Sports College - aylesford.kent.sch.uk · neering machines include anything with a moving part within it. Early mechanical ... modern composite materials ... properties of carbon

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BTEC Engineering

Revision Booklet

Aylesford School Sports College

Name:

Class:

Teacher: Mr Heather 2016—2017

Name:____________________

Class: ____________________

Teacher: Mr Heather 2016—2017

Useful websites

Course Overview Engineering is concerned with a

product or process that has to be

constructed or engineered from raw

materials to produce the final result.

This covers its design, construction,

development, machining and

maintenance. Engineering covers

engines, machines and large scale

structures. This often involves the use

of machining to change the shape of

materials by turning, milling or

grinding. Typical examples of

engineering are often named after the

type of work that they cover.

Marine engineering covers work that

is connected with water for example

boat building or maintenance. Civil

Engineering covers engineering on

roads, railways and infrastructure.

Mechanical Engineering includes

pipework, machines, factories and

production processes. Electrical

Engineering includes electronics and

the use of electricity to make things

operate. There are other specialist

areas of engineering such as nuclear

and biological.

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YouTube links

http://www.technologystudent.com/

https://www.youtube.com/watch?v=7foK-

wVNSMw (Iron Mining)

https://www.youtube.com/watch?

v=wfFcs25KmMc (Metallic Foams)

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Marine Engineering

This covers engineering on or below water. Boat building, construction and maintenance are the main types of work that this sector covers. Diesel marine engines have to be designed and built to operate the worlds ships in transporting goods around the globe. Engines have to be serviced and maintained as well as the boats to make sure that they work efficiently and safely. Boats are often put into a ‘dry dock’ where they can be taken out of the water to be worked upon.

Mechanical Engineering

This covers machines and equipment such as pipework, manufacturing of engineered prod-ucts, structural steel fabrication and other large work involving metals. Mechanical engi-neering machines include anything with a moving part within it. Early mechanical engineer-ing was developed with the design, operation and maintenance of the steam engine that was used to drive a manufacturing process and then a train.

Civil Engineering

This covers heavy engineering to the construction of harbours, roads, motorways, bridges, reservoirs, tunnels and drainage and any large concrete constructed works. Civil engineer-ing is connected with the construction of structures not machinery. Large concrete pours in civil engineering are used to form structures such as dam walls, retaining walls and the lin-ing of tunnels through mountains, under rivers and the tube line in London.

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Topic A1: Engineering sectors and products

What is Electrical Engineering?

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Topic A1: Engineering sectors and products

What is Aerospace Engineering?

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What is Automotive Engineering?

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What is Communications Engineering?

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What is Biomedical Engineering?

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Processes including health and safety issues, characteristics, applications and advantages/disadvantages of the following engineering processes:

machining – turning, milling, drilling

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Topic A2: Mechanical and electrical/electronic

Learn each part. Write down what parts each machine has in common.

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feed

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machining – turning, milling, drilling

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Write down the process for using the metal Lathe

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forming – casting, forging

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Casting or Forging? Explain how to tell the difference.

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Casting is the process where metal is heated until molten. While in the molten or liquid state it is poured into a mold or vessel to create a desired shape. Forging is the application of thermal and mechanical energy to steel billets or ingots to cause the material to change shape while in a sol-id state.

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fabrication – welding, shearing

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Research and explain the welding process.

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● electrical/electronic – PCB manufacture, surface mount technology.

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Surface-mount technology (SMT) is a method for producing electronic circuits in which the compo-

nents are mounted or placed directly onto the surface of printed circuit boards (PCBs). An electron-

ic device so made is called a surface-mount device (SMD). In the industry it has largely replaced the

through-hole technology construction method of fitting components with wire leads into holes in the

circuit board. Both technologies can be used on the same board, with the through-hole technology

used for components not suitable for surface mounting such as large transformers and heat-sinked

power semiconductors.

An SMT component is usually smaller than its through-hole counterpart because it has either smaller

leads or no leads at all. It may have short pins or leads of various styles, flat contacts, a matrix of

solder balls (BGAs), or terminations on the body of the component.

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Characteristics and advantages/disadvantages of the following scales of production used in engineering manufacture:

one-off/jobbing production

batch production

mass production

continuous production.

