Unit 2

Question 1

What are the key aspects of the design process

Answer 1

Problem identification
Design brief
Research - current problem analysis
Specification
Concept sketches
Product development
Cutting lost/working drawing
Manufacture
Testing
Evaluation and future modifications

Question 2

Wood

Answer 2

Hardwood - Mahogany, Oak and Beech

Softwood - Pine and Cedar

Manmade - Plywood, MDF and Chipboard

Question 3

Metal

Answer 3

Ferrous - Mild Steel, Carbon Steel and Stainless Steel

Non ferrous - Aluminum, Brass and Copper

Question 4

Plastic

Answer 4

Thermoplastic - Acrylic, Polyvinyl Chloride, AB, Nylon and Rigid Polystyrene.

Thermosetting Plastic - Melamine, Polyester Resin, Epoxy Resin and Urea Formaldehyde

Question 5

Material properties - tensile strength

Answer 5

The ability of a material to stretch or pull without breaking or snapping

Question 6

Material properties - compressive strength

Answer 6

The ability of a material to resist squashing force.

Question 7

Material properties - bending strength

Answer 7

The ability of a material to resist bending forces

Question 8

Material properties - shear strength

Answer 8

The ability of the material to resist sliding forces

Question 9

Torsional strength - material propertied

Answer 9

The ability of a material to withstand twisting forces

Question 10

Hardness

Answer 10

The ability of the material to resist scratching from wear and tear, bending and indentation.

Question 11

Brittleness

Answer 11

Brittle materials cannot withstand much stretching. They will crack or break rather than change shape.

Question 12

Advantages of standardized components

Answer 12

It speeds up manufacturing and reduces manufacturing and maintenance costs, as the same units can be purchased and used all around the world.

It means manufacturers do not have to create everything from scratch themselves. Pre manufactured parts can be bought in by manufacturers for use in their products. For example a car manufacturer may buy in their headlights from another supplier rather than making them themselves

Question 13

Disadvantages of standardized components

Answer 13

The manufacturer is depending on other manufacturers to supply them which has the potential to be a less reliable system if delivery dates that are not adhered to. Production may slow to cease if a manufacturer is waiting for a delivery of standardized components. Assemblies or bought in components.

Question 14

Sub contracting

Answer 14

Sub contracting is when part of the job or manufacturing process is contracted out to another company to complete. It can happen if a manufacturer has too much work to complete. This occurs when machines and operators are working to full capacity and production is at its full capacity and production is at full efficiency but orders are still being placed. The manufacturers ability to produce products is thus exceeded by the time available, if quality is to remain the same. On time delivery to customers becomes unachievable if there is a back log in the manufacturing process, which can affect customer service. To avoid this happening but without having to refuse orders p, the manufacturers will sub contract

Question 15

Advantages of sub contracting

Answer 15

It provides relief to the manufacturer and prevents the manufacturing plant from being over burdened.
It can improve efficiency by ensuring manufacture of the product is optimized on quality.
It helps manufacturers meet delivery dates without compromising on quality.

Question 16

What is cad?

Answer 16

Cad stands for computer aided design. It is particularly useful for creating a working drawings and 3d computer models.

Question 17

What are the advantages of cad?

Answer 17

They produce high quality and consistent drawings.

Information can be stored easily electronically and transmitted easily through e-mail.

Complex assembly drawings can be produced quicker once the user gets used to the package.

Standard parts can be accessed from a library, reducing time taken to draw them.

Changes can be made easily and instantly on screen.

Components are dimensioned automatically with most packages.

Solid modeling allows the product to be viewed at various different angles and 3d images give a more realistic view than the 2d drawing.

Images can be scanned into the system or photos can be imported which is beneficial to the project.

Question 18

What are the disadvantages of cad?

Answer 18

They are not suitable for free handing sketching, which is quick and essential at the initial design and development stages of a design project.

The initial set up cost can be expensive, as a computer is essential, some software is expensive and operators need to be trained to use it.

Question 19

What is cam?

Answer 19

Cam stands for computer aided manufacture. It is a process that converts drawing produced by cad into actual products.

