graphic products - worthing high school · 2 of 31 © boardworks ltd 2005 learning objectives...

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Graphic Products

Industrial Practices


Learning objectivesL

earn

ing

ob

jecti

ves


different methods of production

scales of production

graphic products investigations

CAD and CAM in industry

jigs, moulds, formers, templates

barcodes

waste reduction.

To learn about:


There are five main types of production, these are:

Many production processes involve a mixture of

these methods. Some parts and components can be

mass produced, while other parts may need to be

individually made.

Just-in-time production

Continuous production

Mass production

Batch production

One-off production

Production types


Advantages Disadvantages

One-off production usually takes a long time and is very labour

intensive. This means that the outcome is often expensive.

One-off products are often hand-made and designed and

manufactured for a very specific need or person.

One-off production is used when only one item is required.

One-off production

Product made to exact client specifications.

Little investment needed.

Labour intensive. Labour often must be highly skilled.

Materials expensive because they are bought in small quantities.

High design and manufacturing costs.


Batch production is used when a set number of products are

needed. One batch can consist of ten items or thousands of

items, depending on the requirements of the project.

Flexible manufacturing systems are used – these involve

production lines that can be altered to produce different items.

The production line is set up for each new batch. Once a

batch is finished, it can be altered for the next product.

Batch production

Advantages DisadvantagesSpecialization of tasks is possible, increasing efficiency.

Quick response to customer needs.

Machines can be reset and used to produce other products.

If you produce too few items, it can cost a lot to set up the equipment again for another batch later.

Production has to stop while production lines are reset.


Mass production makes products on a large scale. It can

involve the production of millions of units. It sometimes

involves continuous production techniques.

Mass production usually leads to lower production costs

because materials can be bought in bulk, and tasks can be

specialized.

Mass production


Specialization – production is split into stages and specific labour matched.

Often highly mechanized, so production is fast and labour costs are low.

Bulk material buying means lower costs.

Social implications –sometimes the jobs can get boring and don’t require much skill. Workers simply look after a machine.

Initial set up costs can be very high.


This is when manufacturing takes place 24 hours a day,

7 days a week. It is sometimes known as 24/7 production or

continuous flow production.

It is most commonly used for mass production. Most tasks are

usually carried out by computers and machines. The few

workers that are needed operate in shifts, so that production

is not interrupted.

Continuous production


Uninterrupted manufacture so goods are produced quickly.

Fewer workers, so lower labour costs.

No time and money wasted in starting, stopping and resetting machines.

Social implications – sometimes the jobs can get boring and don’t require much skill.

Initial set up costs can be very high.

Workers often must be paid more for working at night.


Just-in-time is a tightly organized control system that aims to

ensure that materials and components arrive at the factory at

the exact time they are needed.

This reduces storage and wastage costs and should eliminate

the possibility of running out of materials.

It uses stock management to ensure that materials are

available when needed.

Just-in-time production


Storage costs are very small.

Production is more flexible as there are no large stockpiles of materials.

If supply fails, the production line will just stop.

Relies heavily on suppliers and couriers being punctual.


When you are designing a product, you must think how it will

be made.

The number of units you choose to make will help you

decide whether to:

mass produce your product.

produce your product in batches

produce your product as a one-off

First, you must decide how many

products you are going to need.

The cost of producing each unit is usually lower the more you

make, but you will waste money if you make more than you

can use or sell.

Scales of production


Scales of production


Three of the most common graphic products are packaging,

newspapers and posters. You need to be familiar with how

these products are manufactured.

The next few slides will explore how these products are

manufactured from the raw materials to the finished products.

Graphic product investigations


Once the research and development stages

are complete, the net design will be drawn

on a computer using computer aided

design and linked to a printer.

Graphic product investigation – packaging

Glue will be added to

the joining tabs and

the net assembled.

The net will then be

scored and folded using

a folding machine.

The net will

then be cut

out using a

die cutter.

As soon as the ink is dry,

the net will be spirit varnished.

The package will then be printed. The most

common printing method used for packaging

is lithography. It produces good print quality

and is reasonably fast and cheap.


Graphic product investigation – newspapers

The paper is then folded

using a bending machine.

The pages are cut

using a guillotine.

The newspapers

are then printed

using lithography.

The computer

is linked to the

lithography

printer.

The text is written and arranged

with any images, using a desktop

publishing package. The template

remains the same, but the

information changes daily.


Graphic product investigation – posters

The poster will then be spirit

varnished. This will happen as

soon as the ink is dry. It gives the

poster a glossy finish.

The most common printing method

used for posters is lithography.

Lithography produces good quality

prints, is reasonably cheap and lends

itself well to mass production methods.