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Topic A3: Scales of production

SCALE OF

PRODUCTION SAMPLE

PRODUCTS DESCRIPTION / DETAIL

CONTINUOUS

CARS PETROL / OIL PROD-

UCTS BRICKS

MANY FOOD PROD-

1. PRODUCTION LINE SET UP 2. PRODUCTION LINE SPLIT INTO SEPARATE OPERATIONS. UNSKILLED AND SEMI SKILLED WORKFORCE REQUIRED. 3. PRODUCTION LINE RUNS 24 HOURS A DAY 365 DAYS A YEAR. 4. HIGH LEVEL OF FINANCIAL INVESTMENT NEEDED AS SPECIALIST MA-CHINERY IS USUALLY REQUIRED. 5. QUALITY CONTROL AT EVERY STAGE.

SCALE OF PRODUCTION

SAMPLE PRODUCTS

DESCRIPTION / DETAIL

BATCH

FURNITURE ELECTRICAL GOODS

CLOTHING NEWSPAPERS

BOOKS

1. FLEXIBLE PRODUCTION LINE SET UP - MUST B E ABLE TO CHANGE WHEN THE PRODUCT CHANGES 2. PRODUCTION LINE SPLIT INTO SEPARATE OPERATIONS. UNSKILLED AND SEMI SKILLED 3. PRODUCTION LINE RUNS FOR A SPECIFIED AMOUNT OF TIME UNTIL THE CORRECT NUMBER OF PRODUCTS HAVE BEEN MANUFACTURED 4. WORKFORCE FLEXIBILITY REQUIRED. WORKERS MUST BE ABLE TO SWITCH FROM ONE JOB TO ANOTHER. 5. OFTEN COMPONENTS ARE BOUGHT FROM OTHER COMPANIES AND AS-SEMBLED INTO THE NEW PRODUCT

SCALE OF PRODUCTION

SAMPLE PRODUCTS


ONE-OFF

PROTOTYPES SPECIALIST MODELS HANDMADE ITEMS

SPECIALIST ENGINEER-ING

ONE OFFS

1. SMALL SPECIALIST COMPANIES. 2. A SKILLED WORKFORCE - SPECIALIST SKILLS eg. ENGINEERING. 3. SPECIALIST MATERIALS OFTEN REQUIRED eg. SPECIALIST MODELLING MA-TERIALS. 4. HIGH QUALITY PRODUCTS MANUFACTURED. 5. FINAL PRODUCTS OFTEN EXPENSIVE DUE LEVEL OF SKILL REQUIRED TO MANUFACTURE THEM AND COST OF SPECIALIST MATERIALS. 6. A HIGH STANDARD OF QUALITY CONTROL

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Topic A3: Scales of production

SCALE OF PRODUCTION

SAMPLE PRODUCTS


MASS PRODUC-TION

SCREWS, NUTS AND BOLTS, NAILS

Mass production is the industrial-scale manufacture of large quantities of products, usually on a production line. Standardised production methods mean it is suitable for products that rarely need to be redesigned. Mass pro-duction is used for products that are needed in very large numbers, eg socks or jeans. Often, products are made overseas where labour costs are lower.

Explain why different scales of production are needed?

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Applications and advantages/disadvantages of the following modern production methods for production/assembly lines:

● robots

● Computer Numerically Controlled (CNC) machinery.

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Topic A4: Modern production methods

Many products are manufactured and assembled on a production line. Before the introduction of

computer control and robots production lines were operated by people. Each person would carry out

a limited number of tasks or even just one task and the product would then be passed down the pro-

duction line to the next person. This would continue until the product was completely assembled.

Some modern production lines still operate in the same way whilst others rely on robots and comput-

er control or a combination of people and machines.

The example production line seen below has been simplified. This production line is for the assembly

of a bicycle (seen above). As the bicycle frame travels down the production line each person at a

workstation has a specific task to carry out ( see below). The example production line seen below

has been simplified. This production line is for the assembly of a bicycle. As the bicycle frame trav-

els down the production line each person at a workstation has a specific task to carry out ( see be-

low).

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Applications and advantages/disadvantages of the following modern production methods for production/assembly lines:

● robots

● Computer Numerically Controlled (CNC) machinery.

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Topic A4: Modern production methods

ADVANTAGES: A production line is a very efficient way of manufacturing and assembling a product.

