Lesson video

Hello, I'm Mrs. Taylor, and I'm really pleased you can join me for our lesson today.

Our lesson today is wasting manufacturing processes for timbers.

And this is part of the technical principles unit.

The outcome, I can explain and compare small scale and industrial wasting processes.

There are four key words.

Wasting, which is removing material to shape or size a product.

Small scale production is making one or a few products using hand tools or basic machines.

Industrial, higher volume production using machines for speed, accuracy, and consistency.

And CNC, computer numerical control, computer-controlled machining for precise cutting and shaping.

There are two parts to the lesson, small scale wasting processes and industrial wasting processes.

Let's begin with small scale wasting processes.

A wasting process is a manufacturing method where a material is removed to shape or finish a product.

This includes cutting, drilling, sanding, and chiselling.

These processes are commonly used in both small scale production and industrial settings.

In small scale production, for example, in school workshops, we use hand tools for control and precision, power tools for speed and consistency.

Here we can see a picture of a coping saw and a jigsaw.

Whilst hand tools are easier to control, power tools offer speed.

Cutting tools are used as part of the wasting process to remove unwanted areas.

These small scale production tools can be operated manually.

A coping saw has a thin blade that can be rotated easily to cut intricate shapes.

The blade can also be removed to cut internal shapes.

Here we can see the picture identifying the handle, the frame, and the blade.

A tenon saw has a short, stiff blade with fine teeth.

It also has a reinforced back and is used for making straight cuts in timber.

And again, we can see a picture with the handle, the back, sometimes known as the spine and the teeth identified.

Here we have a check for understanding, which small scale production hand tool is best suited for making a curved cut in a piece of wood.

Is it A, a tenon saw; B, a mitre saw; C, a coping saw; or D, a circular saw? Pause the video and have a go.

Fantastic.

Let's check.

That's right, it's a coping saw.

Well done.

Cutting tools are used to remove unwanted areas.

Small scale production tools can also be operated by power.

A bandsaw has a continuous loop blade and can quickly cut straight lines and curves.

A table circular saw can make fast, straight cuts.

The table allows for large sheet materials to be cut.

Please note that this picture has the guard removed and must not be used without a guard.

Notice the fence in the bandsaw and on the table saw.

This acts like a guide to ensure straight cuts, which are parallel to the blade.

Cutting tools are used to remove unwanted areas.

Small scale production tools can also be operated by power.

A jigsaw is a versatile power tool that can cut straight lines and curves.

A mitre saw can make angled cuts known as mitres very precisely.

Cutting tools are used to remove unwanted areas.

Small scale production tools can also be operated by power.

A fretsaw is used for cutting intricate shapes and curved lines in wood and other materials.

It has a fine blade that moves up and down quickly, allowing for delicate and precise cuts.

The blade can be removed easily to cut internal shapes.

The table can also be tilted to allow for bevelled cuts.

Here we have a check for understanding.

Which machine is best for making fast straight cuts.

Is it A, B, or C? Pause the video and have a go.

Great, let's check.

That's right, it's A, the table saw.

Drilling is also a wasting process that makes holes in a material.

A manually operated hand drill is used for precise small holes.

A cordless power drill is used drilling holes and driving screws.

A pillar drill is fixed to a base and used to make straight accurate holes.

Drill bits are cutting tools that attach to a drill to make holes in materials.

There are different types of drill bits designed for specific materials, hole size, and finish.

Twist drill bits drill smaller holes.

Flat bits drill large holes very quickly.

Forstner bits make flat-bottomed holes with smooth sides, and hole saws create large circular holes.

Here we have a check for understanding.

Is it A, a twist drill bit; or B, a whole saw; or C, a flat drill bit; or D, a forstner bit? Pause the video and have a go.

Fantastic, let's check.

That's right, it's a forstner bit.

Well done.

A chisel is a hand tool with a sharp metal blade used for cutting, shaping, or removing wood.

It is often used for small scale production because of the time and dexterity required.

