BTEC L2 First Award in Engineering Unit One: The Engineered World

BTEC L2 First Award in Engineering Unit One: The Engineered World Learning Aim A: Know about engineering processes used to produce modern engineered products Topic A3: Scales of production Learning Objective Six: Understand the characteristics of different scales of production BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Target Level: What level should you be aiming to work at today? Make sure you tick the level which you are aiming for on your worksheet. Need some help? If you are not sure what these level descriptors mean, the key words are displayed in your classroom! BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Starter Watch the following video of an industrial process and consider the following questions. What scale of production is this? Why is this product manufactured this way? What are the advantages? Are there any disadvantages? BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Starter https://www.youtube.com/watch?v=sYfcRwMA_k8 BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production • Task One: Different scales of production • There are four different scales of production that we need to know about for the exam. They are: • One-off/jobbing • Batch Production • Mass Production • Continuous Production • You have been provided with four paragraphs describing each scale of production. Some of the words have been removed. • Complete each paragraph by adding the missing words. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production One-Off/ Jobbing Production One off production is where ____________ item is designed and made at a time. These items are most often produced to suit a customer’s individual requirements. Each of these products is ______________ and, more often than not, a long time would have been spent designing and making it. For this reason, items produced by this method are _____________ to buy. ONE-OFF production would not be suitable for factories and is more likely to be found in smaller establishments where the emphasis is placed on the ____________ and ____________aspects of a product. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production One-Off/ Jobbing Production One off production is where ONE SINGLE item is designed and made at a time. These items are most often produced to suit a customer’s individual requirements. Each of these products is UNIQUE and, more often than not, a long time would have been spent designing and making it. For this reason, items produced by this method are EXPENSIVE to buy. ONE-OFF production would not be suitable for factories and is more likely to be found in smaller establishments where the emphasis is placed on the HAND MADE and QUALITY aspects of a product. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production One-Off/ Jobbing Production This scale of production is where only one product is made. It might be specifically made at some ones request or manufactured to solve a unique problem Advantages: You get exactly what you want It’s unique It’s an exact solution Disadvantages: High financial cost High time cost (takes time to make) Repair and maintenance is difficult and costly Examples: Custom motorbikes (Think American Chopper) Furniture Kitchens Bridges BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Batch Production BATCH production is used where several of the same product are made. When the required number has been produced, production stops. Another batch of the same product can be made at a later date if the _________for the product is there. All items made in a BATCH are the ________. Therefore production is ________and the cost of labour is ________ . This results in the final product being less expensive for the customer. This scale of production can vary in size but will always have a set number in a “run”. This could be 10s, 100s or 1000s of units. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Batch Production BATCH production is used where several of the same product are made. When the required number has been produced, production stops. Another batch of the same product can be made at a later date if the DEMAND for the product is there. All items made in a BATCH are the SAME . Therefore production is SPEEDED UP and the cost of labour is REDUCED . This results in the final product being less expensive for the customer. This scale of production can vary in size but will always have a set number in a “run”. This could be 10s, 100s or 1000s of units. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Batch Production This scale of production can vary in size but will always have a set number in a “run”. This could be 10s, 100s or 1000s of units. Advantages: Traceability – If a unit is fault a batch can be recalled to the factory Excess stock isn’t generated Reduced production costs over one-off Disadvantages: Stopping and restarting production can lead to machine failure and product malfunction When production isn’t happening you’re not making any money Examples: Shoes and trainers Foods – Bread, cakes, sandwiches Paints and inks Wall paper Limited edition products (Jewellery, clothing) BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Mass Production MASS production is where products are made ____________. Usually an assembly line is organised and, as the product moves along it, parts are added until the final product is complete. These assembly lines can be manned by people, but the work is very ___________and often these lines are ____________. As this method of production relies on machinery, the ____________ of setting up this process can be ______________. As long as there is sufficient _________________ for the product it is worth buying the machines to make them. Products are made in vast numbers – 10000s & 100000s of units in total runs. Products are usually made with some form of automation on a production line. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Mass Production MASS production is where products are made CONTINUOUSLY . Usually an assembly line is organised and, as the product moves along it, parts are added until the final product is complete. These assembly lines can be manned by people, but the work is very REPETITIVE and often these lines are AUTOMATED . As this method of production relies on machinery, the INITIAL COST of setting up this process can be VERY HIGH . As long as there is sufficient CUSTOMER DEMAND for the product it is worth buying the machines to make them. Products are made in vast numbers – 10000s & 100000s of units in total runs. Products are usually made with some form of automation on a production line. