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Technology & Design > Manufacturing Practices & Materials Components And Fabrication > Flashcards

Manufacturing Practices & Materials Components And Fabrication Flashcards

1
Q

What are the different types of scales of production?

A

-One-off/Jobbing production
-Batch Production
-Mass production
-Continuous production

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2
Q

What is one off/jobbing production?

A

Making a single product to the specific requirements of the consumer. So every item will be made differently

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3
Q

What are the disadvantages of one off/jobbing production?

A

-Requires a highly skilled workforce
-Very labour intensive

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4
Q

What are some examples of one-off productions?

A

-Bridges
-Statues
-Personalised jewellery

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5
Q

What is batch production?

A

Where a specific quantity of products are made, between 2 and 100 units.

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6
Q

How does batch production work?

A

A production line is set up where each worker completes a task and passes it along the production line to the next worker.

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7
Q

What are the advantages of batch production?

A

-Workers are only semi-skilled or unskilled
-Flexible workforce

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8
Q

Why does the production line need to be easily and quickly changed in batch production?

A

So different products can be made

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9
Q

What are examples of batch production?

A

-Sport shoes
-Clothes
-Books

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10
Q

What is mass production?

A

High volume production of products, usually over 100 units made

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11
Q

What is the main disadvantage and advantage of mass production?

A

D: Initial set up cost is high for machinery

A: Since high costs are spread across large number of units the cost per unit is reduced greatly allowing more profit

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12
Q

What are the examples of mass production?

A

-Electrical goods
-Cars

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13
Q

What is continuous production?

A

Uninterrupted 24/7 mass production of tens of thousands of identical products.

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14
Q

How does continuous production work?

A

A semi-automated production line is set up using computer control and a combination of skilled and unskilled workers.

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15
Q

What are the advantages of continuous production?

A

-Has unskilled workers
-Workers less flexible than batch manufacturers

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16
Q

What are the disadvantages of continuous production?

A

-Training needed for new equipment or new staff
-Quality control occurs at every stage if production.
-High level of investment in machinery needed

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17
Q

What are examples of continuous production?

A

-Petrol & oil products
-Cars
-Bricks

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18
Q

What is in-line assembly?

A

Used for mass production, most of production line is automated.

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19
Q

What is the used of unskilled labour and semi skilled workers in In-line assembly

A

-Unskilled labour used for assembly
-Semi-skilled workers make sure there is continuous flow along production line

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20
Q

What are the advantages of in-line assembly?

A

-Human error reduced due to machinery
-Company produced larger quantity of one product
-Labour costs reduced and production increases

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21
Q

What are the disadvantages to in-line assembly?

A

-System is inflexible as production process cannot be changed
-Lack of variety in system as all products are all produced on one production line

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22
Q

What are flexible manufacturing systems?

A

Where semi-skilled workers are able to do a variety of jobs

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23
Q

What is the approach to the idea of flexible manufacturing systems?

A

A flexible workforce and flexible machinery is key to successful manufacturing

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24
Q

What are the advantages of flexible manufacturing systems?

A

-Useful for batch manufacturing where change and flexibility needed
-Manufacturing time reduced per product
-Cost per unit reduced

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25
Q

What is the disadvantage to flexible manufacturing systems?

A

Requires alot of pre planning and organisation prior to starting production

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26
Q

What does just-in-time manufacture require?

A

Requires high level of forward planning as materials and components only bought when needed

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27
Q

What are the advantages to just in time assembly?

A

-Resources not stockpiled which saves warehouse space and money
-Reduces chance of stock going out of date
-Avoids build up of unfinished products as demand changes

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28
Q

What are the disadvantages to just-in-time assembly?

A

-Little room for mistakes as minimal stock kept
-Very reliant on suppliers
-No excess finished products to meet unexpected orders

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29
Q

What are the two types of industrial practices?

A
  1. Standardised components, assemblies and bought in components
  2. Sub-contracting
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30
Q

What are standardised components, assemblies and bought in components?

A

Building of blocks of much more complex products

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31
Q

What are the advantages of standardised components, assemblies and bought in components?