There are many different types, but the most common is the bevel edge chisel.

It can be used with a mallet to remove large amounts of material or by hand pressure for finer, more delicate cuts, a technique called paring.

Here we can see a picture of a bevel edge chisel.

The bevel describes the slanted sides of the chisel.

Bevel edge chisels come in different widths to suit various tasks.

The blade has a primary bevel, usually 25 degrees for cutting, and a secondary bevel at the tip, usually 30 degrees for more precision.

Here is a side view of a chisel blade.

The primary bevel and the secondary bevel.

Filing, and abrading is a wasting process that involves removing material to shape or smooth a piece.

A hand file is a tool with a metal surface covered in teeth.

It's used to smooth or shape materials like wood, metal, or plastic by rubbing it back and forth.

Hand files come in different sizes and profiles.

For example, triangular, round, flat, and half-round.

Half-round is the name of the semicircle shape.

Abrasive paper is used to smooth or clean surfaces.

It comes in different grades known as grits, which tell you how rough or smooth it is.

The number corresponds to the size of the abrasive grit on the paper, so coarse would be 50 grit right through to extra fine, which is 800 grit.

Low number grades are rough and remove a lot of material quickly while medium grades offer smoothing things out.

High number grades are used for polishing.

Sanding can also be done with power tools and machinery.

This speeds up the wasting process, especially if there is a lot of material to remove.

A power sander is often used in small scale production.

The abrasive pads are available in different grades or different grits.

A belt sander can remove more material in a shorter amount of time.

Here we have a check for understanding.

Which grade of abrasive paper is smoothest and will give a fine finish? Is it A, 50 grit; B, 400 grit; or C, 200 grit? Pause the video and have a go.

Great, let's check.

That's right, it's 400 grit.

The answer is B.

Well done.

Planing removes thin layers of wood to smooth, straighten, and reduce its thickness.

Using a plane requires a lot of skill and dexterity, which is why it is often used in small-scale production.

Planes can be either a hand tool or a power tool.

A router is a portable tool that cuts grooves, decorative edges, and joints like rebates.

Like a drill, a router can be used with different bits depending on the cut required.

A palm router is small and lightweight and used for trimming edges.

A plunge router is slightly more powerful than a palm router.

It can be lowered from above to cut material in the middle.

A wood lathe rotates material while cutting and shaping tools known as chisels are used to make cylindrical products like table legs and bowls.

Here we have a check for understanding.

Which tool would you use to shape a cylindrical wooden table leg? Is it A, a router; B, a wood lathe; C, a pillow drill; or D, a bandsaw? Pause the video and have a go.

Fantastic, let's check.

That's right, it's B, a wood lathe.

Well done.

We now move to task A.

There are four parts.

Part one, define the term wasting process in the context of manufacturing.

Part two, describe the difference between a tenon saw and a coping saw.

Part three, explain one advantage and one disadvantage of using a power tool instead of a hand tool.

And part four, explain why both hand and power tools are used in small-scale production.

Pause the video and have a go.

Wonderful.

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

For part one, a wasting process is a method of shaping or finishing a material by removing parts of it such as cutting, drilling, or sanding.

And for part two, a tenon saw has a stiff back and is used for straight cuts in wood.

A coping saw has a thin flexible blade used for curved or internal cuts.

For part three, power tools are faster and require less manual effort.

However, they can be more dangerous and require a power source.

And part four, hand and power tools are both used in small scale production because they each have different strengths.

Hand tools allow for greater control, precision, and detail.

While power tools help speed up tasks, cut through material more efficiently, and reduce physical effort.

Well done.

We're now going to move to the second part of our lesson, industrial wasting processes.

Industrial wasting processes require more heavy-duty machinery.

This is because speed, accuracy, and consistency are required for longer production runs.

CNC stands for computer numerical control, which means that some machinery can be controlled by a computer using code.

CNC machinery is often used in industry because it can cut complex and precise shapes repeatedly with minimal human intervention.

