MANUFACTURING PROTOTYPEHow do all the aspects of manufacturing come together to make a final product?

Manufacturing the Big Picture Essential Question:

What role does each part of manufacturing play in the final manufacturing process?

You have been contracted by your local TSA chapter to produce a product for this year’s Manufacturing Prototype event.

Revisit the steps of the manufacturing process to create a production plan for a product you design.

You should keep notes of each step in your design notebook. You will transfer your notes to PowerPoint to communicate your design.

Manufacturing Prototype

THE DESIGN PROCESSThe following is an outline of the process and steps you should complete.

The Design Process

Define the Problem Research the Problem Develop Possible Solutions Choose the Best Solution Create a Prototype Test and Evaluate Communicate Redesign

Define the Problem

Define the problem and list criteria and constraints

Research the Problem

Conduct research on the problem including: What products currently exist in this area? What is the cost of products that currently

exist? What materials can be used? Ergonomic factors? Safety factors?

Research your Customer Needs Sample Questions:

Who would purchase the product? What is the age range of potential

customers? Like and dislikes of potential customers? What do they want from your product? What factors would sway them to or away

from your product? What cost would they be willing to pay?

Create a survey or data sheet and record your results in your design notebook.

Develop Possible Solutions

Create 8 solution concepts – write a detailed description of each solution

Complete thumbnail sketches of at least 4 designs.

Choose the Best Solution

Using the format to the right, answer the following questions: Does it meet each of

your criteria? Ergonomics Materials Aesthetics Construction Method Health and Safety Environmental Other

Create a Prototype

Create a technical drawing using CAD software of your chosen solution. (use color to match your design)

Create a prototype using the materials given and any materials you bring from home.

Test and Evaluate

Evaluate your solution using the format below:

Communicate

You should prepare a PowerPoint presentation of your design process steps and information.

Each team will present their presentation to the class.

Redesign

Using information and feedback from the class – what do you need to redesign? Make any modifications in your design.

Changes to technical drawing Changes to materials

THE FINANCIAL COSTThe following is an outline of the process and steps you should complete.

The Financial Cost

Using your prototype and the internet, research your materials and figure the cost to manufacture your item. How much is one product? How much are 30 products? Where can you purchase the materials

most economically? (remember shipping costs)

Prepare a summary report of your findings to present to the class. Add this report to your PowerPoint presentation.

PRODUCTION PLANNINGThe following is an outline of the process and steps you should complete.

Production Planning - Tooling Create the following chart in your design

notebook: Part of Product– list each part of your game Material – what materials is each part made

from Tool Needed – what tool will you use to create

that part Tooling Needed – we will be learning about this

Create technical drawing and specifications of any tooling that needs to be built.

Part of Product Material Tool Needed Tooling Needed

Production Planning – Facility Create a flow process chart like the one

below for each part.

Production Planning – Facility PLASTIC CLIP

1. Cut to width

2. Cut to length

3. Drill holes

4. Round corners

5. Assemble to clip

Create an operation process chart for your entire production map.

Production Planning

Add your production planning information to your PowerPoint Presentation to present to the class.

QUALITY CONTROLThe following is an outline of the process and steps you should complete.

Quality Control

Answer the following questions: Where will you use quality control? What methods will you use for your quality

control?

Add your quality control to your PowerPoint Presentation to present to the class.

TAKING IT FURTHER - ADDING A LOGOThe following is an outline of the process and steps you should complete.

Logo Design

Basic rules for a successful logo: Simple in design Easy to understand, even at a distance One or two colors are normally used Writing is simple and easy to read A simple drawing or symbol is sometimes

used.

Logos

Simple pictures can be altered easily to make logos.

Logos

Create a mockup design of 3 different logo choices for your product and put them in your design notebook.

Add these designs to your PowerPoint presentation.

TAKING IT FURTHER - PACKAGINGThe following is an outline of the process and steps you should complete.

Packaging

Purpose of packaging: Protect a product from damage or

contamination by micro-organisms and air, moisture, and toxins.

To keep the product together, to contain it. To identify the product. Protection during transport and ease of

transport. Stacking and storage.

Packaging Symbols

Polythene Terephthalate (PET) is used for widely packaging, especially for dink containers. It is 90% recyclable and the symbol reminds the consumer to recycle the container.

International recycle symbol – to remind the consumer to recycle the packaging.

Material is recyclable and made from aluminum. Look at drink cans and you may find this symbol.

Store package upright

Card packaging – materials used to make package were harvested in sustainable forests. Trees are managed and replaced when cut down.

Contents are fragile Professional quality

control and precision is used in manufacturing

Do not store package in damp conditions

Store at a particular temperature

Environmental Issues with Packaging Waste – ensure minimum waste of

materials and if possible no waste. Why –

wasted materials = wasted money Helps conserve the environment Less energy is needed to run machines

Recycle as much waste as possible to save the environment and money

Manufacturing Packaging

Use a straight edge to draw the lines of the packaging

Use design software to design the packaging appearance and attach it

Use a craft knife and straight edge to cut each of the outside pencil lines and score each of the inside lines.

Use a ruler to help fold the package into its shape

Example – Self Locking Package Folds and holds its shape without glue

Example – Hexagonal Packages The top folds and locks into place. The

bottom has a number of tabs that must be glued.

Example – Box with Handles

Handles are part of the packaging

Example – Gift Box Small Scale

Logos

Using the packaging concepts we have discussed. create your own packaging for your product.

You will need the following: Template for packaging Packaging outside – logos and design

Write a rational for why you choose this type of packaging.

Include all of these items in your design notebook.

Add these designs to your PowerPoint presentation.

REVIEW OF THE PROBLEM

Did you know your problem?

You have been contracted by your local TSA chapter to produce a product for this year’s Manufacturing Prototype event.

Revisit the steps of the manufacturing process to create a production plan for a product you design.

You should keep notes of each step in your design notebook. You will transfer your notes to PowerPoint to communicate your design.

Manufacturing Prototype

Grading Rubric