……..PRODUCT DESIGN BIBLE AS……..
1. ICT in uses of manufacturing and designing…
CADD
computer aided design and drafting
used in product design, architecture, engineering or textile design
KEY FEATURES
edited quicklycompared to paper
can be viewed from many angles 3d and 2d
apply different renders to the surface to see how the product looks
animation
presentation drawings, edited into intended environments
virtual models, strength can be measured virtually
walk through tours, of a building “virtual tour”
zoom in and out and out to see all details
CADD drawings can be sent to CAM machines and then can be used to create 3d models
can change the models into wire frame so that you can see hidden details
performance modelling aesthetic visual tests, can be rendered with different finishes so that a client can
decide which is more appealing
performance tests, can be bested under working conditions to see how the product would perform
CAN SEE THE PRODUCT IN THE ENVIRONMENT
VEWIED FROM ALL ANGLES
RESEARCH
USED TO COMMUNICATE FROM DIFFERENT LOCATIONS
GOOD AT COMMUNICATING A DESIGN VIA EMAIL
SCALE UP DRAWINGS
ASSEMBLY PLANNING
PREPAREING FOR MANUFACTURING
ANIMATION
PREPARE FOR MANUFACTURE
SPEED UP MANUFACTURING TIME
VISUAL SPECTS CAN BE ALTERED 2D TO 3D
SIMULATION
CAD SPEED
RAPID PROTOTYPES >PHYSICAL MODEL PRODUCED
TEST MATERIAL AND PRODUCT FOR STENGTHS AND PROPERTIES
SPECIFIC SERCH ENGINES
ALWAYS TALK SPECIFICALLY ABOUT GOOGLE SKETCH UP IF TALKING ABOUT A SOFTWARE
RESEARCH HELPS AID DESIGN WORK
ACCURACY IS KEY
Previous exam question on how it is used in each of these areas…
Research
Using the internet, specific search engines, and collation of data in research
to aid designing.
Modelling
Compute aided modelling and using specific programmes to produced
models. Communication of modelled ideas via the web to other locations.
Prototyping
The use of rapid prototyping machines and how this benefits the whole
process before manufacture.
Manufacturing
The use of CAD and CAM systems during manufacturing. The use of
computers to control and production line and monitor progress.
,CAM
machines that are controlled by computers most commonly CNC machines (computer numerical control)
laser cutter, CNC router CNC lathe CNC miller
difficult shapes can be achieved that would be achieved another way
repetition of identical shapes
accuracy of shapes and interlocking fittings
useful in both batch and mass production due to speed
can work in hostile environments
expensive to set up and maintain
ALLOWS THE MANUFACTURER TO GET THE PRODUCTS PRODUCED QUICKER (LEAD TIME)
DRAWINGS INTO PROTOYPES (RAPID PROTOGRAPHING)
ACCURACY
batch and high volume production
********* RAPID PROTOTYPING ***********
creates models quickly
saves lead time
less money wasted
enable manuactures and designers to see any flaws in the design
Advantages of producing prototypes
Designer
Various visual aspects (colour, form, 3 dimensional).
Function (working parts, scaling, simulation, form).
Methods of assembling the product may be planned.
Working across sites (sending drawings to other manufacturers, designers)
Manufacturer
Reference to rapid prototyping – physical model produced from CAD – speed of production.
Testing product performance before manufacturing.
Materials test are carried out.
Check on the quality of the product.
Precise mould production produced by CAD/CAM.
2)PRODUCTION
(from exam)
Batch or modular production is when a small quantity of identical products are
made.
Batch production may also be labour intensive where jigs and templates are
used to aid production.
Batches of the product can be made as often as required.
The machines can be easily changed to produce a batch of a different product.
e.g. fashion items, a range of seasonal products.
Mass or continuous production is when hundreds of identical products are made,
usually on a production line.
Mass production often involves the assembly of a number of subassemblies of
individual components.
Parts may be bought from other companies.
There is usually some automation of tasks (e.g. by using Computer Numerical
Control machines) and this enables a smaller number of workers to output more
products.
e.g. a range of machinery parts, a range of kitchen/household products.
Responses may also refer to:
,Continuous flow production is when many thousands of identical products are
made.
The difference between this and mass production is that the production line is
kept running 24 hours a day, seven days a week to maximise production and
eliminate the extra costs of starting and stopping the production process.
