| Essential Question:
How are raw materials shaped
into finished products? |
Manufacturing Techniques
Relevance:
If you are involved in an entrepreneurial venture involving the
manufacture or marketing of a product, to be successful, you will have to
understand how to select an appropriate manufacturing technique.
-
Be able to fill in and discuss
the information in the following table:
|
Technique |
Description |
Typical Materials |
Pros |
Cons |
|
Molding |
A powder, liquid,
or malleable solid is forced
under pressure to take the shape of a mold |
ceramics, metal, plastic, food |
High speed production of complex parts. |
Expensive equipment, especially molds. Less
precision. May need to remove flashing |
|
casting |
A liquid or slurry is poured into a
mold. |
ceramics, metal, plastic, food, concrete |
Molds can
be fabricated from soft, easily worked materials then used to cast complex shapes in harder more durable materials. |
Large set up time. Mold may not be reusable. |
|
fusing |
|
|
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|
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stitching |
|
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cutting |
|
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|
|
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machining |
|
|
|
|
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abrading |
|
|
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adhesives |
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fasteners |
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Assessment --
Materials Vocabulary
Specifications: Create the above table in Excel and input the
missing information using the internet and the glossary in the IB Design Tech
syllabus.
Deliverable: Place the
completed Excel file in the IB Design Technology folder of your student
drive.
Work Group: individuals. |
| Essential Question:
How are one-of-a-kind products
made and why in the past were all products one-of-a-kind? |
-
Relevance:
If you want to be an artist you will invariably be involved with craft
production.
-
Your understanding of it along with your talent will determine whether
or not you can make a living as
an artist.
-
-
Define craft production
-
small scale
-
multiple items
-
manual skills
-
Define one-off production
-
Describe why most products were
manufactured by craft techniques prior to the Industrial Revolution.
- the skills and knowledge required to remain employed typically changed
very little over time as compared to modern times. For example: blacksmith
vs. computer programmer.
sources of materials
- highly limited, hence, individuals could easily specialize in working
with a specific material such as wood, leather, iron (blacksmith)
sources of energy
- human or animal power
sales and distribution
- distribution was highly limited by slow
transportation: horse drawn wagons over dirt roads. Demand for goods was
relatively low and could be met with the limited output of a few skilled
workers.
relationship of craftsman or
designer with client or customer
- likely to live nearby and be acquaintances, relatives, or friends
-
Discuss the importance of craft
production for developed and developing countries.
- Craft production requires very little economic
development to support it.
infrastructure and market needs
- developing countries lack the infrastructure for large scale
distribution of goods. Small scale distribution limits the size of
markets. Craft production may be the only viable way to earn the money
needed for making the infrastructure improvements required for
development.
the rise of the “master craftsman”
in industrialized countries
- a wealthy industrialized country can support “master craftsman” with
highly specialized skills related to the arts. It requires a certain
number of “master craftsman” with highly specialized industrial skill
such as tool and die makers ( a type of machinist that makes the tools
used in automation. This type of job will not exist in a developing
country.
|
Assessment --
Introduction to CAD
Specifications: Define all vocabulary terms highlighted in yellow
for objectives 1- 33
Deliverable: Place Word
document with completed list in the IB Design Tech folder on your student
drive.
Work Group: individuals. |
| Essential Question:
Does mechanization eliminate
jobs? |
Mechanization
-
Define
mechanization:
-
Describe how the availability of new sources of power in the
Industrial Revolution led to the introduction of mechanization.
- the
energy source is actually solar energy stored in the water as gravitational
potential energy. Energy from the sun evaporates water which eventually
falls as rain. The rain collects behind a dam and then is allowed to flow to
a lower level, driving a water wheel or turbine in the process. Water is a
working fluid. It is not by itself a source of energy.
steam
- the
energy source is
actually
coal. Steam is a working fluid. It is not by itself a source of energy
-
Define
assembly-line
production.
Explain the relevance of assembly-line production to
mechanization.
The cost per unit greatly declines for two reasons, economies of scale and
reduction of time related expenses such as labor, rent, and working capital.
product design:
parts must be standardized interchangeable, and designed for ease of
assembly.
effect on the workforce:
Tends to lower the required worker skills. Can be extremely tedious.
Typically does not make use of worker's thinking abilities.
consumer choice:
Reduces costs but also reduces the variety of available choices.
-
Outline two advantages and two disadvantages of mechanizing a
production process.
|
Advantages |
Disadvantages |
| Low cost per unit |
Tedious repetitive jobs for most workers |
| High and uniform quality |
Less variety in consumer choices |
| Standardized parts for maintenance and
repair |
Capital intensive |
| Requires less worker training and skill |
Difficult and expensive to alter production
process |
-
Define batch production and
mass production for a
mechanized production system..
| |
Batch
Production |
Mass Production |
| Description |
All the steps in the process must be completed before the
process can be repeated. The process produces product in discrete units or
batches with significant time lags between batches. |
Each step in the production process is continuously
repeated. The process continuously produces product. |
| Examples |
growing crops, wine and beer production,
production of specialty chemicals and medications. |
automobiles, injection molding of parts, many types of
chemical processes such as distillation. |
| Production rate |
Best for limited production |
Best for large scale production |
|
market needs |
Easy to change with quickly changing market |
Difficult for traditional mass production to change with quickly changing
market |
|
consumer choice
|
Generally easier to increase the number of choices |
|
|
product differentiation |
Easy |
Difficult for traditional mass production |
|
economies of scale |
Depends on production rate |
Best choice for economy of scale |
-
Compare batch production and mass production in a mechanized
production system.