Question 20

What are the advantages of cam?

Answer 20

The have a high production speed, ideal for large volume production.

Machines can work 24/7 with little human intervention.

They ensure products are produced accurately and consistently.

They are reliable

That are flexible as they can be reprogrammed.

Cam systems require less skilled operators than traditional manufacturing that is not computerized.

Question 21

What are the disadvantages of cam?

Answer 21

Initial set up cost is high.

Training is required for operators.

Cam systems can be slower than traditional methods of manufacture for one off or low production.

Question 22

One off/jobbing production

Answer 22

Making a single product. The specific and individual requirements for the customs have to be met, so every item will be made differently. It required a highly skilled workforce and is very labor intensive.
Applications - bridged, one off structures such as the Eiffel Tower, racing car engines, one off furniture and jewelry pieces.

Question 23

Advantages of one off production.

Answer 23

Made to exact personal expectations.
High quality materials used.
Hugh quality crafts.
Person ensures a high quality product at the end.

Question 24

Disadvantages of one off production.

Answer 24

Final product is expensive.
Labor intensive and a slow process.

Question 25

Batch production

Answer 25

When a specific quantity of product is made, between 2 and 10. A production line is set up where each worker completes one task then passes it along the production line to the next worker. The workers are either semi skilled or unskilled but must be able to switch from one part of the production line to the other. This is known as a flexible work force. The production line needs to be easily and quickly changed, so that different products can be made. Generally batches of product are produced for a period of time and then the product is changed. It is common for individual parts of the product to be purchased from other companies and assembled on the production line.

Question 26

Advantages of batch production.

Answer 26

Making in batches reduces unit costs and still addresses specific customer needs (e.g. size, weight, style).
Use of specialist machinery and skills can increase output and productivity.

Question 27

Disadvantages of batch production

Answer 27

Time lost switching between batches, machinery may need to be reset.
Need to keep stock of raw materials
Cash also investment in work in progress.
Potentially demotivating for staff

Question 28

Mass production

Answer 28

Mass production is the high volume production of products usually in their thousands. Often uses a high proportion of machinery and energy. The initial cost of set up is high for machinery and energy.

Question 29

Advantages of mass production

Answer 29

Labor costs are usually lower. Materials can be purchased in large quantities, so they are often cheaper.
Large number of goods are produced.

Question 30

Disadvantages of mass production

Answer 30

Machinery is very expensive to buy, so production lines are expensive to set up.
Workers are not very motivated, since their work is very repetitive.
Not very flexible as the production line is very difficulty to adapt.
If one line breaks, the whole production line has to stop until it is repaired.

Question 31

Continuous production

Answer 31

Continuous production is non stop 24/7 mass production of tens of thousands of identical products. A semi automated line is set up using computer control and a combination of skilled and unskilled workers. The workers are less flexible than those working in batch production as the product almost never changes.

Question 32

Advantages of continuous production line

Answer 32

Reduced processing time of work pieces.
Saving costs for temporary storage
Control over the entire course of production

Question 33

Disadvantages of continuous production

Answer 33

Much capital is required to install production lines
Low flexibility in changing products
High receptiveness to malfunctions since a single fault can stop the entire production line.

Question 34

In line assembly

Answer 34

In line assembly is used for mass production, as most of the production line is automated, unskilled labor is used mainly for assembly, whilst some semi skilled workers ensure there is continuous flow along the line.

Question 35

Advantages of in line production

Answer 35

As tasks are mainly carried out by machines, human error and validation is reduced.

A company can produce a larger quantity of one product at a lower cost than traditional non linear methods because labor costs are reduced and production is increased.

Question 36

Disadvantages os in line assembly

Answer 36

The system is inflexible because it is difficult to alter a design or production process after the production line has been implemented.
The system can lead to a lack of variety, as products are all produced on one production line so they are almost identical or very similar, making it very difficult to cater for individual needs or wants.

Question 37

Flexible manufacturing systems

Answer 37

Flexible manufacturing systems use semi skilled workers who are able to do a variety of jobs. The approach is based off a flexible workforce and flexible is the key to successful manufacturing.

