Worksheet 6 Efficient manufacturing

Unit 11 Product design considerations

Answers
Task 1
When considering ease and efficiency of manufacture, what factors should a manufacturer take
into account?
 Reducing waste, pollution and use of raw materials
 Minimising environmental impact
 Maximising productivity
 Maximising output
 Maintaining quality
 Reducing costs
 Reducing the number of parts needed
 Reducing storage space required
 Increases production rate – shipped to market quicker
 Reducing the risk of errors during manufacture

Task 2
Tick the correct type of snap fittings used in the following products

Plastic Hub Cap Remote Control Lunch box lid Highlighter lid

Cantilever

Annular

Torsion

U-shaped

Suggest two disadvantages for using internal moulded screw posts.

 Restricted to using screws – self tapping screws

 Overtightening the screw can damage/strip the screw thread or snap the screw post
 Using a different type of screw (longer or thicker) can damage the part
 If the screw is lost it can make the product unsafe to use until it is replaced.
 If the screw post is damaged repairs will be difficult, the two parts will not securely fit and
may need to be replaced.
 If the casing is damaged it is unlikely to be repaired and sourcing the part can be difficult
if it is a discontinued product.
 Internal electrical components cannot be replaced with newer models as it may have
different dimensions and not fit into the cavity, pushing out the two parts.

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Worksheet 6 Efficient manufacturing
Unit 11 Product design considerations

Task 3
Study the image of the car stereo below

Explain why an automotive manufacturer would choose to order in pre-made components such
as this car stereo.

 Reduces the processes and thus machinery and skilled labour needed in-house

 Parts can be ordered as required (JIT) reducing the number of parts kept in stock

 Specialist suppliers may have a reputation for quality which will enhance the reputation
of the vehicle

 Suppliers may offer cost incentives for bulk orders

 Components can be inspected and tested by the supplier to meet regulatory standards,
whether imported or made in the UK

 Using a trusted reputable brand inspires confidence in the consumer

 Faulty parts can be sent back without the need for in house repair

 Using removable brought in stereos gives the consumer the opportunity to upgrade their
stereo easily is desired

 At end of life, these brought in parts can be easily disassembled / removed and
components can be reused, repaired, replaced or recycled