A

-Speed up manufacturing and reduces maintenance and manufacturing costs
-Means manufacturers do not have to create everything from scratch

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32
Q

What is the disadvantage of standardised components, assemblies and bought in components?

A

-Manufacturer depends on other manufacturers to supply them

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33
Q

What is subcontracting?

A

When a part of a job or manufacturing process is contracted out to another source or company to compete.

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34
Q

When does sub-contracting occur?

A

When machines and operators are working to full capacity and production is at its full efficiency but orders are still being placed

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35
Q

What are the advantages of sub-contracting?

A

-Provides relief to manufacturer
-Prevents manufacturing plant from becoming overburdened
-Improves efficiency
-Helps manufacturers meet delivery dates

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36
Q

What are the disadvantages to sub-contracting?

A

-Time consuming
-Difficult to ensure quality
-Tracking parts can be an issue

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37
Q

What should improved quality and improved reputation of company return in?

A

-Greater demand for products
-Increase in production volumes
-Unit costs being reduced
-Higher selling prices
-Customer satisfaction

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38
Q

What is quality assurance?

A

Setting standards and meeting them.

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39
Q

What is quality control?

A

How you check standards of product.

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40
Q

What does quality control ensure?

A

-Does job it was designed to do
-Conforms to design specifications
-Gives customer satisfaction

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41
Q

What are the 3 types of sample testing?

A
  1. Measuring
  2. Non-destructive testing
  3. Destructive testing
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42
Q

What happens in measuring in sample testing?

A

Where measuring can be completed using a limiting gauge, micrometer, vernier gauge. Very time consuming and costly

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43
Q

What is non-destructive testing in sample testing?

A

Testing where the sample isn’t damaged, as testing is visual it used x-rays or dyes to find defects.

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44
Q

What is destructive testing in sample testing?

A

Testing that is physical and destroys product to see how product would collapse or how fractures develop

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45
Q

What is tolerance in testing a sample?

A

The amount of error allowed.

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46
Q

What is manufacturing cost?

A

The sum of all costs of resources needed in process of making a product

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47
Q

What are the 3 categories of manufacturing cost?

A

•Direct costs
•Overhead costs
•Manufacturing overheads

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48
Q

What are the 2 types of direct costs?

A
  1. Human
  2. Material costs
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49
Q

What are the 4 types of overhead costs?

A
  1. Management
  2. Administration
  3. Research and development
  4. Marketing and sales
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50
Q

What are the 3 types of manufacturing overheads?

A
  1. Manufacturing equipment
  2. Manufacturing plant
  3. General overhead costs
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51
Q

What are the direct labours cost?

A

The cost of paying employees directly involved in production process.

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52
Q

How to calculate direct labour costs?

A

Multiply production time period by hourly cost of paying each worker

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53
Q

What are the direct materials cost?

A

The raw materials that become a part of the finished product

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54
Q

What are the manufacturing overhead costs?

A

Any costs which are not the direct labour or direct materials, e.g equipment

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55
Q

What is the total cost of manufacturing a product?

A

The direct costs + the indirect costs

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56
Q

What is reforming?

A

When plastics or metals are liquefied with heat pressure, then shaped with a mould

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57
Q

What is deforming?

A

When the shape of a material is changed

58
Q

What are methods of reforming

A

-Extrusion
-Die casting
-Injection moulding

59
Q

What are methods of deforming?

A

-Blow moulding
-laminating
-press/compression moulding

60
Q

What materials and what is extrusion used for?

A

Used on Thermoplastics and some metals.
Used to make sheets of plastic for fabrication, pipes, tubes etc… And to mould copper for pipes, wires etc…

61
Q

What are the advantages of extrusion?

A

•High production rates are achievable
•Many materials can be extruded
•Products have very good surface finish

62
Q

What are the disadvantages of extrusion?

A

•Complex parts can’t be produced
•Only shapes with uniform cross sections can be produced

63
Q

What is injection moulding used for?

A

To produce bottles, sand buckets, electrical components etc

64
Q

How does injection moulding work?