Question 38

Advantages of flexible manufacturing?

Answer 38

FMS is useful for batch production where change and flexibility is essential.
Manufacturing time is reduced per product.
Cost per unit is reduced

Question 39

Disadvantages of FMS

Answer 39

FMS required a great deal of pre planning and organization prior to production starting.

Question 40

Toughness

Answer 40

The ability to resist breaking or shattering. The opposite of brittle.

Question 41

Plasticity

Answer 41

A material has good plastic qualities if it can change its shape permanently without breaking or cracking

Question 42

Durability

Answer 42

The ability of the material to withstand repeated use, wear and tear, weathering and corrosive attack.

Question 43

Pliability

Answer 43

The ability of the material to be shaped, bent or drawn out. For example, ductile copper or mailable metals such as gold.

Question 44

Malleability

Answer 44

The ability of the material to be reshaped in all directions without cracking.

Question 45

Elasticity

Answer 45

The ability of the material to absorb force and flex in different directions then return to its original position.

Question 46

Ductility

Answer 46

The ability of the material to change shape (deform) usually by stretching along its length.

Question 47

Heat conductivity

Answer 47

The ability of the material to conduct heat.

Question 48

Electrical conductivity

Answer 48

The ability for the material to conduct electricity.

Question 49

Corrosion resistant,

Answer 49

The ability for the metal or alloy to resist being destroyed by oxidation or chemicals.

Question 50

Product analysis

Answer 50

Looking at existing designs to see what makes the design good and work well. Asking questions about the design such as; does the product look good? Is the product what the customer what’s? Is the product safe? Are the materials used for the product suitable?

Question 51

Modeling

Answer 51

Models are very important to help judge proportion. They can be either full size or a scale model, and a variety of model types are available such as card, foam, corrugated paper, styrofoam and cad prototypes.

Question 52

Mock up

Answer 52

A model of a product built for study, testing and display. It is usually quick, rough and often simply to “test the concept” for further development.

Question 53

Prototype

Answer 53

A life size working/functional model of a design used for testing, development and further evaluation.

Question 54

Product analysis - fit for purpose.

Answer 54

Has the design been met?
Are the needs of the intended user been met?
Find out if the product user is satisfied with the final product. Does the product match the environment it is used in?
If the product fit for the purpose it was designed and manufactured for? Does it do what it was intended for?

Question 55

Product analysis - quality

Answer 55

Has the product been designed to meet the needs of the intended user?
How well has the product been made?
The users needs to- have the intended users needs been met by the product?
Material choice - are the materials chosen for manufacture suitable?
Manufacture - is it well manufactured? Was it checked for quality during manufacture?
Maintenance - will the product be easily maintained or replaced if necessary?

Question 56

Aesthetics

Answer 56

The term aesthetics concerns our sense and our responses to an object. If something is aesthetically pleasing then you will like it , if something is aesthetically displeasing you won’t like it.

Texture - how the object feels, or will look if it is touched. This is perceived by touch and sight. An object can have a rough or smooth texture and a matte or shiny surface.

Color - if a color is displeasing then the product is less likely to be purchased but if the color is pleasing it is more likely to be purchased.

Proportion and balance -proportion is used to describe the relationship between one product part to another. Balance looks at the designers use of symmetry snd use of asymmetry to create a visually appealing impact.

Question 57

Ergonomics

Answer 57

This is the study of people in their environment. This means making the product fit the user.

Sight is a major consideration for designers. People learn to react to visual information such as signs, symbols and displays. Designers make use of color to make the product more attractive.

Touch is a key factor in products as it can be designed to give the user texture, warmth or coolness, or be controlled by touch such as a computer mouse or a games console.

Smell is an important factor for the development for items such as cosmetics and household fragrances. Our sense of taste is influenced by smell.

Sound is used by designers in warning products or alarms, alarm clocks and car horns as humans react to noise.

Question 58

Anthropometrics

Answer 58

The study of the human body and the movement of each part. As the developer you must consider the person or people who are your intended users. There is a wide range of sizes between people so anthropometric data is collected and collated