and Quality Assurance (PO3) Engineering Production Planning (PO4) Performing Manufacturing Processes (PO5) devices Risk assessments Use of jigs and moulds Safe working practices Carrying out manufacturing processes resources are available within the school). Teacher demonstration of the use of a Computer- aided manufacturing (CAM) machine to manufacture the mould and the casting process, also describing the possible alternative processes, and the measurement of the mould. Teacher explanation of risk assessment, modelling the risk assessment for the CAM machine. Students could customise the CAD designs to improve their engagement, if appropriate. Each pair should carry out a risk assessment for the pewter casting process. They should also manufacture the mould for their product using a CAM machine. This could be a 2D in thin MDF that will be sandwiched between two other pieces of MDF, or a 3D shape manufactured using a computer numerical control (CNC) router. The shape should allow for a sprue and runner. They could then measure their machined moulds and compare these to the drawing. Possible reference resources include: and communication skills used in the risk assessment. The dimensions on the CAD drawing must be quantified; they could also use measurement equipment to check the dimensions of the machined mould. This could link with performance outcome 3 of the Engineering Design unit and assessment outcome 1 of the Mathematics for Engineers unit (through the use of maths to solve problems).
4 Manufacturing Processes (PO1) Quality Control and Quality Assurance (PO3) Engineering Production Planning (PO4) Performing Manufacturing Processes (PO5) Material removal and shaping Selection and use of measurement devices Risk assessments Use of jigs and moulds Safe working practices Carrying out manufacturing processes Continuation of mini-project: jewellery. Teacher demonstration of the use of hand tools to finish the product (eg hacksaw to cut it to size, cross and draw filing). Each pair should carry out the pewter casting process, making two copies of their item. They should then use hand tools to finish the item to a high standard, and complete a quality record form. This could include measuring their machined moulds and comparing these to the drawing and the dimensions of the mould and reviewing how the work could have been improved. Possible reference resources include: technologystudent.com/equip1/pewter1.htm and instructables.com/id/Simple-Pewter-casting/ Evaluation of practical work in progress The context of this activity is domestic; however, a part could be made in conjunction with an appropriate local company instead. Written skills used in the quality record form. Checking the dimensions of the finished item relative to the CAD drawing and the machined mould. This link with performance outcome 3 of the Engineering Design unit and assessment outcome 2 of the Materials Technology and Science unit. on
6 Quality Control and Quality Assurance (PO3) Selection and use of measurement devices Measurement skills: round robin activity. Teacher presentation of a of measurement devices, with an explanation of what they are used for and a demonstration of how the equipment is used. At minimum, the demonstration should include: • vernier callipers • micrometers • Go-No Go gauges • multimeters. Automated measurement systems, including sensors for weights and colours could be demonstrated if available or shown using video clips of case studies. Around the workshop 10+ stations could be set up, each with a component or product that requires measuring and an appropriate test specification (for example, a CAD drawing or requirements sheet). This could include complex 3D components that require multiple different types of measurement. Working individually, learners have to select and use an appropriate test device, completing a test record sheet. At the end of the activity the can discuss any variations between their results and provide feedback to their peers. Possible reference resources include: , and Completed test record sheets; contribution to the evaluation discussion The context could be determined by the availability of test specimens for measurement from local companies. Written skills used in the test record sheets. Speaking and listening skills in the evaluation activity. Dimensions used during the measurements. The use of drawings could link with performance outcome 3 of the Engineering Design unit. on
23 Manufacturing Processes (PO1) Engineering Manufacturing Systems(PO2) Quality Control and Quality Assurance (PO3) Engineering Production Planning (PO4) Scales of manufacture Selection of measurement devices Production requirements and planning Product Analysis Activity: planning the manufacture of a product. Working in small teams, learners should be given the designs for a complex product and a statement of the quantity required – each team could have a different design or product. This could be a prototype of a product that they need to disassemble first. The teams need to: • Identify each of the component parts, and an appropriate scale of manufacture to produce them. • Identify the main processes that could be used to manufacture the components, in sequence. They also identify any quality assurance activities and quality control checks that may be needed and the measurement devices needed to carry these out. Ideally these should be recorded a laptop or PC, to avoid identification of the author by the handwriting. The teams then provide their analysis to the teacher, who redistributes them to another team. Without guidance from the first team, each team then has to identify which of the products their instructions are for, justifying their selection. The other teams should give feedback on their decision. Product analysis forms Feedback given by the teams Context could be determined by the products or resources available; depending upon local companies. It could also be used to support the more general objectives of the qualification, for example, by focussing on a of different mechatronic products. Opportunity to demonstrate written communication skills in the product analysis. Speaking and listening skills demonstrated during the ‘swapped sheet’ activity and feedback. This could include reference to quantity to be