Lesson video

Hello, there.

My name's Mrs. Taylor, and I'm really pleased you can be here for our lesson today.

Our lesson today is manufacturing considerations and selection, and this is part of the designing and making principles unit.

The outcome.

I can explain how a range of factors affect manufacturing process selection in industry.

We have five keywords.

Scale of production, which is the amount or volume of goods produced.

CAM, which is Computer Aided Manufacture.

Lead time, the length of time from order to production completion.

Efficient, using materials in a way that minimises waste.

And automation, the use of technology to perform tasks.

The lesson has two parts.

The first is factors in manufacturing process selection, and the second is CAM within manufacturing processes.

Let's begin.

When designing a product, manufacturers must decide which process to use.

This decision is influenced by various factors.

Understanding these factors helps determine the most efficient and cost effective process for the job.

Efficient refers to using materials in a way that minimises waste.

Some key factors that affect the process selection include the scale of production, which is the amount or volume of goods produced.

This also affects cost.

Lead time, which is the length of time from order to production completion.

Shorter lead times means satisfied customers.

Material properties, and this may be the working properties or the physical properties.

Can you remember the difference? And product complexity.

Simple shapes can be automated, which is the use of technology to perform tasks.

However intricate shapes may need manual intervention and cannot be completely made by machines.

Here we have a check.

Which of the following factors affects the selection of a manufacturing process? Is it A, product aesthetics? B, material properties? C, worker ability? Or D, lead time.

Pause the video and have a go.

Wonderful, let's check.

That's right, it's both B and D.

It's material properties and lead time.

Well done.

Scales of production refer to the amount or volume of goods produced.

It can be split into four categories.

One-off, sometimes, known as bespoke.

It's usually handmade, unique in appearance, and only one is made.

Batch, some automation, consistent in appearance, and a certain amount is made.

For example, 10 or a batch of 100.

Mass is mainly automated, users Computer Aided Manufacture, abbreviated to CAM, and high volume.

This may be a hundred thousand.

Or continuous, it's highly automated.

They are identical in appearance and it runs constantly.

This is for something that is in constant demand.

This selection of a suitable manufacturing process can be determined by the scale of production required.

One-off where only one is needed.

For example, a printed prototype.

A batch where a certain amount is needed.

For example, the vacuum formed Easter egg package.

Mass produced, a high quantity is needed to be made precisely.

For example, a smartphone.

And continuous.

A constant supply is needed to be made precisely.

For example, drinks, cans.

Let's have another check.

Order the following processes by their most common scale of production volume from low to high.

And the processes include A, CNC machining.

B, 3D printing.

And C, injection moulding.

Pause the video and have a go.

Wonderful, let's check.

3D printing would be the lowest volume production followed by CNC machining, which would be medium volume, and high volume production would be injection moulding.

Well done.

Lead time refers to the length of time from order to production completion.

Shorter lead times demand quicker, more efficient processes, such as automated systems, whilst longer lead times allow for more traditional and slower methods.

For example, a plastic water bottle has a shorter lead time than handcrafted jewellery.

The materials used in a design impact the process selection.

Understanding the properties of materials helps ensure the chosen method can handle the material effectively.

Polymers tend to be moulded by processes like blow moulding, extrusion, and injection moulding.

Metal processing can include press-forming, casting, deep-drawing, and CNC milling.

Here we have a check.

Match the manufacturing process to the material type.

And the options include screen printing, extrusion, deep-drawing, and die-cutting.

And the material types.

Metal, polymer, paper, and fabric.

Pause the video, have a go.

Fantastic, let's check.

That's right.

Fabric is suitable for screen printing.

Extrusion would be polymer.

Deep-drawing, metal.

And die cutting, paper.

Well done.

Different materials require different manufacturing processes.

Properties such as strength, flexibility, and melting point influence process selection, as well as any additional processing.

Some metals may require extra processing methods like heat treatment, for example, steel.

Some timbers can be laminated but require additional manufacture of bending jigs.

Simple products can use faster, more automated processes.

Complex designs may require multiple processes or detailed hand-finishing.

For example, this food container is made from a polymer, which is usually self-finishing.

An electric guitar is mainly timber-based and made using machinery, but requires hand-finishing.

Here we have your first task.

Task A, part one.

Polymers are usually used to make lunchboxes.

Name a suitable polymer that could be used, and give two working or physical properties that make it suitable.

