Question 1: Define the term 'manufacturing' and explain its importance in the context of the design and production of products.

Answer: Manufacturing is the process of converting raw materials into finished products through various methods such as machining, assembly, and finishing. It is important because it allows for the mass production of products efficiently and consistently, meeting market demand.

Question 2: Describe a typical flow of manufacturing a plastic product, starting from raw materials to the finished item.

Answer: Raw plastic pellets are fed into an injection molding machine, heated until molten, then injected into a mold cavity shaped like the final product. Once cooled and solidified, the mold is opened to remove the finished plastic component, which may undergo further finishing processes.

Question 3: Identify and explain three key factors a manufacturer must consider when designing a product for mass production.

Answer: Factors include: (1) Ease of assembly to reduce time and costs; (2) Material selection for durability and cost-effectiveness; (3) Design simplicity to facilitate quick manufacturing and minimize defects.

Question 4: Explain the difference between batch manufacturing and continuous flow manufacturing.

Answer: Batch manufacturing produces a set quantity of products in groups, with machines stopping and starting for each batch. Continuous flow manufacturing runs products non-stop, with materials constantly processed, ideal for high-volume production.

Question 5: Discuss one environmental consideration a manufacturer should account for during the manufacturing process.

Answer: Manufacturers should consider waste management, such as recycling scrap materials and reducing emissions, to minimize environmental impact and comply with environmental regulations.

Question 6: Sketch a simple flowchart illustrating the stages involved in manufacturing a wooden chair.

Answer: A clear flowchart would include stages such as: Raw material selection, cutting, shaping, assembly, sanding, finishing, quality control, and packaging.

Question 7: Draw a cross-sectional view of an injection molding machine, labeling key parts such as the hopper, barrel, screw, mold, and ejector.

Answer: A correct sketch will show a vertical or horizontal machine with labeled components: the hopper at the top for raw material, the barrel where heating occurs, the screw that pushes plastic into the mold, the mold cavity, and the ejector system for releasing the finished part.

Question 8: Design a brief plan for how a factory might improve its manufacturing efficiency without compromising quality.

Answer: Implement lean manufacturing principles such as reducing waste, optimizing workflow, automating repetitive tasks, and providing staff training to improve skills and reduce errors.

Question 9: Identify two types of quality control methods used in manufacturing and briefly explain each.

Answer: Inspection, which involves visually or physically checking products for defects; and testing, which involves performing specific tests (e.g., stress tests) to ensure products meet safety and performance standards.

Question 10: Propose a new feature or improvement for a standard product (for example, a water bottle) that could be developed through manufacturing innovations.

Answer: A water bottle with a built-in filtration system that can be easily replaced, using modular manufacturing to allow easy assembly and replacement parts, improving usability and sustainability.