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Mass Production Products are made in vast numbers – 10000s & 100000s of units in total runs. Products are usually made with some form of automation on a production line. Advantages: Low unit cost – cheaper to make Fast rate of production Lower labour costs due to high level of automation Disadvantages: Large stock produced Often lower quality item Examples: Newspapers and magazines Children toys Mobile phones Games consoles BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Continuous Production As the name suggests this method involves the continuous ____________ of products over a period of time. This method usually means that the product is relatively __________ to purchase as thousands of _________ products will be produced. Examples include machine screws, paper clips and plastic sheet material. Continuous production is called a continuous process or a continuous flow process because the materials, either dry bulk or fluids that are being processed are ____________ in motion, undergoing chemical reactions or subject to mechanical or heat treatment. Continuous processing is contrasted with ___________ production. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Continuous Production As the name suggests this method involves the continuous PRODUCTIONof products over a period of time. This method usually means that the product is relatively INEXPENSIVEto purchase as thousands of IDENTICALproducts will be produced. Examples include machine screws, paper clips and plastic sheet material. Continuous production is called a continuous process or a continuous flow process because the materials, either dry bulk or fluids that are being processed are CONTINUOUSLYin motion, undergoing chemical reactions or subject to mechanical or heat treatment. Continuous processing is contrasted with BATCHproduction. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Continuous Production This is similar to mass production but the production line runs 24hrs a day, seven days a week. This process is highly automated with very few workers. Advantages: Initial setup then runs indefinitely Low unit cost Fast production rate Disadvantage: High level of maintenance required Initial setup cost is high Stopping and restarting costs are very high Examples: Screws Bricks Food products (Sausages) Fuel and Oil BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Task Two: Products from each scale of production You have been provided with a list of different products and a table of the four different scales of production. You need to complete the table by deciding which of the following products are produced by each scale of production. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Task Three: Comparison of different sales of production Each scale of production requires different levels of investment, equipment and labour. Complete the table to best describe what each scale requires. The first one has been completed for you. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Task Three: Comparison of different sales of production BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Task Four: Advantages of each scale of production There are a number od advantages and disadvantages or each scale of production depending on the product. Consider an advantages of each scale and explain in the space provided. One-Off ……………………………………………………………………………………………………………………………………………………………… Batch ……………………………………………………………………………………………………………………………………………………………… Mass ……………………………………………………………………………………………………………………………………………………………… Continuous ………………………………………………………………………………………………………………………………………………………………. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: WHICH This type of question is always worth 1 mark (Per answer) Manufacturers use different scales of production when manufacturing products. The video shows the production of blank DVDs. Which scale of production would be used to manufacture the blank DVDs? (1) Click on one of the boxes. The video shows an automated process where the machine is moving DVDs in-between different parts of the manufacturing process. One-Off Jobbing Continuous Cellular BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: EXPLAIN This type of question is always worth 2 mark (Per answer) The image shows the mass production of trucks on an assembly line. Explain two disadvantages of using mass production when manufacturing trucks. (4) Type your answers in the box. Remember an explain question needs to to write down a fact and then explain it! Without the explanation you can only achieve one mark! BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: EXPLAIN This type of question is always worth 2 mark (Per answer) The image shows the mass production of trucks on an assembly line. Explain two disadvantages of using mass production when manufacturing trucks. (4) Type your answers in the box. Large numbers of defective trucks might be produced (1) as errors are not always detected at the first opportunity (1) Mass production is set up into assembly lines (push production) to produce the same product in large quantities (1) which means there is a lack of flexibility in types of trucks manufactured (1) Mass production assumes steady volumes of trucks being produced (1) which means it may not take into account variety in level of demand/storage space requirements (1) If one process breaks down the whole assembly line is likely to stop producing trucks (1) this downtime can have a detrimental effect on the business (1) Large capital investment is required (1) because mass production of trucks requires investment in processes and material handling equipment (1) Do not accept expensive without justification. