Question 1: Define the term 'manufacturing' in the context of the Design and Technology industry.

Answer: Manufacturing refers to the process of producing goods on a large scale using machinery, tools, and labour, often involving systematic steps to transform raw materials into finished products.

Question 2: List three common manufacturing processes used in industry today.

Answer: Casting, machining, and assembly are three common manufacturing processes.

Question 3: Explain the main difference between batch production and mass production.

Answer: Batch production involves manufacturing a specific quantity of a product at a time, often with variations between batches, while mass production involves continuous, large-scale manufacturing of identical products.

Question 4: Describe how automation has changed modern manufacturing processes. Provide two specific examples.

Answer: Automation has increased efficiency, precision, and safety in manufacturing. Examples include robotic arms used for welding and automated conveyor systems for assembly lines.

Question 5: Design Brief: A company wants to manufacture a new ergonomic office chair that is both comfortable and cost-effective. Outline the key considerations you would include in the design brief.

Answer: The design brief should consider user comfort, adjustability, material cost, durability, ease of manufacturing, and environmental impact.

Question 6: Sketch a plan for a simple manufacturing process flowchart for producing plastic bottle caps. Include at least four stages and label them.

Answer: A correct sketch would show stages such as: Raw material preparation (plastic pellets), moulding (injection moulding process), cooling and ejection, and quality inspection.

Question 7: Identify and explain two environmental impacts associated with large-scale manufacturing.

Answer: Environmental impacts include pollution from waste and emissions, and resource depletion from excessive use of raw materials.

Question 8: Discuss one advantage and one disadvantage of using robotic automation in manufacturing.

Answer: Advantage: Increased production speed and consistency. Disadvantage: High initial investment and potential job losses for workers.

Question 9: Draw a sectional view of a typical injection mould used in plastic manufacturing, showing the core, cavity, and ejector pin.

Answer: A correct sketch would depict a cross-section with the mould cavity, core, ejector pin, and the plastic part being formed within the mould.

Question 10: Explain what is meant by 'just-in-time' (JIT) manufacturing and its benefits.

Answer: 'Just-in-time' manufacturing is a strategy where materials and components are delivered exactly when needed in the production process, reducing inventory costs and waste.

Question 11: Create a rough annotated sketch of a factory layout for a small manufacturing plant producing metal brackets. Include at least three different areas or stations.

Answer: A suitable sketch would show areas such as raw material storage, machining/assembly stations, and quality control/packing, with clear labels and flow direction.