And part 2, a factory is considering producing 100,000 units of a lunchbox.

Part A, which scale of production would be most suitable and why? And part B, explain which manufacturing process should be selected.

Consider factors such as scale of production, material properties, and lead time.

Pause the video.

Fantastic, let's have a look at some of the answers you may have come up with.

Sofia and Jun share their answers with us.

Sofia says, "Polypropylene because it is durable enough for repeated use and lightweight enough to be carried." Jun says, "Polyethylene because it is food-safe and can be easily moulded into interesting shapes." And part 2a, which scale of production would be most suitable and why? Batch production is the best scale of production, because it is more efficient at making multiple units at the same time, especially when there is a fixed amount.

This method of production also ensures that all the lunchboxes are consistent in size and function.

And part 2b, explain which manufacturing process should be selected.

The ideal manufacturing process would be injection moulding.

Injection moulding is cost-effective when producing large quantities due to its automation and ability to quickly create complex shapes.

The lead time is also short, making it suitable for the manufacturer's needs.

Additionally, polymer is well suited for this process because it can be moulded into the desired shape quickly and cost-effectively.

Well done.

We now move on to the second part of our lesson, CAM, within manufacturing processes.

Usually, as the scale of production increases, so does the level of automation.

This is because automation is key for producing large quantities more efficiently.

The use of CAM, which is Computer Aided Manufacture, can aid with high volume production.

Cam, Computer Aided Manufacturing, involves the use of computers to control machinery and manufacturing processes.

CAM software translates digital designs, Computer Aided Design models or CAD, into machine commands, improving speed and accuracy.

Here we have a check.

Which of the following is a major benefit of using CAM in manufacturing? Is it A, increased production time? B, lower precision in parts? C, improved speed and accuracy? Or D, reduce flexibility in designs.

Pause the video and have a go.

Fantastic, let's check.

That's right, it's C.

Improved speed and accuracy.

Well done.

The benefits of CAM are speed, quickly completes repetitive tasks.

Accuracy, no human error, high precision, and consistency.

Flexibility.

Manufacturing adjustments made easily.

Cost-effectiveness.

Though initially expensive, costs are recovered through volume of production.

Here we have an example of a CNC milling machine.

CAM is particularly useful in manufacturing complex shapes and precise components such as aeronautical parts or medical devices.

Automobile parts or consumer electronics often rely on CAM to ensure consistent quality in high quantities.

The needles of these medical syringes would've been mass produced as a high volume is needed, and the needle gauge, thickness, needs to be precise.

The challenges of CAM are costs.

CAM software and machines can be expensive to set up and maintain.

Training.

Skilled operators are needed to run and troubleshoot CAM systems. Whilst this CNC router is an example of high precision automation, a human is still needed to programme and maintain it.

Let's have another check.

True or false.

CAM technology can only be used for high volume production.

Pause the video.

Let's have a look.

That's right, it's false.

CAM can also be used for precision, custom, or complex parts in low-volume production.

And now, we move on to your second task, task B.

A company is looking to produce custom-designed metal hinges for a lunchbox.

100,000 units are needed and the parts must be precise.

Part one, suggests which CAM technology would be the best choice for this situation.

Part two, explain why this process is suitable for the specific needs of the company.

And part three, discuss how CAM can lead to both cost saving and increased spending using the following points to help.

Initial costs, long-term cost benefits, and reducing waste and improving efficiency.

Pause the video.

That's great.

Let's have a look at some of the answers you may have come up with.

For part one, CNC milling is the best choice for custom-designed metal hinges.

For part two, CNC milling offers high precision and can handle small batches effectively.

The hinges may require complex detailing, which CAM technology can achieve with minimal human error.

CNC machines can quickly and efficiently produce precise components, which makes it an ideal choice for this situation.

And part three, CAM requires a high initial investment in machinery, software, and employee training.

The upfront costs can be significant, especially for small businesses.

In the long run, CAM reduces labour costs by automating repetitive tasks to improve production speed, allowing manufacturers to produce more parts in less time.

This will offset the initial expense.

CAM improves precision, reducing defects, and material waste.

Well done.

Here we have a summary of our learning today.

Process selection depends on material, scale of production, lead time, and product complexity.

Different processes suit different products based on shape and material.

CAM improves speed, accuracy and efficiency, especially in mass production.

CAM reduces waste and labour costs, but requires high initial investment.

Thank you for joining me today.

And well done.