Question 1: Define 'mass production' and explain how it differs from 'batch production'.

Answer: Mass production involves manufacturing large quantities of identical products continuously, often using assembly lines. Batch production produces a set number of items at once, with variations possible between batches, and is more flexible than mass production.

Question 2: Identify two advantages and two disadvantages of using continuous flow production for manufacturing a popular consumer product.

Answer: Advantages: High efficiency and low unit costs; consistent product quality. Disadvantages: High initial setup costs and less flexibility to change product design.

Question 3: Describe a scenario where job production would be the most suitable manufacturing method. Explain why.

Answer: Job production is suitable for custom-made furniture or bespoke jewellery, where each product is unique and requires individual craftsmanship, making flexibility and customization essential.

Question 4: Sketch a simple flowchart showing the main steps in a batch production process for baking bread. Include at least four stages.

Answer: A clear flowchart with stages such as mixing ingredients, dividing dough, baking, and packaging. Each step should be connected sequentially.

Question 5: Create a rough sketch of a product that would be best produced using one-off (job) production. Label the key features of your design.

Answer: A sketch of a bespoke piece such as a custom guitar or a handmade sculpture, with labels indicating unique features like material choice, shape, or decorative elements.

Question 6: Design a small product (e.g., a key holder or a pen) suitable for batch production. Include a basic plan and explain your reasoning.

Answer: A simple sketch of the product with dimensions and a brief explanation stating that batch production allows for efficient manufacturing of multiple units with consistent quality, ideal for retail.

Question 7: Explain how economies of scale can reduce the cost per unit in large-scale production.

Answer: Economies of scale occur when increasing production volume lowers the average cost per unit because fixed costs are spread over more units, and operational efficiencies improve.

Question 8: Identify a product that is likely produced using continuous flow production and justify your choice.

Answer: Products like soft drinks or bottled beverages are often produced using continuous flow because of the need for high-volume, consistent output with minimal variation.

Question 9: Discuss the environmental impacts associated with large-scale, automated manufacturing processes.

Answer: Large-scale automated manufacturing can lead to increased energy consumption, waste generation, and pollution. However, it can also reduce waste through precision and improve resource efficiency when managed responsibly.

Question 10: Propose a new product idea suitable for small batch production. Include a brief sketch description and explain why small batch production is appropriate.

Answer: A bespoke wooden phone stand with a unique design, produced in small batches to maintain quality and customization. The sketch should show the stand with dimensions and design features, emphasizing flexibility and craftsmanship.

Question 11: Describe the main considerations when choosing a production scale for a new product idea.

Answer: Considerations include expected demand, production costs, flexibility for design changes, quality control, lead times, and available equipment or resources.