T Level Technical Qualification in Design and Development for Engineering and Manufacturing (8714) > Unit 1 > Flashcards

Unit 1 Flashcards

Working within the engineering and manufacturing sectors (89 cards)

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1
Q

Give the three stages of a manufacturing process

A

To change physical properties
To change shape and size of workpiece
To achieve the required tolerances and surface finish

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2
Q

Give seven types of manufacturing processes

A

Forming, shaping, finishing, casting, additive, joining, wasting

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3
Q

Define forming

A

Raw material is converted into a product through stresses

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4
Q

Give an example of forming

A

Sheet metal forming and copper wire drawing on large rollers

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5
Q

Define shaping

A

Processing involves removing material to create a desired shape

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6
Q

State the four categories of shaping processes and define each one

A

Casting - pouring liquid into prepped moulds
Manipulative processes - plastic deformation of material
Powder techniques - shape is produced by compacting powder
Cutting and grinding - cutting to shape and size for precise finish

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7
Q

Give an example of shaping

A

Metal components being pressed into shape

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8
Q

Define finishing

A

Altering the surface of manufactured parts in order to achieve particular characteristics

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9
Q

State the two categories of finishing

A

Removing and reshaping
Adding and altering

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10
Q

Give an example of finishing

A

Lasers being used to engrave a design into wood
Powder coating parts

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11
Q

Define casting

A

Use of molten liquid which is poured in a mould that takes form of finished part

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12
Q

State the two categories of casting

A

Expendable mould processes
Permanent mould processes

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13
Q

Why are cast objects highly dependent on pattern

A

Replica is needed to prepare cavity into which molten material will be poured to make the finished part

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14
Q

Define additive manufacturing

A

Form of industrial 3D printing that adds material layer by layer

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15
Q

State the seven types of additive manufacturing

A

Powder bed fusion
Vat photopolymerisation
Sheet lamination
Directed energy deposition (DED)
Binder jetting
Material jetting
Material extrusion

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16
Q

Give an example of additive manufacturing

A

Filament loaded into a device for material extrusion
DED process used to create parts

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17
Q

Define joining

A

Parts of a component meet at joints to form complex components or assembly

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18
Q

Define wasting

A

Cutting away material using tools and equipment

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19
Q

State what tools or equipment is used for wasting

A

Guillotining
Drilling
Laser cutting
Computer numerical controlled (CNC) routing

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20
Q

Give examples of wasting

A

Drilling a car component using CNC machinery
Guillotine used to cut sheet metal to size

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21
Q

State the difference between essential features and desirable features in design

A

Essential - must do its intended function
Desirable - additional requirements (ex. providing storage)

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22
Q

List the functional requirements for a car

A

Usefulness, safety, reliability, comfort, economy, attractiveness, transport ability

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23
Q

List some influences that might impact design & manufacture

A

Function, materials, aesthetics, target market, performance, environment

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24
Q

Define the two types of environment considerations

A

Environment (aesthetic) - visual impact of the product in its surroundings
Environment (pollution)) - damage done by manufacture, disposal or end of product life

