Lesson video

Hello, my name's Mrs. Taylor and I'm really pleased you can be here to join me for our lesson today.

Our lesson today is quality control and production planning and this is part of the "Collaborative Design, Tactile Toys to Teach" unit.

The outcome.

I can use quality control strategies to check the batch.

We have three keywords.

Quality control, which are checks made on a product before, during and after its production so it meets quality and safety standards.

Tolerance, which is the acceptable range of variation in a product's dimensions or weight.

And time planning, which is organising and scheduling tasks efficiently.

The lesson has two parts, quality control, abbreviated to QC and plan production.

Let's begin with quality control.

Quality control refers to the process of checking and testing products before, during and after production to ensure they meet quality and safety standards.

Quality control checks are done throughout the manufacturing process to ensure quality is a constant.

Quality control identifies defects in finished or semi-finished products.

Here we have a check for understanding.

Why is quality control important? Is it A, it helps identify and correct defects in products, B, it speeds up the production process or C, it allows more defective products to be sold? Pause the video and have a go.

Great, let's check.

That's right, it's A, it helps identify and correct defects in products.

Well done.

Quality control involves inspecting and testing products to ensure components are the highest quality possible.

Quality control checks can include visual inspections, measuring components with accuracy, comparing components against templates, checking components are within a tolerance and testing product performance.

Digital callipers are precise measuring tools that can be used to check whether components are the correct dimension or within the allowed tolerance.

Here we have a check for understanding.

What is the name of this precise measuring tool? Is it A, a ruler, B, digital callipers, or c, vernier callipers? Pause the video and have a go.

Great, let's check.

That's right, it's digital callipers.

As no two products are exactly the same, there needs to be a tolerance within quality control checks.

A tolerance is the acceptable range of variation in a product's dimensions or weight.

A tolerance is shown as a number with a plus minus in front of it, and the plus minus sign is used to show a range of possible values.

For example, when a tolerance of plus or minus 0.

1 millimetre is applied to a five millimetre dimension, the acceptable size is between 4.

9 millimetres and 5.

1 millimetres.

We can see here visually the tolerance of 0.

1 millimetres applied to a five millimetre dimension.

If a product fails quality control checks, it may be fixed so it meets the required standard or discarded if it cannot be fixed.

In some cases, products that fail QC checks because of slight imperfections can be sold onto the public at a discounted price.

The benefits of this are the materials are not wasted, consumers save money.

Here we have another check for understanding.

What happens if a product does not meet the required tolerance during quality control checks? Is it A, it is always thrown away, or B, it is ignored and production continues, C, it is immediately sent to the customer or D, it may be reworked, rejected or sold at a discount? Pause the video.

Great, let's check.

That's right, it's D.

It may be reworked, rejected or sold at a discount.

Well done.

Quality control checks are made on a product before, during and after its production.

Using the hammer and peg toy as an example, what different types of quality control checks could be made at any stage of its production? The quality control checks could include before production, the incoming quality checks on stock form could include inspecting surfaces, defects like knots, use a digital calliper to check thickness, dimensions and checking for warping.

During production, testing at certain points to catch defects early, checking quality of edges, using a digital calliper to check all dimensions are within the tolerance, especially the holes that have been drilled, using templates for checking.

And after production, final checks on a product, checking overall dimensions and testing the performance of the toy.

Here we have task A.

As a collaborative design team, identify the quality control checks that will take place before, during and after the manufacture of the team's final design.

Ensure that tolerances are considered.

Pause the video and have a go.

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

Your design team answers could look like this.

Before production, inspect surfaces of boards and planks looking for defects like knots.

Use a digital calliper to check the thickness dimensions and check for warping.

During production, we could check quality of edges after sawing and sanding.

Use a digital calliper to check all dimensions are within tolerances and use the templates for checking the shapes are correct.

After production, we can check overall dimensions, test the performance of the toy and ensure all pieces fit together.

Well done.

We now move to the second part of the lesson.

Plan production.

Manufacturing a product from start to finish can present many challenges.

Planning time efficiently for production can help to reduce those challenges.

Manufacturers will produce detailed plans for the manufacture of their products.

This ensures consumer cost efficiency, identifies and prevents bottlenecks and improves productivity.

Here we have a check for understanding.

Being able to plan time during the manufacturing stage can improve A, demand, B, productivity, C, iterations, or D, efficiency? Pause the video.

Great, let's check.

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

Well done.

A tool that is well-known and used for time planning in production is a Gantt chart.

A Gantt chart is a way of displaying tasks in a horizontal bar chart that visually displays a schedule over time.

Here we have a check for understanding.

Complete the sentence with the missing word.

Pause the video.

Great, let's check.

A tool that is well-known and used for time planning is a Gantt chart.

Well done.

The design team have already identified the separate components needed to construct their final design.

We have the overall shape, base and then the top section with the cutout mouth, the teeth, the inside mouth section and the toothbrush.

The design team will now use those separate components to help them construct a Gantt chart.

Here we have an example of a blank Gantt chart.

The components in the column on the left, quantity, cell and quality control checks in the subsequent columns, and then time period in the row across the top.

Let's have another check for understanding.

Referring to a manufacturing Gantt chart, what is on the left in a column? Is it A, stages of time, B, components, C, quantities, or D, quality control checks? Pause the video.

Great, let's check.

That's right, it's B components.

Well done.

The team adds the components and their quantities.

They also add the manufacturing cells, which indicate what workers are completing what tasks.

Jacob and Aisha are in cell one.

They will be manufacturing five base components.

Deciding when each component will be manufactured is the next step.

The toothbrush component will be manufactured during week three.

Finally, adding the quality control checks that have been identified by the design team completes the Gantt chart.

Now, we have task B.

As a collaborative design team, create a Gantt chart that supports time planning for the production of the team's final design.

Use the same format as this example here.

Pause the video.

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

Your design team's answers could look similar to this.

The base, which is the overall shape, we need five of those and cell one are going to complete them.

The quality control checks are to use templates for checking shape, accuracy and tolerances, and this will be completed in week one.

Each component is listed, the quantity, which cell will be used to create this, quality control checks and then finally, which week each item will be completed in.

Well done.

We now have a summary of our learning today.

Quality control refers to the process of checking and testing products before, during and after production to ensure they meet quality and safety standards.

A tolerance is the acceptable range of variation in a product's dimensions or weight.

Manufacturers will produce detailed plans for the manufacture of their products.

A Gantt chart is a way of displaying tasks in a horizontal bar chart that visually displays a schedule over time.

Thank you for joining me today, and well done.