Duration: 3 hours (4 class periods) The Big Idea:

1. Lesson 2 Push Pull Manufacturing • Duration: 3 hours (4 class periods) • The Big Idea: Manufacturing is the production of physical goods using a variety of mechanical processes

2. Lesson 2 Benchmarks • 13F Design and use instruments to gather data. 3 • 13H Identify trends and monitor potential consequences of technological development. 3 • 13I Interpret and evaluate the accuracy of the information obtained and determine if it is useful. 3 • 19F Manufacturing systems use mechanical processes that change the form of materials through the processes of separating, forming, combining, and conditioning them.

3. Lesson 2 Benchmarks • 19G Manufactured goods may be classified as durable and non-durable. 4 • 19H The manufacturing process includes the designing, development, making, and servicing of products and systems. 2 • Materials must first be located before they can be extracted from the earth through such processes as harvesting, drilling, and mining.

4. Objectives • Identify examples of mechanical processes that change the form of materials through the processes of separating, forming, combining, and conditioning them. • Classify durable and non-durable manufactured goods. • Solve simple problems involving rates and derived measurements for such attributes as velocity and density. • Use graphs to show a variety of possible relationships between two variables. • Describe the role of manufacturing in the United States and the world. • Explain how manufacturing impacts their lives. • Compare and contrast push and pull manufacturing processes

5. Standards/Learning Targets • Standard: Students will develop an ability to assess the impact of products and systems. • Learning Target: Recognize the impact of technology on our lives.

6. Warm-up Question: • What have you used today that was manufactured? • The construction of many of the same item at one time, usually using assembly lines and interchangeable parts.

9. Warm-Up • Identify two different ways to change the form of a material.

10. Manufacturing • The construction of many of the same item at one time, usually using assembly lines and interchangeable parts.

11. Cheaper goods Better quality goods Jobs, jobs, jobs, Higher standard of living Food Fuel Shoes and Clothes Cars Modular Homes Integrated Circuit Chip Pencils and Pens How does manufacturing affect our lives?

12. What do you think? • How do you think manufacturing has improved our lives?

13. Standards/Learning Targets • Students will develop an understanding of and abilities to select and use manufacturing technologies. • Learning Targets: • Identify examples of mechanical processes that change the form of materials through the processes of separating, forming, combining, and conditioning them • Classify durable and non-durable manufactured goods

14. Manufacturing Processes • The form of materials is changed by: • Separating • Forming • Combining • Conditioning

15. Durable Goods • Do not quickly wear out. • May be used over and over • Cars • Bricks • Electronics • Non-durables include: • Food • Clothing • Paper products

16. Steps in Manufacturing • Turning raw materials into finished goods on a large scale. • Obtaining and preparing raw materials • Processing the materials mechanically or chemically • Assembling • Testing • Inspecting • Packaging

17. Standards/Learning Targets • Standard: Students will develop an understanding of and abilities to select and use manufacturing technologies. • Learning Target: Compare/contrast push and pull manufacturing processes.

18. Traditional Manufacturing • Mass Production – • Uses interchangeable standardized parts that can quickly be assembled • Breaks complex operations down into simple steps that can be performed by unskilled workers • A ‘PUSH’ Manufacturing system • Output from the first process in the sequence drives the second process and so on • What's Up In Factories - 1

20. New Trends in Manufacturing • Lean Production – • Less of everything is required to produce the same quantity that traditional mass production generated • Less materials, equipment, manhours, time, effort, capital • A ‘PULL’ Manufacturing system that is driven by customers orders and need for specific parts • What's Up In Factories - 1

21. New Trends in Manufacturing • KANBAN • Cards that carry information from one process to processes that come afterward • Tell about what and how much to produce next. • Identifies the type of part, how many there are, and other basic information. • “Pulls” only needed parts without maintaining extra inventory

22. New Trends in Manufacturing • Quality Circles • Employees, working in teams, set aside time to review work procedures • Come up with ways of enhancing their performance.

23. New Trends in Manufacturing • KAIZEN • Continuous improvement • an on-going process involving a variety of activities to reduce waste and inefficiency

24. New Trends in Manufacturing • ANDON • A system to notify management, maintenance, and other workers of a quality or process problem • Uses a signboard incorporating signal lights to indicate which workstation has the problem

25. Standards/Learning Targets • Standard: Students will develop an understanding of and abilities to select and use manufacturing technologies. • Learning Target: Students demonstrate push and pull manufacturing processes.

26. Push Production • As each person finishes his/her job, it is pushed to the next person. • Faster production. • Increased chance of error - less quality.

27. Pull Production • Each person does not start a new part until their last one has been pulled from them. • Increased quality. • Slower production.

28. Bolt Processing Assembly Line

29. Push versus Pull Manufacturing • PUSH – complete task as quickly as possible • Faster Production (more items made in shorter period of time) • Less quality (more likely to make mistakes) • PULL – complete task only when the previously completed item is removed or ‘pulled’ • Slower production (more likely to have idle time) • Increased quality What is QC rate when 50 shirts are made and only 40 pass inspection?

30. Card Marking Assembly Line

31. Standards/Learning Targets • Standard: Students apply appropriate techniques, tools, and formulas to determine measurements. • Learning Targets • Solve simple problems involving rates and derived measurements for such attributes as velocity and density. • Use graphs to show a variety of possible relationships between two variables.

32. Quality Control Rate

35. Evaluation • Students complete Formative Assessment. • Provide examples of manufacturing processes from the card making assembly or other manufacturing • Students complete Lesson 2 Quiz.