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25
Define user requirements
Focuses on identify the needs of customer and ensuring the system is designed to meet those needs
26
Properly written user requirements ensure that, what?
Supplier **understands client's requirements** **Detailed specification** is written to capture scope of work System or specialised equipment **completely satisfies needs and expectations** Customer's **investment in system** delivers required results
27
Give the common steps in a **design process**
Empathise, Define, Ideate, Prototype, Test
28
What is a **linear design** process?
A design process where stages are completed one after the other, from design concept to delivery
29
What is an **iterative design** process?
An approach used to **continually improve** and **refine a design or product
30
What is user-centered design? (UCD)
Form of iterative design focusing on user needs in each phase of the process
31
What is inclusive design?
Process where a product, service or environment is designed to be usable by as many people as possible
32
What is ergonomic design?
A design process that factors anthropometric data to create products
33
Give the types of factors in ergonomic design
Posture, clearance, strength
34
Define **design for manufacturing** (DFM)
An engineering practice that designs products so they are **easy to manufacture**
35
List some principles considered in DFM
Process, design, materials, environment, compliance
36
Define **design for assembly** (DFA)
A design process that focuses on **ease of assembly** prioritising fewer parts using **component elimination**
37
What is sustainable design?
Design process involving compliance with principles of sustainability (protecting the environment)
38
State some sustainable design principles
Reducing consumption of non-renewable resources Minimising waste Reduce carbon Consider entire product life cycle
39
State the 6 R's of sustainability and what they mean
Reduce - cutting out excess material or energy for manufacture Refuse - say no to single use products Reuse - Can the product or its parts be reused? Repair - Can you fix the product? Recycle - Can the product be reprocessed into something new? Rethink - Is the product essential?
40
Give the three types of research methodologies in design and define them
**Qualitative** - researched conducted using words or visuals **Quantitative** - relies on measurement and testing of numerical data **Mixed-methods** - mix of both
41
Define **testing methodology**
Strategies and approaches used to test a product is fit for purpose
42
Why is it important that products work the way they're functioned?
So that their are no undesirable side effects and in, the worst case, **fail safely**
43
Give three types of testing methods
**Temperature and pressure testing** **Fatigue testing** **Fastener stress testing**
44
Define **maintenance**
Where machines and equipment receive appropriate care to keep them in good working order
45
What is the main purpose of maintenance?
**All equipment is operating at 100% efficiency at all times**
46
What is planned maintenance?
Refers to any maintenance activity that is planned or scheduled. Aims to reduce downtime
47
State the two main types of planned maintenance and define them
**Planned preventative maintenance (PM)** - maintenance before equipment fails **Planned unscheduled maintenance** - rapid maintenance when equipment fails
48
Give the advantages and limitations of planned maintance
Adv - Reduces costs, improves overall equipment performance, decreases downtime Limit - Labour intensive, high up front costs, potential for over-maintenance
49
What is **reactive maintenance**?
Maintenance that addresses problems when they arise using a **run-to-failure approach**
50
Give the advantages and limitations of reactive maintenance
Adv - Fewer staff needed, low upfront costs Limit - Safety issues, indirect costs, higher energy costs
51
What is preventive maintenance?
Regular and routine maintenance of equipment to keep them running to prevent any costly unplanned downtime from equipment failure
52
Give the advantages and limitations of PM
Adv - Longer asset life, increases efficiency and workplace safety Limit - Labour intensive, potential for over-maintenance
53
Define **condition-based monitoring (CBM)**
Process of monitoring the parameters of conditions in machinery such as vibration, temperature or noise to identify change
54
Give the advantages and limitations of CBM
Adv - Optimises maintenance intervals, reduces the cost of asset failures, improves worker safety Limit - Cost to train staff, fatigue isn't easily detected with CBM measurements, equipment for CBM is expensive
55
**Maintenance, repair and operations** can be:
**Routine** - planned maintenance activities **Predictive** - when data indicates machinery is degrading **Corrective** - after an incident occurs
56
Give examples of MRO
PPE, CNC, Forklifts, Jacks, Heating, ventilation and air conditioning (HVAC) maintenance, facility lighting
57
Define operations monitoring
Observation of performance of a machine or equipment over time by collecting key system performance metrics at planned intervals
58
Give examples of types of data used in operations monitoring
Machine status, environmental data, operator effectiveness, energy, quality-right part first time (RPFT) scrap rate
59
When is repair not possible?
When damage is **beyond repair** and spare parts are obsolete or equipment is outdated
60
When is **shutdown maintenance** performed?
When equipment is not in use
61
Why should **servicing** be included in a maintenance schedule?
Protecting those who use the machinery and others surrounding them, ensures machines are running safely and as productively as possible
62
Define **commissioning**
Assuring all systems and components are designed, installed, test operated and maintained according to operational requirements
63
Define **decommissioning**
Used for removal of something from an active service
64
What are machine operators and what do they do?
Machine operators (aka **production operators**) are builders, fabricators, mechanics etc that work with heavy machinery on the factory floor to make sure they are working properly
65
What are maintenance engineers and what do they do?
Responsible for continuous running of equipment and machinery using computerised systems to organise repairs and monitoring
66
What are maintenance managers and what do they do?
Lead maintenance teams to ensure equipment stays in good working order and health & safety standards are maintained. They carry out inspections and develop maintenance procedures to follow
67
State the difference between hand tools and power tools
Hand tools require manual labour to use Power tools are powered by a battery, electricity or compressed air
68
Give some examples of common hand tools
Spirit level, engineer's square, steel rule, files, marker pen, screwdrivers, Allen keys
69
Give some examples of common power tools
Hammer drill, impact wrench, belt sander, electric screwdriver, soldering iron
70
What are **insulated tools**
Tools designed to protect against injury when making contact with an energised source
71
Give some examples of electronic tools
Voltage tester, insulated pliers, clamp meter, electrical tape
72
Give some examples of **software tools** for both **CAD** and **CAM**
Solidworks, CATIA, Fusion 360, SolidCAM
73
Give examples of **CNC** machinery
Cranes, hoists, pumps and compressors
74
Define batch production
Identical products are produced simultaneously before moving to make another group of products
75
Give examples of batch produced products
Baked goods, clothing, computer chips, electrical goods, newspapers/magazines
76
Define mass production
Creation of standardised goods in large quantities used to describe **continuous production** or **flow production**
77
Why is mass production **capital intensive**?
High investment in machinery to use **assembly line** techniques and relies on **economies of scale** to be profitable
78
Define continous production
Where materials are processed continuously 24/7
79
Give examples of continuous production manufacturers
Food and beverage, paper, cement, electronics, glass, steel, chemical
80
State the meaning on infrastructure
Infrastructure refers to advanced manufacturing systems, engineering tools, manufacturing deployment or business practices
81
Define **product layout**
Where equipment and work processes are arranged based on their progressive steps in which the product is made
82
Define **process layout**
When similar equipment or functions are grouped together
83
What is **cellular manufacturing**?
Where production workstations and equipment is arranged in a sequence that supports smooth flow through the production process with minimal delay
84
Define automation
Technology by which a process is completed without human input
85
State the different types of robots used in automation and define their features
Cartesian - straight line on three axis, SCARA (selective compliance assembly robot arm) - rotary motion, Articulated - resembles a human arm on a base with two to ten rotary joints, Delta - three arms connected to a base mounted above workspace, quick and precise, Collaborative - "cobots" intend to assist human workers
86
How is performance measured in manufacturing?
Key performance indicators **(KPIs)**
87
What do KPIs measure?
Operator efficiency Cost of scrap and rework Downtime **Mean time between failures (MTBF)** Production deadlines Budgets
88
Define **quality assurance (QA)**
Refers to processes used to maintain consistent, expected quality levels for products
89
T Level Technical Qualification in Design and Development for Engineering and Manufacturing (8714)
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