The design is either drawn on a computer

using computer aided design, or transferred

onto computer using an input device, such as

a scanner. The computer is linked to a printer.


Computer Aided Design and Computer Aided Manufacture

are terms used for a range of different ICT applications that

can help in the design and manufacture of products.

COMPUTER AIDED DESIGN

A computer aided system for creating, developing, modifying

and communicating design ideas.

COMPUTER AIDED MANUFACTURE

A term used for manufacturing processes controlled by

computers.

CAD and CAM systems


Computer aided design is widely used in industry. It allows

you to:

generate working drawing from

presentation images

render products to look exactly as

you would like them.

draw with great accuracy, scale

drawings when needed and duplicate

images easily

generate 3D images

view a design from any angle

CAD and CAM


Computer aided manufacture is also used extensively in

industry. Computers control hi-tech machines and robotics

that can manufacture products with great speed and

accuracy. CAM devices include:

CAD and CAM

Solid laser plotters (stereolithography)–

A new range of 3D printers that can

create products by building up layers.

Cutters/plotters – A vinyl cutter/plotter

can be programmed to draw or cut out

text and images accurately.

Routers – These are computer

controlled milling machines. They can

create 3D and rotational objects from

blocks of material.


CAD and CAM

The video clip below shows how labels for sandwich

packaging are designed on computer, and then cut out

using a computer controlled vinyl cutter.


Barcodes consist of a series

of vertical lines of different

widths, which correspond

to numbers. They are now

printed on most products.

Barcodes contain

information about the

product. They are read by

an optical scanner.

The scanner sends a laser beam over the barcode. The bars

are detected because they reflect less light back. The scanner

transmits the code to the in-store computer, which then relays

the product description and price back to the checkout.

Barcodes

Manufacturer code

Product code

Guard bars separate numbers


Jigs, moulds and formers are used by manufacturers to

make the same object repeatedly and identically.

This ice cube tray is a mould.

It allows you to make ice cubes

that are all the same size and

shape over and over again.

Jigs, moulds, formers and templates

Jigs help you to line objects up.

Moulds help you to form objects by surrounding and

shaping them.

Formers help you to bend and shape objects accurately

and consistently.


This mould is used to

manufacture a hand held drum.

You can see that it has been

split into two parts to allow the

drum to be removed once it

has been moulded.

This jig allows holes to be drilled

in a sheet of material in exactly

the same places every time.




Formers are a bit like the opposite of moulds – instead of

placing the material to be shaped inside, you bend or

shape the material around the former.

Here are two examples:

You can make a papier mâché

sphere by pasting newspaper to

a balloon. The balloon acts as a

former. Once the papier mâché

is dry, the balloon can be burst

and removed.A former can be used to

bend a metal rod into a

particular shape.


You will find that you use a lot of

templates in graphic products.

Templates allow you to replicate

designs over and over again, with

great accuracy.

This template helps

you draw letters.

These are french curve templates

– you can use them to help you

draw lots of different curves.



You also get templates within desk top publishing (DTP)

packages. These are graphical templates for producing a

variety of standard documents such as CVs, letters, flyers and

signs. The templates shown here are from Microsoft Publisher.



Many graphic products are related to packaging. Companies

package their products for a number of different reasons.

Look how

much

packaging a

simple cookie

can create:

To protect the product

For easier transportation To advertise the product

To preserve the product

individual

plastic

wrapper

plastic

traylarge plastic

wrapper

cardboard box

bound in cellophane

Product packaging


Waste costs money – any materials that are used must be

used in the most economical way. Designs need to be laid

out so that the amount of waste created is minimal.

Lets look at how we might layout the net for a cube.

A layout like this is uneconomical. It wastes materials and only

four cubes could be manufactured. Is there a better way?

Waste reduction


By turning the shapes around, you can fit six on the sheet

and reduce the wastage. A manufacturer could make 50%

more cubes from the same card by laying them this way.

Waste reduction


Waste reduction


Cost restrictions can sometimes limit our designs. If the

product is on a tight budget, then the designer will have to

make sure that their design will not be too expensive to make.

E.g. rather than making boxes with round bases that create a

lot of waste, square based boxes may be used.

Should cost impact design this much?

Waste reduction


Key pointsK

ey

po

ints


There are five main methods of production – one-

off, batch, mass, continuous and just-in-time.

The most appropriate method of production is

determined by the number of items required.

CAD and CAM systems are widely used in

industry to improve the speed and quality of

manufacture.

Jigs, moulds, formers and templates are used to

manufacture products faster and with greater

accuracy.

Manufacturers seek to cut costs by reducing

waste in the production process.

graphic products - worthing high school · 2 of 31 © boardworks ltd 2005 learning objectives...

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