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: EXPLAIN What not to do! What is wrong with this answer? The image shows the mass production of trucks on an assembly line. Explain two disadvantages of using mass production when manufacturing trucks. (4) Type your answers in the box. You could be wasting materials and money because they will be sitting in storage when people don’t need them. They will also get damage if the are in storage for too long because rust and the wheel will rot if they are just standing still for too long in storage. It will waste money for the company because they will not be sold if they are ruined and the company will have to make new ones for the clients if they don’t have any of them up to standard. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: EXPLAIN What not to do! What is wrong with this answer? You could be wasting materials and money because they will be sitting in storage when people don’t need them. They will also get damage if the are in storage for too long because rust and the wheel will rot if they are just standing still for too long in storage. It will waste money for the company because they will not be sold if they are ruined and the company will have to make new ones for the clients if they don’t have any of them up to standard. In this example the learner has identified that there will be a variety in demand and that this ay mean that finished trucks will be in storage, this is extended to indicate the cost implication for the component. Whilst this is an explained disadvantage, there is no second disadvantage identified or explained. Therefore two marks have been awarded. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: EXPLAIN What not to do! What could they do to get full marks? The image shows the mass production of trucks on an assembly line. Explain two disadvantages of using mass production when manufacturing trucks. (4) Type your answers in the box. If there is a mistake and it isn’t spotted in the checks then a batch of trucks will go out and these will have to be recalled costing the company money as well as time due to a mistake. If you mass produce these trucks and they aren’t selling very efficiently then you will to store the trucks costing you storage money or storage space. Also if you decide to change the look of the truck on the production line then it’s not easy as you will have to change production line lay out and how it works the production line which is risky and expensive and could stop production for a long period of time. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: EXPLAIN What not to do! What could they do to get full marks? If there is a mistake and it isn’t spotted in the checks then a batch of trucks will go out and these will have to be recalled costing the company money as well as time due to a mistake. If you mass produce these trucks and they aren’t selling very efficiently then you will to store the trucks costing you storage money or storage space. Also if you decide to change the look of the truck on the production line then it’s not easy as you will have to change production line lay out and how it works the production line which is risky and expensive and could stop production for a long period of time. In this example the learner has given one disadvantage by identifying the risk of an error not being spotted, which may have an impact on a large number of trucks. The second disadvantage is the variety in demand, which may mean storage and the associated cost. The learner also identified a third disadvantage in that the production may need to be sopped costing money, if the production line required remodeling to accommodate changes to the design/appearance of the truck. Where there are more than the number of require responses the best responses will be rewarded. Four marks have been awarded. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Exam Style Question: IDENTIFY This type of question is always worth 1 mark (Per answer) One-of jobbing production techniques are sometimes used when making engineered products. Identify two reasons why one-off/jobbing production techniques are used. (2) Click on the two correct boxes. Because robots can complete repetitive operations To produce a unique product Because product demand is low To make use of low skilled labour To allow for continuous processing BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production • Task Five: Exam style questions • You have been provided with five exam style questions. • These are the common styles of questions found in this section of the exam. • The question will always appear in a box. The other information may be important so make sure you read all the information and the question carefully. • The amount of marks for each question will be shown in brackets. • Make sure you answer ALL questions fully! BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Case Study/ Homework Sculpture made from over 1,000 custom machined parts Read the following news article. http://www.engineering.com/AdvancedManufacturing/ArticleID/14842/This-Sculpture-was-Made-with-Over-1000-Machined-Parts.aspx Which scale of production has been used here? Evaluate the use of this scale of production. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production • Oracy: Think about then complete the following sentences. • An example of a product produced by one off production is …… • An example of a product produced by batch production is …… • An example of a product produced by mass production is …… • An example of a product produced by continuous production is …… • …… is a labour intensive production method. • …… produces identical products. • …… requires high initial investment costs because …… • …… requires a highly skilled work force …… • Products produced by …… production are inexpensive because …… • Products produced by …… are expensive because …… BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production • Plenary • Mobile phone batteries are usually produced in batches. Explain why they are produced in batches rather than being mass produced. BTEC L2 Engineering Unit One: The Engineered World Topic A.3

6. Understand the characteristics of different scales of production Self-Assessment What level did you work at today? Make sure you tick the level which you worked at on your work sheet and explain why. Need some help? If you are not sure what these level descriptors mean, the key words are displayed in your classroom! BTEC L2 Engineering Unit One: The Engineered World Topic A.3

BTEC L2 First Award in Engineering Unit One: The Engineered World