Whilst circular saws and bandsaws are used in an industrial setting, vertical panel saws are designed for cutting sheet material efficiently.

They enable fast, straight cuts with minimal waste, ideal for large batches.

Some vertical panel saws are CNC-controlled, allowing precise, repeatable cuts.

Here we can see the rotating circular saw blade.

The saw can move up and down this guide and the edge of the panel is supported by resting it here.

Let's have a check for understanding.

How does a CNC vertical panel saw differ from a bandsaw? Is it A, it cuts by hand; B, it is manually-powered; C, it is automated and programmable; or D, it can't cut large panels? Pause the video and have a go.

Great, let's check.

That's right, it's C.

It is automated and programmable.

Well done.

Drilling large numbers of holes that are accurate is important when manufacturing products in bulk.

For example, flat-pack furniture.

CNC drills can create many holes quickly and precisely by following a computer programme to match a digital design.

This reduces human error and guarantees consistency across batches.

Here we can see rows of precise holes like these are common in adjustable bookcases.

Linishers are industrial sanding machines with a moving belt or disc of sandpaper.

They efficiently sand large, flat, or curved components to a uniform finish.

Here we can see a picture identifying the belt and the disc.

Let's have a check for understanding.

What main advantage does a linisher have over hand sanding? Is it A, it's cheaper; B, it's quieter; C, it's less messy; or D, it's quicker? Pause video and have a go.

Brilliant, let's check.

That's right, it's quicker.

Well done.

For industrial production, planers and thicknesses control dimensions precisely.

Planers cut a flat surface to give a datum reference and a 90-degree adjacent edge.

A datum is a starting point for accurate cuts and measurements.

A thicknesser passes material through rollers to a uniform thickness across the length.

A planer thicknesser machine combines these two functions so that less floor space is occupied.

CNC routing and milling are used in industry to create complex shapes that would be difficult or time intensive to produce by hand.

Both machines follow computer instructions to move their cutting tool accurately along the X, Y, and Z axes to cut and shape the material.

CNC routers are used for softer materials and usually operate across a wider surface area.

CNC milling is used for harder materials and offer more precision and depth along the Z axes.

A CNC lathe holds material and rotates it while a cutting tool moves against it.

As it is controlled by a computer, it produces precisely sized and shaped components, ideal for higher volume production of staircase, spindles, and wooden bowls.

Here we have a check for understanding.

What is a key advantage of industrial CNC wasting processes.

Is it A, higher production speed; B, less control over dimensions; C, higher power consumption; or D, lower accuracy? Pause the video and have a go.

Fantastic, let's check.

That's right, it's A, higher speed production.

Well done.

We now move to task B and there are four parts.

Part one, explain one advantage of using CNC machines in industrial production.

Part two, name two industrial wasting processes and describe their main function.

Part three, answer the question, why are industrial processes more suitable for higher volume production? And part four, compare a small-scale production process to its industrial counterpart.

Give one example and explain the main difference.

Pause the video and have a go.

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

For part one, you may have said CNC machines can cut and shape materials with high precision and consistency, allowing large batches of identical components to be manufactured efficiently.

And for part two, you may have said a CNC router cuts and shapes sheet material according to a computer programme, and a linisher sands large parts quickly and uniformly with a moving belt of sandpaper.

For part three, you may have said industrial machines, especially CNC, can produce large numbers of parts quickly, accurately, and with very little variation between them, which is ideal for higher volume production.

For part four, you may have said a hand drill versus a CNC drill.

A hand drill is manually operated and less accurate, while A CNC drill is computer controlled, faster, more precise, and can produce large batches efficiently.

Well done.

We now have a summary of our learning today.

Wasting involves removing material to shape or size a product.

Tools and small machines remove material in small scale production.

CNC stands for computer numerical control, which means that some machinery can be controlled by a computer.

Larger machines remove material quickly, more accurately, and consistently at scale.

I'm so pleased you could join me for our lesson today.

Well done.