A

By forcing the molten material into a closed mould

65
Q

What are the advantages of injection moulding?

A

•High production rates are achievable
•Products have good surface finish

66
Q

What is the disadvantageof injection moulding?

A

Very expensive

67
Q

What is die casting used for?

A

Kitchen equipment and castings for car industry

68
Q

How does die casting work?

A

Material is melted and poured into a mould that is the required shape of product

69
Q

What are the advantages of die casting

A

•Fast
•Produces durable parts
•Parts have good surface finish

70
Q

What are the disadvantages of die casting?

A

•Initial cost setups are high
•Large production volume is required
•Only non-ferrous metals can be used

71
Q

What is made with blow moulding?

A

drink bottles, cosmetics, plastic pipes

72
Q

What are the advantages of blow moulding?

A

•Less expensive
•Fast production
•Need for adhesives is reduced

73
Q

What is the disadvantage of blow moulding?

A

Can only be used to manufacture hollow products

74
Q

What is laminating?

A

Process of constructing a material with two or more layers together

75
Q

What is made with laminating?

A

Table, chair legs, roof beams

76
Q

What is press moulding and how does it work?

A

A mould is made in two halves and sheet plastic is placed between them, they’re heated and pressurised forcing plastics to form the shape

77
Q

What are circular saws used for?

A

Cutting woods into size

78
Q

What are band saws used for?

A

To cut wood and other materials for straight or curved cuts

79
Q

What are jigsaws?

A

A power tool with a thin blade that reciprocates

80
Q

What are jigsaws used for?

A

Cutting curves and custom shapes into wood and other materials

81
Q

What is a planer used for?

A

To remove shavings of wood. Used to reduce material to its required size

82
Q

What is a sander used for?

A

To sand or smooth wood

83
Q

What are the tools used in manufacturing processes?

A

-Circular saw
-Band saw
-Jigsaw
-Sander
-Planer

84
Q

What is computerised production?

A

When manufacturing process becomes automated by using computer aided design

85
Q

What are the advantages of CAD systems?

A

•Produces high quality and consistent drawings
•Changes to drawings are easily made
•Drawings can be emailed

86
Q

What are the disadvantages of using CAD systems?

A

•Not a substitute to freehand sketching
•Initial set up cost is high

87
Q

What is computer aided manufacture?

A

The process that converts drawings produced by CAD into actual products

88
Q

What are the advantages to using CAM?

A

•High production speed
•Flexible as they can be reprogrammed
•Ensures products are produced accurately

89
Q

What are the disadvantages to using CAM?

A

•Initial setup costs are high
•Training required for the operation

90
Q

What materials are laser cutters used for?

A

-Plastic
-Wood
-Card

91
Q

What materials are lathes used for?

A

-Wood
-Metal
-Nylon

92
Q

What materials are routers used for?

A

-Foam
-Wood
-Metal

93
Q

What materials are milling machines used for?

A

-Wood
-Metal
-Plastic

94
Q

What materials are milling machines used for?

A

-Wood
-Metal
-Plastic

95
Q

What is computer integrated manufacture? (CIM)

A

Central computer system used to link together all stages of design and manufacturing process

96
Q

What are the advantages to using CIM?

A

•Lower costs
•Human error is reduced

97
Q

What are the disadvantages to using CIM?

A

•Initial setup cost are high for machinery and training
•Fast special purpose machines cheaper to run for large scale production

98
Q

What is the intended uses for selection of materials?

A

-What will it be used for?
-Where will the product be used?
-How long will it last?

99
Q

What are the properties for the selection of materials?

A

-Strength
-Hardness
-Durability
-Malleability
-Heat, electrical conductivity

100
Q

What are the functions of its finish for selection of materials?

A

-Does product need aesthetically pleasing finish?
-Does it need a protection finish?

101
Q

What are the shape and cross sections of materials?

A

Sheet, bar, tube, angled, u-shapes channel, i-shaped section

102
Q

What shapes and cross sections can metals be?