The process is highly automated and few workers are required.
e.g. pins, nails, screws, a range of high volume components.
Describe the principles of JIT manufacture and its benefits to both the
manufacturer and supplier. 2 x [4]
Key principles of Just in Time (JIT) manufacture:
Manufacturing according to an agreed plan
Governed by material and resource availability.
Principles may be descriptions of aspects of production and meeting the needs of
customers.
Control of stock
The arrival of materials and components just in time
Benefits to both the manufacturer and the material or component supplier. (Up to two
marks for each benefit.):
Less storage space
Efficient and faster manufacturing system thereby:
Getting products to the customer/consumer quickly
Releasing capital for use elsewhere
No depreciation in material costs
Increased profit margins
Consistent deliveries
Ability to specialise in component production.
BATCH PRODUCTION
is where specific quantities of products are made for example 13 loaves is a bakers dozen
batch production can be a very small number or products or a very large number of products
from aeroplanes in these few to agreements in there thousands
expensive to set up production line and equipment
end product is cheaper to sell
this is a good method if the item or product goes out of fashion or sells poorly, as production can stop. And
you can change the production so that it suits a new product the suits the market demands
the company needs to be flexible to accommodate to different types of product batch
initial set up costs are high
can be a product that is in fashion for a certain period of time like clothes or seasonal products
usually more expensive than mass production due to the complexity of the product
more processes than mass production and also more skilled workers needed
FEATURES OF MASS PRODUCED PRODUCTS
• Mass production or high volume production is the production of large
amounts of standardised products on production lines.
• few materials
• Named products may contain several components e.g. screws, fittings.
• Product lends itself to assembly
SMALL QUANTITIES OF IDENTICAL PRODUCTS
MADE WHEN REQUIRED
MACHINES CAN BE CHANGED TO PRODUCE OTHER PRODUCTS
LIMITED EDDITION RPODUCTS
LABOUR INTENSIVE
FASHION , LIMITED EDITION PRODUCTS OR SEASONAL ITEAMS
GROUPS OF PRODUCTS
MACHINES EASILY CHANGED TO PRODUCE ANOTHER PRODUCT
, MAKE SURE THAT YOU STATE THAT THE PRODUCT IS SUITABLE FOR BATCH PRODUCTION
FEATURES OF BATCH PRODUCED PRODUCTS
Batch production is used to produce or process any product in groups that
are called batches as opposed to a mass or continuous production
process, or a oneoff production.
• Named products may be fashion items, food based products produced in
small runs, incremental improvements of products, testing the market,
fluctuations in supply of materials, seasonal demands.
MASS PRODUCTION
manufacturing in large qualities (24/7 )
this means that product is geared to make large quantise of similar products such as drink cans,
disposable razors, popular biscuits, tights, lightbulbs
fairly simple products are eligible for mass production
not many materials or components involved meaning assembly should be simple and quick
the end product is cheap
labour costs are very cheap, due to most of the work is automated or unskilled workers are needed
initial set up costs are very high
quality control issues have be in place to make sure the quality is high
ASSEMBLY OF A NUMBER OF INDIVIDUAL COMPONENTS
AUTOMATION CNC
LESS SKILLED WORKERS
HOUSEHOLD PRODUCT PRODUCE THOUGH MASS PRODUCTION
POOR QUALITY
HUNDREDS OR THOUSANDS
LARGE SCALES
LENDS ITSELF TO THIS STYLE OF ASSEMBLY
SEVERAL PARTS NOT COMPLEX
Increased sales of products, selling price is less, use of unskilled workforce,
speed of production
CONTINUOUS LINE PRODUCTION
Features:
Products produced in quantity, can be supported by subassembly systems,
components added along the assembly line, workers with specific tasks.
Up to four marks for a full description.
More Features of Continuous Production Lines – production in a line, with assembly
workers adding components.
Advantages: uses low cost unskilled labour, fast and efficient for the manufacturer,
smooth running and uses computer control.
FMS
Is a manufacturing system in which there is some amount of flexibility that allows the system to react in case
of changes, whether predicted or unpredicted
CELL PRODUCTION
Features of Cell production – groups or cells of workers working as teams in the
production process.
Advantages – small teams working together, shared responsibility, workers know
their job and are able to carry out specific role to a high standard, easily traced
problems, when breakdowns occur it does not affect the whole operation, workers
have responsibility for parts of production which includes quality control.
