a jig?

Answer 5

A device used to hold, guide and position a tool or workpiece during manufacturing to ensure precision and consistently

Question 6

What are 4 types of knockdown fittings?

Answer 6

• Connecting blocks- Join two pieces of wood at 90 degrees
• Connector Nuts- Join two parallel pieces of material using an Allen key
• Connector screw nut- Join two pieces that are 90 degrees but not on a corner

Cam lock connectors- Connect two pieces that are 90 degrees

Dowels- Used in combination with another fitting at a locator

Furniture screws- Used like a normal screw but has threads wider apart and works with furniture screws

Question 7

What is JIT?

Answer 7

Just in time manufacturing is when materials/ parts are ordered so they go straight into the production line.

Question 8

What are the advantages and disadvantages of JIT?

Answer 8

Advantages
- Reduces the amount of storage space needed for parts
- Minimal wastage of parts due to no backlog
- Flexibility in what is manufactured
- Errors are easily noticeable in small batches

Disadvantages
- Logistics of the operation can be difficult as it is hard to forecast future demand
- Prices of components fluctuate
- Need for multiple/ flexible suppliers
- Increased carbon emissions due to separate orders