Topic 4.3 Scales of production Guiding Questions & Tasks 1. List a range of products that would be made as a ‘one­off’ 2. Outline the advantages and disadvantages of One­off production 3. Explain when batch production might be used 4. List a range of products manufactured using batch production 5. List the advantages and disadvantages of batch production 6. List a range of productions manufactured using mass production 7. Outline the difference between batch production / mass production and continuous flow 8. List the advantages and disadvantages of continuous flow 9. Define mass customisation 10. List the advantages and disadvantages of mass customisation 11. Identify the production methods for certain products in this video https://www.youtube.com/watch?v=DTWnQDAhp9k Topic 4.3: Scales of production The growing phenomenon of mass customization brings consumers into the design process, allowing them to make choices that make a product unique, to make it their own. Companies have developed “design stations” in their retail stores where consumers can create virtual 3D models, “try them out” using digital technology and place their order. Essential idea: The scale of production depends on the number of products required. Nature of design: Decisions on scale of production are influenced by the volume or quantities required, types of materials used to make the products and the type of product being manufactured. There are also considerations of staffing, resources and finance. Concepts and principles: • One­off, batch production and continuous flow • Mass customization Guidance: • Selecting an appropriate scale of production • Advantages and disadvantages of different scales of production Scales of production When selecting an appropriate scale of production for a product, you must consider a number of factors, including: ● product characteristics ● material characteristics ● size of market ● nature of market ● desired manufacturing processes ● desired production system. You should be able to explain the choice of scale of production and the advantages/disadvantages of different scales of production. The way products are manufactured depends on the quantity required. For example, cars are continually manufactured in hundreds of thousands , a prototype is a ‘one off’ (just one made) and DIY furniture is made in batches of thousands or hundreds. [​
http://www.technologystudent.com/joints/scalep1.htm​
] There are three main types of production: One­off, Batch production and Continuous flow This video gives a good overview ​
https://www.youtube.com/watch?v=CLPFG5QCx0g One­off / Job In one­off production a single product is designed and made to a client's specification. Labour and material costs are high, and a high level of design and manufacturing skills are needed. An example of one­off production would be a made­to­measure wedding dress, a custom made guitar, a high­end piece of furniture or a wedding cake. [​
http://www.bbc.co.uk/schools/gcsebitesize/design/textiles/texsystemspracticesrev3.shtml​
] The image on the right shows a one of piece of furniture designed by Jolyon Yates Advantages and Disadvantages Involves a highly specialised company. Small highly skilled workforce, possibly one or two workers, sometimes more. Constant communication with the client, constant discussion regarding the design. Company specialises in particular areas such as engineering or musical instruments etc... Specialist materials are often required eg. specialist woods or modelling materials The final product is expensive due to the level of skill needed to manufacture the product and the cost of specialist materials and equipment. A high standard of quality control Products are manufactured for a specialist market / clientele eg. musicians, medical profession, aerospace. [​
http://www.technologystudent.com/joints/sing1a.htm​
] Batch production When a small quantity of identical products are made. Batch production may also be labour intensive, but jigs and templates are used to aid production. Batches of the product can be made as often as required. The machines can be easily changed to produce a batch of a different product. [​
http://www.bbc.co.uk/schools/gcsebitesize/design/​
] The image on the right is of a lamp on sale at IKEA Mass Production When hundreds of identical products are made, usually on a production line. Mass production often involves the assembly of a number of sub­assemblies of individual components. Parts may be bought from other companies. There is usually some automation of tasks (eg by using Computer Numerical Control machines) and this enables a smaller number of workers to output more products. [​
http://www.bbc.co.uk/schools/gcsebitesize/design/​
] Continuous flow When many thousands of identical products are made. The difference between this and mass production is that the production line is kept running 24 hours a day, seven days a week to maximise production and eliminate the extra costs of starting and stopping the production process. The process is highly automated and few workers are required. [​
http://www.bbc.co.uk/schools/gcsebitesize/design/​
] Mass customization A marketing and manufacturing technique that combines the flexibility and personalization of "custom­made" with the low unit costs associated with mass production [​
http://www.investopedia.com/terms/m/masscustomization.asp?layout=infini&v=3A​
] Watch these videos for an overview: https://www.youtube.com/watch?v=3nbVRQ8skdI https://www.youtube.com/watch?v=hhnXFMrxR7E