LO2 Flashcards
(91 cards)
1
Q
What is a standard component?
A
- Standard components are used in a variety of products and made by a variety of manufacturers
2
Q
Give examples of standard components
A
- Tyres
- Power supplies
- Motors
- Screws
- Nails
- Bolts
- Cogs/ gears
- Fuse
- Bearings
- Washers
3
Q
What are the advantages of using standard components?
A
- Available from a variety of suppliers
- Inexpensive as mass produced
- Can buy in bulk
- Cheaper to buy than make
- Saves production time
- Likely to be very reliable as made by specialist
- Easy to obtain parts for repair
- Reduces production costs
4
Q
Explain why using standard components is more sustainable
A
- Products can be disassembled easily
- Materials can be separated and recycle
- Parts can be reused
- You can fix or replace broken parts
- They are durable
5
Q
Why are standard components manufactured to certain tolerances?
A
- People know the components will work or fit
- Making components to be an exact size would be too expensive
6
Q
What is a premanufactured component?
A
- Pre-manufactured components are made by specialist manufacturers and used in just one product
7
Q
Give examples of premanufactured components
A
- Car windscreens
- Engines
- Touchscreens
- Some electric motors
- Circuit boards
8
Q
What are the advantages of using pre-manufactured components?
A
- Saves production time
- Easier to assemble products
- Quality of components is high
- Likely to be very reliable as made by specialist
- Reduces the range of manufacturing equipment needs
- Outsourcing saves buying expensive machinery
9
Q
Define manufacturing constraints
A
- Are things which could stand in the way of manufacturing a product
10
Q
List some manufacturing constraints
A
- Costs
- Availability of materials
- Meeting laws/ safety legislation
- Assembly time
- Shipping/ distributing the products
11
Q
What are the factors which influence design?
A
Safety:
* Strength, durability, stability, rounded edged/no small parts
Sustainability:
* Can it be recycled
Working environment
* Where the product will be used and what it will need to cope with
Cost of production
* Can it be produced in high volumes, if additional components needed, on single piece reduces cost to make each unit
Materials:
* Availability, colour, using plastics - self finishing, easy to mould
12
Q
Define client requirements
A
- What a client wants the product to do, be or have
- What features the product will have to ensure the requirement is met
13
Q
What is included in a client requirements?
A
*
14
Q
Define ergonomics
A
- How a product is designed to fit the user, be easy and comfortable to use
15
Q
Why must ergonomics be considered when designing products?
A
- So the user can easily use the product
- So it functions correctly
- Poor ergonomics can cause injuries
- Consider ergonomics of target market, e.g. elderly
16
Q
What do ergonomics consider?
A
- Weight, height, hearing, sight & touch
17
Q
Define anthropometrics
A
- The study of different sizes of the human body, used to determine average ties when designing a product to suit a market
18
Q
Define performance requirements
A
- What a user wants the product to do, be or have
19
Q
What might performance requirements relate to?
A
- Durability - how long it will last
- Energy efficiency
- Weight (light)
- Product having different functions/ settings
- Safety
- Noise produced (not loud)
20
Q
What are the legal requirements of a product in terms of hygiene?
A
- Some products must be hygienic for example, food related items.
* If a product was not hygienic it could lead to: - Loss of customers
- Health risks to customers
- Contamination (food poisoning) if food related
* It is a legal requirement
21
Q
What are the advantages of using plastics over metals?
A
- Easier to mould complex shapes
- Cheaper manufacturing
- Quicker production
- Plastic is easy to recycle
- No finish needed – plastic is self coloured
22
Q
Why is it important to consider the availability of materials when designing and making products?
A
- If there are no materials, production stops which is expensive/looses money.
- Buying materials in bulk is cheaper.
- Just in time (JIT) manufacturing is used, so if materials don’t arrive on time, production stops.
- If a material is rare, it makes the selling cost more expensive.
- If a material isn’t available to meet demand (how much they need) a different material might need to be selected.
23
Q
Define supply chain
A
- Where materials and components are being ordered from and when they are being delivered.
24
Q
What happens if the supply chain breaks down?
A
* If the supply chain breaks down or cannot provide the materials or deliver them on time, manufacturing will stop.
25
Why should manufacturers should consider the supply chain when developing a new product?
* Check the supply can meet the demand (how much the company need)
* Check the materials and components are actually available
* To work out costs to make the product
* To work out delivery times and dates
26
What are composites?
* Composites are a mixture of 2 or more materials to give a material with combined and improved properties
e.g. stronger, attractive.
27
Give examples of composites materials
* Kevlar
* Carbon fibre/ fibre glass
* Glass reinforced plastic
28
What is kevlar and what is it used for?
* Artificial fibre woven together to create a very light and strong material.
* Strong and tough material
* Used for body armour
29
What is carbon fibre/ fibre glass and what is it used for?
* Fibre woven into a textile material and epoxy resin is applied (glue) and left to dry.
* Very strong, has the best weight to strength ratio.
