processes Flashcards
mass production
the production of large quantities of a standardised article by an automated mechanical process
continuous production
highly automated production of large quantities 24/7 to maximise productivity
why might you use continuous production
-if you know the product is always going to be in high demand e.g nappies
-has to be simplistic with limited components
advantages of continuous production
+cheaper for the user
+cheap labour due to minimal workers required
disadvantages of continuous production
-initial set up costs high
-quality control issues
batch production
made in specific quantities e.g 12 or 1000
labour intensive
advantages of batch production
+can be altered to meet demands
disadvantages of batch production
-initial set up costs high
one off production
one product made at a time, very labour intensive
advantages of one off production
+unique
+have to answer client brief exactly
disadvantages of one off production
-requires skilled worker
-more expensive
-labour costs expensive
fabrication
components joined together by nuts and bolts, welding, riveting
moulding
plastics moulded into different forms
casing can be injection moulding
PET bottles can be blow moulded
sintering
making objects from powder, by heating the material until particles adhere to each other
laminating
bonded layers of materials with bonding agent to form intricate shapes and forms that are much stronger than original
stamping
pressing or stamping shapes under high pressure into a former sheet material
milling
shaping product from solid block of material
turning
rotating materials in a lathe to achieve cylindrical shapes
injection moulding
injecting molten material under high pressure into a mould or die to achieve certain form
extrusion
pulling or pushing softened material through a specially shaped die to achieve different material properties
bonding
gluing or joining different materials together under high pressure to produce sheet form of materials
casting
material in liquid form poured into a prepared mould
no waste
cutting/wasting
material removed to create desired shape
shaping and forming
bending material or laminating wood to form a shape
assembly line disadvantages
-work can be repetitive and boring
-no job satisfaction
assembly line advantages
low level skill and training
cell production advantages
better quality products
just in time manufacturing
only buy enough stock for immediate use, saves on manufacturing costs
advantages of just in time manufacturing
+no large warehouses filled with stock
+not tied up in material ands stock standing
+if change in product the manufacturing can be changed quickly
using standardised parts and components
used to reduce costs e.g nuts and bolts, screws springs or circuit boards
advantages of using standardised parts and components
+don’t have to specialise in creating own product
+concentrate time on product
+no space required to manufacture them
+save costs
disadvantages of using standardised parts and components
-quality not guaranteed
-dependant on other company for delivery
-dependant on external factors like if the company go on strike
primary processing
1.buying raw material, forward ordering
2.processing of material
secondary processing
3.assembly of components
4.finishing
5.packaging
what are the tools used in batch production
jigs, former, template, pattern and mould
blow moulding
-used to manufacture bottles or any hollow containers
-heated plastic granules injection moulded into mould where air forces the plastic to the sides to create the shape, cooled then extracted
rotational moulding
-used to manufacture hollow plastic products
-moulds loaded with thermoplastic powder rotated in a heated chamber until it covers all the insides of the mould, cooled then extracted
thermoforming
-sheet plastic is heated then enclosed by the moulds it sits between and a vacuum is applied through the lower mould
-mostly used for rigid food packaging
vacuum forming
-sheet plastic is stretched into a single-surface mould and held against the mould by applying a vacuum
calendaring
-thermoplastic fed into heated rollers a set distance apart to create the right thickness, chilled on the final roller
-creates sheet, film and coating materials
press forming/ deep drawing
-pressing sheet metal into 3D shapes e.g sinks
3D printing
making three-dimensional solid object of any shape from a virtual model using plastic filament
laser cutting
form of cutting and decorating material using a fine beam of light controlled by a CNC machine
plasma cutting
stream of ionised gas that becomes so hot it vaporises the metal being cut
blanking and piercing
blanking- when a part to be used is punched out of a sheet of metal
piercing- sheet of metal having a hole punched through it
dip moulding
simple and cheap method of manufacturing shapes where a shape is dipped into a melted plastic
sand casting
low cost method of casting metal in sand moulds, used for one-off or low volume products
steam bending
the moistening of certain woods to make it more pliable (flexible)
me when I hate cutting
die cutting
-process for cutting, perforating and creasing thin sheets of material to create things like stickers
brazing
forming permanent joints in metal by melting a brazing rod at 880°C between two parts
TIG welding
precise and high quality form of electric arc welding that uses non-consumable tungsten electrode
