Product Design

1. Describe the features and characteristics of products that would make them suitable for: (a) Batch Production [4] (b) Mass Production [4]

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 one-off production. Features may be fashion items, food based products produced in small runs. Mass production or continuous flow production is the production of large amounts of standardised products on production lines. Maximum of 2 marks if no product is discussed.

2. Describe how two-dimensional (2D) and three dimensional (3D) modelling and prototyping are used to assess design proposals. [8]

Features in a Product: can produce physical working/moving parts, cost, models can be produced to scale, materials can be tested in different locations/conditions (colour, texture, environments), the transfer of models to other manufacturing locations. Able to see ideas in two and three dimensions, products can be placed and viewed in different locations, can be viewed from any direction. Testing different markets for a particular product (assessing need, ergonomic/ anthropometric considerations), aesthetic considerations. Maximum of 5 marks for discussing 2D or 3D only. Accept "virtual" "CAD" testing or windtunnels etc.

3. Primary processing and Secondary processing are two important stages in the production process. (a) Define these two stages of production. 2x[2] (b) Describe the processes that will be specific to each in a named product. 2x[2]

Preparation or primary processing – the stage of getting the raw material into a workable state (thread, granules, sheet, woven forms). Secondary processing – the stage of forming the material through hand and machining processes. The answers can relate to a wide range of materials and processing methods. 1 mark for a product named. Must name a product to achieve full marks.

4. (a) Define the term Just in Time (JIT) in manufacturing. [2] (b) List three benefits of JIT to the manufacturer. 3x[2]

Key features of Just in Time (JIT) manufacture – manufacturing according to an agreed plan that is governed by material and resource availability. Features 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 the manufacturer – 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. Accept responding to demand.

5. Flow charts, GANTT charts and critical path analysis charts are used by product designers and manufacturers within project management. For any two of the above project management systems: (a) describe the main features; [4] (b) describe how they are used in effective project management. [4]

GANTT Charts Features: A Gantt chart is a type of bar chart that illustrates a project schedule. Gantt charts illustrate the start and finish dates and summary elements of a project. Mapping tasks, time factor, gives the user a project overview (reference to production plan, manufacturing process). Flow Charts Features: A flowchart is a schematic representation of a process. Generally the start point, end points, inputs, outputs, possible paths and the decisions that lead to these possible paths are included in the chart. Elements of a block flow diagram (system diagrams), flow process diagrams such as a material processing system or instructions for a bicycle's assembly. Critical Path Analysis Features: In project management a critical path is the sequence of project network activities with the longest overall duration, determining the shortest time possible to complete the project. Understanding of the critical path (the shortest route), planning the outcome of a project, the overlap of certain activities within a manufacturing process.

6. (a) Explain the term Reverse Engineering. [2] (b) For a specific product identify three important insights a designer might gain through reverse engineering. 2x[3]

Reverse engineering - the process of discovering the technological principles of a product/component or system. Designers analyse its function, structure and operation. Involves taking something apart and analysing its workings in detail, usually with the intention to construct a new device. The new device does the same thing without actually copying anything from the original. Maximum of 4 marks if no product is identified in part b.

7. BSI (British Standards Institution) and ISO (International Organisation of Standardisation) apply to a range of consumer products. Describe four positive effects that these standards have on the design of products. 2x[4]

Importance to the public: safety reassurances (related to the points below) Quality assurance aspects from …..Products: crash helmets, safety clothing, toys, specific electrical products. Tests carried out: crash resistance, flammability, component size and material in relation to toys, electrical safety. 2 marks for each positive effect. Qualified statements for 2 marks.

8. (a) Name and categorise three regenerated materials and three alloys or composite materials. [6] (b) Name a specific application for one material in two of the categories. [2]

Regenerated materials – include blockboards, cellulose based boards (card), chipboard, MDF, paper and viscose) Alloys are a combination, of two or more elements at least one of which is a metal - e.g. brass, bronze, steel, silver. Composites use a polymer resin solution. There are many different polymers available depending upon the starting raw ingredients – polyester, vinyl, phenolic, polyamide and others. The reinforcement materials are often fibres, fabric knit or stitched construction. Uses in aerospace, sport and racing cars. Do not accept Aluminium, glass. Accept Plywood, Blockboard as a composite. Accept newspaper as a regenerated material.