* Used for fighter planes, sports cars.
30
What is glass reinforced plastic and what is it used for?
* Strands of glass are woven to form a flexible fabric. which is placed in a mould with resin (glue) and left to dry.
* Strong and light material
* Used for canoes, surf boards, swimming pools.
31
What are smart materials?
* Smart materials have a reactive capability.
* Their properties change when in contact with things like heat or pressure.
32
What does polymorph come in?
* Polymorph comes in plastic granules.
33
What is the function of polymorph?
* Has the reactive capacity to change from a solid to mouldable when heated.
34
How do polymorphs work?
* Heat granules with boiling water and they’ll melt and can be moulded.
* Once the plastic cools, it sets into a solid plastic.
* Can be re-heated with hot water and re-moulded.
35
What are polymorphs useful for?
* Useful for making unusual shaped items, ergonomic handles or modelling.
36
What is the function of thermochromic pigments?
* Thermochromic pigments are added to plastics to make them change colour when heated to a certain temperature.
37
Give examples of thermochromic pigments
* Baby spoons - change colour if the food is too hot
* Kettle - changes colour when the water is boiled.
38
When would the thermochromic pigments be added to the product?
* The thermochromic pigments would be added when the product was being made
e.g. with plastic powder when being injection moulded.
39
What does a thermochromic sheet consist of?
* Thermochromic sheets consist of a thin layer of liquid crystal which has been printed onto a black background.
40
What happens when you place your hand on a thermochromic sheet?
* When you place your hand on the strip, the print will appear in a range of colours which represent different temperatures on parts of the hand. * Can be reused.
41
What is the function of photochromic sheets and inks?
* Photochromic sheets and inks react to UV light
42
What is the function of hydrochromic sheets and ink?
* Hydrochromic sheets and ink which react to water and liquids.
43
What is a shape memory alloy?
* Shape Memory Alloys have a reactive capability to change their shape when heated.
44
Give examples of shape memory alloys
* Nitinol
* Memoflex glasses
45
What is nitinol? Name an example
* Nitinol is a type of smart wire which changes length when heat is applied to it.
e.g. Braces for teeth are made from Nitinol – your body heat will have attempted to shorten the length of the wire which then pulled your teeth into shape.
46
What are memoflex glasses?
* Memoflex glasses are made from a shape memory alloy
* Once shaped into the design of the glasses frame, they will continue to return to this original shape even after being badly bent.
47
What does FSC stand for? And what is its purpose?
* Forest Stewardship Council
* To make sure more trees are replanted than are cut down so we don’t run out.
48
How are FSC forests managed?
* FSC forests are managed with consideration for people, wildlife and the environment.
49
Where is the FSC logo found?
* Logo is found on wooden and paper products.
50
What does the FSC logo show (to the user)?
* As trees are chopped down, they are replaced.
* Parts of the forest are untouched to protect animals and plants.
* Once a section of the forest has been cut down, it is left for 20 years so the trees can re-grow.
* Local workers run the forest, get a fair wage and safe conditions.
51
What are the advantages of mass/volume production?
* Cost savings
* Once set up, cost per product/component is very low
* Less skilled workers needed = cheaper
* Efficient
* Material costs are cheaper the more you make
52
What are the disadvantages of mass/volume production?
* High setup costs
* Lots of specialist equipment needed
* Storing materials for large numbers of products
53
Define Just In Time production
* Just in time production is where parts/materials/components arrive just as they are needed.
a.k.a lean manufacturing
54
What are the advantages of JIT production?
* Less storage space needed = Lower costs
* Used in car manufacturing as the parts are large.
55
What are the disadvantages of JIT production?
* If materials/parts don’t arrive on time, production stops
56
When is JIT production used?
* Used when making large products like cars to save money on warehouse space.
57
What is one-off production used for?
* One-off items or prototypes – individual.
e.g. bespoke item of clothing, football stadium etc.
58
What is batch production used for?
* Used for limited production runs like books and bread up to 10,000 products made.
59
What is mass production used for?
* Used to make millions of products at the same time like mobile phones and standard components.
60
What is continuous production used for?
* Production 24 hours a day, 7 days a week – makes products like paper, glass and cans.
61
How does the scale of production impacts material selection?
* When using plastics, a large scale of production is needed to offset/counteract the high setup costs and machinery.
* Using modern materials is expensive and are not used for mass production.
* The sustainability of mass produced products must be considered.
* We must consider how the materials and components will be reused or recycled.
* One-off or custom products are more expensive for a customer to buy. It also often uses more expensive materials.
* Mass production processes like injection moulding, casting or CNC require parts to be designed with geometry so they are easier to produce.
62
What is design for manufacturing & assembly? (DFMA)
* DFMA is designing a product in such a way as it is as easy and inexpensive as possible to manufacture
63
What are the characteristics of DFMA?
* Consideration of the design to optimise manufacturing or assembly time.
* Designed so it can be manufactured efficiently.
* Components allow them to be assembled effectively.