-
market needs
-
consumer choice
-
product differentiation
-
economies of scale
|
Assessment --
Introduction to CAD
Specifications:
Do SolidWorks Tutorial exercises 1-3
Deliverable:
Show each completed exercise to the teacher before proceeding to the next
one
Work Group: individuals. |
| Essential Question:
Does mechanization eliminate
jobs? |
Automation
-
Define automation. Relevance:
Worldwide, the number of manufacturing jobs
are in decline thanks to automation, but it is mostly the less desirable
manual labor jobs that are disappearing. Employees who understand and know how
to use concepts like JIT, CAM, CNC, and mass customization are going to be in
great demand.
-
volume
production process
-
done with machines controlled by computers or
electronic/mechanical controllers.
-
Humans act in design, supervisory, quality control, or
maintenance roles.
-
Describe how the development of computer and information
technology in the “technological revolution” led to the introduction of
automation.
-
Define
computer-aided manufacture (CAM)
and
computer numerical
control (CNC).
-
Explain how CAD, CAM and CNC contribute to an automated
production system.
-
Define just-in-time
(JIT) and just-incase (JIC).
-
Explain the advantages of JIT and JIC to manufacturing.
-
Define mass
customization.
-
Outline how mass customization is changing the relationship
between the manufacturer and the consumer.
Using sophisticated computer controlled robotics, individual features of a
product such as color can easily be customized for individual customers.
Discuss the impact of automation on working conditions.
--less exposure to
dangerous chemicals or conditions
challenging technician level work --work less physical,
more mental
higher pay --lower labor cost per unit of production
-
Outline how automation has improved the type and range of
products available to consumers.
|
Assessment --
Introduction to CAD
Specifications:
Do SolidWorks Tutorial exercises 5-7
Deliverable:
Show each completed exercise to the teacher before proceeding to the next
one
Work Group: individuals. |
| Essential Question:
Does mechanization eliminate
jobs? |
Economic considerations
-
Define:
fixed costs--costs
do not change with the level of production.
variable costs--costs
that
vary with output,
Relevance:
Control of fixed and variable costs is essential for making a profit in
today's business environment.
-
List the costs that contribute to the
final cost of a product. (Note, in general the scale of production, size,
weight, and complexity of the product are major factors in its cost.)
Fixed costs
(These increase with greater
mechanization and automation.)
Variable costs (These tend to be higher for craft
production.)
| Essential Question:
Does clean technology eliminate
jobs? |
Clean Manufacturing
Relevance:
Clean manufacturing helps prevent pollution and lowers total long term the
cost of goods.
-
Explain why the introduction of mass production increased
damage to the natural environment.
-
not an issue in the 18th and 19th centuries --long
term effects were unknown, industrial and economic growth were given
higher priorities
increased energy use --greater C02 emission,
NOx, SOx, heavy metals, especially for coal burning.
greater use of raw materials --strip mining (coal and
metals), deforestation
created disposal problems
the
long term cost of goods was typically not reflected in their price.
-
Outline the reasons for cleaning up manufacturing.
-
Outline that an initial response to reducing emission of
pollutants is adding clean-up technologies to the end of the manufacturing
process
(“endof-pipe”
approach).
scrubbers--remove sulfur compounds from the exhaust of
coal burning power plants
dust filters
electrostatic precipitators--removes smoke and other
sources of particulate pollution from exhaust streams
waste ponds--used for treating raw sewage, in chemical
plants all rain water runoff from the process areas drains into treatment
ponds
-
State that the legislation can be policed by monitoring
through the collection of quantitative data.
The data is often collected by the manufactures themselves, which to some
extent is a conflict of interest. However, the penalties for lying are very
high and include large fines, felony convictions with significant prison time,
and the loss of customer good will with a subsequent loss of sales.
Explain that strategies for cleaning up manufacturing are
mainly reactive, and that more radical approaches require a rethink of the
whole system and may result in significant product and/or process modification
or radically new technologies.
Explain that targets for reducing pollution and waste from
industry are agreed internationally, but not all industrial nations agree to
the targets.
Countries with lax pollution standards can lower manufacturing costs and
attract more industry, putting manufactures in more responsible countries out
of work. International agreements can help prevent this from happening by
leveling the playing field.
Summative Assessment: Test Objectives 1-35
Note: Items highlighted in this
color
are directly related to the 2009 IB Syllabus which is the set of standards for
the class. In many cases the wording has been altered, but every attempt has
been made to preserve the meaning. These objective, however, should not be
considered a substitute for the actual syllabus.
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