9. Describe two qualitative and two quantitative tests which can be carried out on a named product or component. 2x[4]

Quantitative testing are objective, measurable criteria, which can be assessed against specific performance measurable objectives. Marks allocated with a full description with any of the following examples up to a maximum of 4 marks: The material must weigh no more than….. The material used must be light enough to…. Related to material hardness, malleability, ductility….. 2 for each Qualitative testing will reflect the intended quality of certain defined aspects of a material's specification. They are a more subjective form of criteria. Marks allocated with a full description with any of the following examples up to a maximum of 4 marks: The material must be aesthetically pleasing… Material used must be recyclable…. The material must be bright……… 2 for each

10. Materials such as acrylic, PET (polyethylene terephthalate), Polyester and PVC (polyvinyl chloride) have replaced many traditional materials used in products. From any two of the named materials: (a) name the traditional material which has been replaced in a specific product; 2x[1] (b) state three benefits that each replacement material brings to the product. [6]

Acrylic – replaced signs, baths, toys PET - Used as a raw material for making packaging materials (therefore replaced paper, wood, glass) such as bottles and containers for packaging a wide range of food products and other consumer goods. Polyester – replaced natural materials in the making bed sheets, bedspreads, curtains and fabrics. PVC – replaced a large number of building materials, clothing and upholstery. 2 marks for each characteristic. Accept the terms "hardwoods" or softwoods". 1 mark for single worded answers.

11. Global manufacturing can involve the research and design development being undertaken in one country and production in another. Discuss the advantages and disadvantages of global manufacturing to the designer, manufacturer and consumer. [22]

Advantages: Designer – being able to work from a preferred location in designing (communication where necessary with the manufacturer possible through the use of a range of technologies). Manufacturer – obvious production cost savings. Getting the products to market quickly and utilising local resources. Consumer – cost savings. Local employment opportunities. Availability of products. Disadvantages: Designer – location. The technology may not be available to communicate effectively with the manufacturer. Manufacturer – limited resources may be an issue. Difficulties in production and workforce skills available locally. Consumer – for consumers in other locations (countries) it may have a negative effect (ethical issues in what is being manufactured and how it is manufactured). Look for reference to designer, manufacturer and consumer. Maximum of 12 marks for one area of discussion.

12. The applications of ICT have a significant effect on traditional manufacturing processes. Discuss the advantages and disadvantages the use of ICT has had on manufacturing processes. [22]

Up to 2 marks for each relevant point up to a maximum of 20 marks Communication - 2 marks. Candidates may refer to a range of manufacturing methods which may have replaced hand and commercial methods: Cutting textiles with flat bed cutters, the use of laser cutting (metals and plastics). A range of plastics moulding machines (blow moulding, injection moulding etc) controlled by computers. Die casting as a continuous process controlled by computers. Benefits – speed and precision in manufacturing. Large volume production is possible. Production is possible where there may be a risk in terms of health and safety to humans. Prototypes can be produced quickly, tested and therefore getting products quickly to market/consumer. Look for advantages and disadvantages

13. When designing, aesthetics, function, maintenance, cost and disposal are important considerations for the product designer. Discuss this statement in relation to named products. [22]

Considerations: Product Aesthetics (4 marks) – form and function and the development of products. The development of new materials allowing designers new possibilities. Adapting product aesthetics to trends/fashion. Function (4 marks) – new technologies provide new possibilities. Multi functional products being possible. Product function in relation to specific users or user groups. Maintenance (4 marks) – implications of maintenance on a product, servicing needs (all affecting product life). Cost (4 marks) and disposal (4 marks)– cost can include the cost to manufacture and the cost to the consumer (candidates may also refer to cost to the environment). Designers consideration of markets and the costs of products within those markets (are they sustainable?). Note: Up to 6 marks per area can be allocated. Up to 2 marks for each relevant point up to a maximum of 20 marks Communication - 2 marks.