* Minimal parts are used
64
Why do designers consider DMFA when designing products?
* Speed up assembly
* Increase production
* Reduce making costs
* They need less skilled workers (cheaper)
65
How could a design be optimised for DFMA?
* Make it easy to assemble
* Use standard components where possible
* Consider pre-manufactured components
* Error-proofing
* Reduce number of components
* Design to assemble using standard tools where possible
* Removing unnecessary material from the design
66
Why is design for disassembly important?
* Components or materials can be easily separated at the end of the products life
* Allows components or materials to be recycled or reused
* Allows parts to be replaced
* Allows the user to carry out maintenance & cleaning
* Easier to transport or store if not in use
67
How could a design be optimised for maintenance?
Make the products easy to disassemble and maintain by:
* Using clips or other non-permanent fixings
* Reducing number of parts
* Using standard parts where possible
* Making components easy to clean
68
Define tolerances
* Tolerance is the amount a product/component can be too big or too small (than its intended size) before it is discarded (thrown away).
69
What symbol is used to indicate tolerance for parts?
* The tolerance for parts of a product is recorded using this plus or minus symbol.
+
-
70
Why are tolerances important?
* Tolerance is important for safety and quality– if parts aren’t the right size, accidents could happen. Also, if products don’t fit, customers would complain.
71
How can designers improve the reliability of a product?
* Use components that are easily replaceable by the user
* Rigorously test a product to ensure it will last for desire product life span
* Choose high quality material and components
72
Why do designers use general tolerances?
* When making components, there are always slight variations in sizes.
* Creating products to an exact size is expensive
* Using a small tolerance means cheaper production
* Products will work and be safe
73
Define specific or close tolerances
* A specific or close tolerance is used for specific parts of a design where the size may be more critical.
74
Why are specific or close tolerances used?
* Safety reasons
* So parts fit
* So they are accurate
* So they function correctly
* Used for location and fit
75
How might copyright, patents, registered designs, and trademarks influence the design of new products?
* Designers will avoid copying product features that are protected
* Alternatively, manufacturers may have to pay a license fee to use the feature
76
What is one-off production used for?
* One-off production is used for prototypes and commissioned custom products
* Requires highly skilled workers
* Slow
* Expensive
* Hand tools
* Rapid prototyping e.g. 3D printer
77
What are the features of batch production?
* Used for relatively smaller fixed numbers of products. Typically 10-200
* Middle-ranged cost and speed per copy
* Workers specialise in a few processes
* Little automation
*Uses manufacturing aids:
-templates
-jigs
-fixtures
78
What are the features of mass production?
* Used for high volume production
* Highly automated, robotic manufacture
* Assembly lines
* Design optimised for mass production
* Employment is in maintaining machines or in simple, repetitive assembly
* Lowest cost per copy
* Expensive set up cost
79
What is the difference between durability and reliability?
* Durability is a measurement of how long a products entire life is
* Reliability refers to how likely the product will fail within a specific time period
80
Define engineering tolerance
* Tolerance is an acceptable amount of variation from the design - usually applies to sizes
81
Why do designers need to specify manufacturing tolerance?
* It is not possible to manufacture a component with complete accuracy
* A tolerance is used to state the amount of accuracy required
* Essential to ensure components fit together
82
What is intellectual property?
* Intellectual property is the idea that a person or company owns their creative work and it should not be freely copied
* Laws can be used to protect designs/ideas
- Copyright (written and art work)
- Patents (mechanisms)
- Registered designs (product shape)
- Trademarks (logo etc)
83
Draw the "UKCA" and "British Standards" quality symbol?
UKCA
- required in the UK
- Manufacturer declares product meets all applicable laws
- UK version of "CE" mark
British Standard
- optional
- product is independently tested by British Standards Institution
- Common on safety equipment
84
What are the 5 main parts of a design specification?
* Users needs
* Product requirements
* Manufacturing considerations
* Consideration of production costs
* Regulations and safeguards
85
What are the different types of user needs?
* Aesthetics
* Ergonomics
* Anthropometrics
* Benefits and features
* Product safety
86
What are the different types of product requirements?
* Function
* Features
* Performance
* Target group/intended users
* Working environment
* Limitation and constraints, size, weight, functional limitations
* Appearance
* Ergonomics
* Lifecycle
87
What are the main types of manufacturing considerations
* Materials availability & supply chain
* Ease of manufacture
* Production method (batch, mass, one-off)
* Manufacturing process (must match production method)
* Durability & reliability
* Tolerances
88
What might influence production costs?
* Scale of production
Materials cost
* Production method
* Tolerance needed
* Manufacturing process cost
89
Which regulations and safeguards would be considered?
* Copyright
* Patents
* Registered designs
* Trademarks
* British Standards
* European Conformity (CE)
90
Explain what a supply chain is
91
Why might an engineer specify an older traditional material rather than an innovative new one with better properties?
* If traditional material is likely to be available from any suppliers
* A failure on one supplier would not stop production as the material could be sourced elsewhere
