Question 1: Describe the main differences between batch production and continuous flow production in manufacturing. Include at least two points for each method.

Answer: Batch production involves producing a specific quantity of a product in groups or batches, with each batch completed before starting another. Continuous flow production operates 24/7, with products constantly moving through the process, often on assembly lines. Batch production is flexible for small quantities; continuous flow is efficient for large-scale output.

Question 2: Explain the purpose of quality control in manufacturing and give two examples of quality control methods used in factories.

Answer: Quality control ensures products meet specified standards and reduces defects. Examples include visual inspection, where products are checked for defects, and sampling, where a subset of products is tested to assess overall quality.

Question 3: Identify and describe three common materials used in manufacturing and mention one typical product made from each.

Answer: Steel - used in construction and machinery; Plastic - used in bottles and packaging; Wood - used in furniture and flooring.

Question 4: Sketch a simple flowchart that shows the main stages in a typical manufacturing process, starting from raw materials to finished products.

Answer: A flowchart with stages such as: Raw Materials → Processing/Manufacturing → Assembly → Quality Control → Packaging → Distribution. The sketch should clearly show arrows linking these stages in sequence.

Question 5: Design Brief: Your task is to develop a new reusable water bottle that is environmentally friendly and easy to manufacture. What key features would you include in your design to achieve this?

Answer: Features could include using biodegradable or recycled materials, a simple screw-top lid for easy assembly, a lightweight design for portability, and minimal parts to simplify manufacturing.

Question 6: Sketch a design for an ergonomic handle suitable for a cooking pot. Label three features that improve comfort and grip.

Answer: The sketch should show a handle with a comfortable grip, possibly curved to fit the hand. Labels might include: non-slip surface, contoured shape for hand comfort, and a sturdy attachment point.

Question 7: List three environmental considerations manufacturers must take into account during production and explain why each is important.

Answer: Energy consumption – to reduce carbon footprint; Waste management – to prevent environmental pollution; Use of sustainable materials – to conserve resources and promote eco-friendliness.

Question 8: Explain what is meant by 'mass customization' in manufacturing and give an example of a product that uses this approach.

Answer: 'Mass customization' is producing large quantities of a product but with personalized features according to customer preferences. An example is custom-printed T-shirts or sneakers.