Question 1: Explain the main differences between batch production and flow production. Provide one advantage of each method.

Answer: Batch production involves producing a specific quantity of a product at a time, with equipment set up for each batch. Flow production is continuous, with products moving through the manufacturing process on a conveyor. Advantage of batch: flexibility to produce different products; advantage of flow: high efficiency and large output.

Question 2: Describe a common manufacturing process used in the mass production of plastic components. Include the typical equipment involved.

Answer: Injection moulding is commonly used, where molten plastic is injected into a metal mould under pressure. Equipment includes an injection moulding machine with a heated barrel and a mould cavity.

Question 3: Identify and explain two environmental considerations manufacturers need to address during the production process.

Answer: Manufacturers must manage waste disposal to prevent pollution and reduce energy consumption to lower carbon emissions. Recycling materials and using energy-efficient machinery are common practices.

Question 4: Draw a simple schematic of a production line layout that includes at least three different workstations involved in manufacturing a product.

Answer: A correct sketch would show a linear or U-shaped layout with three distinct stations, such as: 1) Material preparation, 2) Assembly, 3) Finishing/Packaging, connected by conveyor belts or pathways.

Question 5: Design a brief plan for a manufacturing process to produce a small plastic toy. Include key steps and equipment needed.

Answer: Step 1: Design moulds for the toy; equipment: CAD software and mould-making tools. Step 2: Use injection moulding to produce parts; equipment: injection moulding machine. Step 3: Assemble parts; equipment: assembly tools. Step 4: Quality control; equipment: inspection gauges. Step 5: Packaging.

Question 6: Explain what is meant by 'quality control' in manufacturing, and give two methods used to ensure product quality.

Answer: Quality control involves checking products during and after production to ensure they meet specified standards. Methods include visual inspection and using measurement tools or gauges for dimensional accuracy.

Question 7: Identify a common method used to join metal components in manufacturing. Describe how it works.

Answer: Welding is a common method, where heat and sometimes pressure are used to fuse two metal parts together, creating a strong joint.

Question 8: Sketch a cross-section of a simple conveyor belt system used in manufacturing. Label the main components.

Answer: A correct sketch would show a belt looped around rollers, with a motor-driven roller at one end, and labels for 'conveyor belt,' 'rollers,' 'motor,' and 'support frame.'

Question 9: What are the key health and safety considerations a manufacturer must address when operating machinery? List three.

Answer: Key considerations include ensuring operators wear protective equipment, providing proper machine guarding, and implementing emergency stop procedures.

Question 10: Identify two sustainability practices that can be incorporated into manufacturing to reduce environmental impact.

Answer: Using renewable energy sources and recycling waste materials are two sustainability practices.