International Baccalaureate: Design & Technology
Topic 5: Production Systems
This topic is concerned with the commercial aspects of design and manufacture: the management, economics and politics of assimilating products into the market. It explores how the scale and type of production affects the nature, quality and cost of a product.
5.1 Designers and the Product Cycle
5.1.1
5.1.2
Discuss the role of the designer in the product cycle. Designing is part of the product cycle: as a need is generated, a product is designed, made and sold, eventually becoming obsolete. The cycle is complicated by distribution and retailing, accountants, production engineers, all of whom have an influence over the cycle. Although the designer is an integral part of the process he/she is not necessarily in control (unlike in the design process). CAD/CAM, where a prototype is produced by the designer from his/her PC, blurs this distinction.
5.1.3
Outline the product life cycle in terms of early, mature and late stages of development. In the early stages many changes to the product may take place until it develops to the mature stage where it is diffused into the market, gains acceptance and sells well. In the late stage the product begins to decline in need and therefore in sales.
5.1.4
Outline the life cycle of the ballpoint pen and the cassette tape in terms of early, mature and late stages of development. The ballpoint pen is in the mature stage as it still sells well though the
design does not change much. The cassette tape is in the late stage as the compact disk and the mini disk have replaced it.
5.1.5
Compare the design cycle with the product cycle. The differences should highlight how the design process is aimed at producing a suitable solution to a problem and that the product cycle is concerned with putting that solution into commercial practice.
5.2.1
Define one-off production, batch production and volume production
A historical overview would help, ie how craft methods of production became superseded by mechanization after the Industrial Revolution and by automation during the Technological Revolution of the second half of the 20th century.
5.2.2
Describe two advantages and two disadvantages of each scale of production. These may be related to economic or social considerations.
5.2.3
Explain when it is most appropriate to use each scale of production. Use an example of a product to explain the suitability of each production scale taking into account the needs of the consumer and market conditions.
5.2.4
Define craft production, mechanization, automation and assembly line production
5.2.5
Describe why most products were manufactured by craft techniques prior to the Industrial Revolution. Refer to the development of skills; sources of materials and power; sales and distribution; and relationship of craftsman/designer with client/consumer.
5.2.6
Explain how the availability of new sources of power in the Industrial Revolution led to the introduction of mechanization. Refer to water and steam power.
5.2.7
Explain how the development of computer and information technology in the Technological Revolution led to the introduction of automation. Refer also to the importance of electricity in assembly line procedures.
5.2.8
5.2.9
Describe how CAD/CAM and CNC can contribute to an automated production system. Note the purpose of each when used alone or together as part of a larger system.
5.2.10
5.2.11
Explain how industrial robots offer greater flexibility to automated production systems. Note the ability to reprogramme and change the physical components to alter the activity.
5.2.12
Describe an example of a domestic robot. For example, a robotic vacuum cleaner or lawnmower.
5.2.13
Define automated guided vehicle (AGV).
5.2.14
Explain how AGVs contribute to an automated production system. They are coordinated with the other aspects of the system to ensure maximum efficiency by transporting components or finished products from one part of the factory to another.
5.2.15
State two advantages and two disadvantages of mechanizing a production process. Consider cost, quality of product, social conditions, labour, etc.
5.2.16
State two advantages and two disadvantages of automating a production system. Consider cost, flexibility, skills, effect on the workforce, quality, complexity of product and process, type of market, traditions, training and management structures.
5.2.17
Discuss the advantages and disadvantages of each system from the point of view of the designer, manufacturer and consumer. Relate to different target groups.
5.2.18
Outline one (different) example of a product manufactured by each mode of production. Consider the characteristics of the product that make it suitable for each method of production.
5.3.1
Explain the factors that determine the final cost of a product. Take into account scale of production; complexity of product, material, resources and skills required; quality control; size and weight of product for storage or distribution; type of advertising and marketing; profits and
taxes. Include costs of availability and procurement of raw materials, research and development, labour, manufacturing costs, capital costs, overheads, distribution and sales.
5.3.2
Define fixed costs and variable costs.
5.3.3
Identify the costs in 5.3.1 as fixed and variable.
5.3.4
Explain how the costs in 5.3.1 vary in proportion, depending on the type of product and the mode of production. Some costs are more relevant than others eg raw materials and labour costs will be a significant part of the final cost of an individually crafted mahogany table but for an injection moulded plastic component these costs would be low and the capital cost of machinery high. Quantitative calculations are not required.