A

-Flat sheet
-Solid bar
-Tubes
-Angled u-shaped channel
-I-Shaped sections

103
Q

What shapes and cross sections can plastics be?

A

-Rods
-Sheets
-Extruded mouldings

104
Q

What shapes are metals in stock form available in?

A

-Sheet
-Bar
-Rod
-Tube

105
Q

What shapes are plastics in stock form available as?

A

-Sheet
-Rod
-Bar
-Granules

106
Q

What is different groups of woods?

A

-Hardwoods
-Softwoods
-Manufactured boards

107
Q

What is the appropriate use of hardwoods?

A

-For furniture as very aesthetically pleasing.
-Building beams and flooring as very strong

108
Q

What is the appropriate use of softwoods?

A

-Furniture, ceilings, doors as it is aesthetically pleasing and easily cut
-Staircases as it also cheaper

109
Q

What can be done to improve the aesthetic of manufactured boards?

A

They can have a thin layer of wood covering them to improve appearance.

110
Q

What are the different types of manufacturing boards?

A

-MDF
-Chipboard
-Plywood
-Blockboard

111
Q

What is the issues with using wood?

A

Shrinkage
Expansion

112
Q

What is the difference between ferrous and non-ferrous metals?

A

Ferrous contains metal
Non-ferrous don’t contain metal

113
Q

What is an alloy?

A

A mixture of two or more metals

114
Q

What are the appropriate uses for metals such as brass?

A

-Malleable and machines well
-Doesn’t tarnish and resist corrosion
-Has good acoustic properties which makes it ideal for musical instruments

115
Q

What is the difference between thermosetting plastics and thermoplastics?

A

Thermosetting can’t be reheated and reshaped.
Thermoplastics can be reheated to be shaped and moulded

116
Q

What is an advantage and a disadvantage of thermosetting plastics?

A

A: Resists heat and fire well
D: Cannot be recycled

117
Q

What is an advantage and a disadvantage to thermoplastics?

A

A: Can be recycled
D: Doesn’t resist heat well

118
Q

Where can butt joints be used?

A

-Basic boxes or cabinets,
-Building frames

119
Q

Where can dowel joints be used?

A

-Chair and table legs
-Table tops
-Cabinets

120
Q

Where can comb or finger joints be used?

A

-Tables and chairs
-Floor boards
-Roof and door construction

121
Q

Where can dovetail joints be used?

A

-Drawers
-Jewellery boxes
-Cabinets

122
Q

Where can half-lap joints be used?

A

Framing

123
Q

Where can mitre joints be used?

A

-Picture frames
-Pipes
-Moulding

124
Q

Where can housing joints be used?

A

-Bookcases
-Cabinets

125
Q

Where can mortise and tenon joints be used?

A

-Table and chair legs

126
Q

Where can bridle joints be used?

A

-Legs or stiles to rails
-Frames

127
Q

Where can corner halving joints be used?

A

Frames

128
Q

Where can cross-halving joints be used?

A

-Strengthening rails for tables and chairs
-Trellis

129
Q

Where can biscuit joints be used?

A

Table tops

130
Q

What are the smart materials?

A

Shape memory alloy (nithinol) and polymorph

131
Q

What are shape memory alloys?

A

Alloys that change to their original shape when heated

132
Q

What are shape memory alloys used for?

A

Glasses frames

133
Q

What is nithinol?

A

An alloy that when cool is easily shaped but if heated to certain temperature it will return to remembered shape

134
Q

What is nithinol used for?

A

Glasses frames, wires of teeth braces, equipment for medical industry

135
Q

What is polymorph?

A

A new type of plastic smart material ideal for model making

136
Q

What is polymorph used for?

A

One off moulds, orthopaedic splints and specialised prototyping

137
Q

What are the types of composites?

A

-Fibre based
-Particle based
-Sheet based

138
Q

What are fibre based composites?

A

Composites reinforced with fibres

139
Q

What is glass reinforced plastic (GRP) made from?

A

Glass fibres and resin

140
Q

What is carbon reinforced plastic made from?

A

Carbon fibre and resin

Technology & Design (4 decks)

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