A car is composed of thousands of components and yet hundreds of cars roll of the production line

of a typical car plant every day. If each car was to be assembled by a group of individuals in a garage

rather than on a production line it could take months to produce just one.

DISADVANTAGES: However, the workers on production lines often complain that little skill or

training is required to complete their individual tasks and that working on a production line is ex-

tremely boring and unfulfilling. Workers often see their task as not being very important as they are

just producing one small part of a larger product made up of thousands of components

Research

advantages and disadvantages of Robots and CNC technology being added to a production line.

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Applications, characteristics, properties and advantages/disadvantages of the following modern and smart materials used in engineering:

modern composite materials – glass reinforced plastic (GRP), carbon fibre, Kevlar®

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Topic B1: Modern and smart materials in engineering

A composite material (also called a composition material or shortened to composite which is the com-

mon name) is a material made from two or more constituent materials with significantly different

physical or chemical properties that, when combined, produce a material with characteristics differ-

ent from the individual components. The individual components remain separate and distinct within

the finished structure. The new material may be preferred for many reasons: common examples in-

clude materials which are stronger, lighter, or less expensive when compared to traditional materials.

What's so good about Kevlar?

These are some of Kevlar's properties:

It's strong but relatively light. The specific tensile strength (stretching or pulling strength) of both

Kevlar 29 and Kevlar 49 is over eight times greater than that of steel wire.

Unlike most plastics it does not melt: it's reasonably good at withstanding temperatures and decom-

poses only at about 450°C (850°F).

Unlike its sister material, Nomex, Kevlar can be ignited but burning usually stops when the heat

source is removed.

Very low temperatures have no effect on Kevlar: DuPont found "no embrittlement or degradation"

down to −196°C (−320°F).

Like other plastics, long exposure to ultraviolet light (in sunlight, for example) causes discoloration

and some degradation of the fibers in Kevlar.

Kevlar can resist attacks from many different chemicals, though long exposure to strong acids or ba-

ses will degrade it over time.

In DuPont's tests, Kevlar remained "virtually unchanged" after exposure to hot water for more than

200 days and its super-strong properties are "virtually unaffected" by moisture.

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modern composite materials – glass reinforced plastic (GRP), carbon fibre, Kevlar®

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Carbon Fibre

To produce a carbon fibre, the carbon atoms are bonded together in crystals that are more or less

aligned parallel to the long axis of the fibre as the crystal alignment gives the fibre high strength-to

-volume ratio (making it strong for its size). Several thousand carbon fibres are bundled together to

form a tow, which may be used by itself or woven into a fabric.

The properties of carbon fibres, such as high stiffness, high tensile strength, low weight, high chem-

ical resistance, high temperature tolerance and low thermal expansion, make them very popular in

aerospace, civil engineering, military, and motorsports, along with other competition sports. However,

they are relatively expensive when compared with similar fibres, such as glass fibres or plastic fi-

bres.

Carbon fibres are usually combined with other materials to form a composite. When combined with a

plastic resin and wound or molded it forms carbon-fibre-reinforced polymer (often referred to as

carbon fibre) which has a very high strength-to-weight ratio, and is extremely rigid although some-

what brittle. However, carbon fibres are also composited with other materials, such as with graphite

to form carbon-carbon composites, which have a very high heat tolerance.

Glass Reinforced Plastic

The glass fibres are made of various types of glass depending upon the fiberglass use. These glasses

all contain silica or silicate, with varying amounts of oxides of calcium, magnesium, and sometimes bo-

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modern high-performance materials – tungsten, titanium, superalloys (nickel based, co-balt based), ceramics (boron carbide, cubic boron nitride, zirconia)

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Tungsten.

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Titanium.

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Superalloys (nickel based, cobalt based).

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● smart materials – shape memory alloys (SMAs), shape memory polymers, electrochromic, piezoelectric actuators and transducers.

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These are sometimes called ‘memory metals’. After becoming deformed (e.g. as a result of heating,

the application of external force and cooling) they return to their original or ‘permanent’ shape when

reheated. They are alloys containing combinations of copper, zinc, nickel, aluminium and titanium

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Applications, characteristics and advantages/disadvantages of metallic foams as used in the automotive, biomedical and aerospace sectors e.g. aluminium, steel.

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Topic B2: Modern material foams in engineering

https://www.youtube.com/watch?v=wfFcs25KmMc

Watch the link above then explain:

How metallic foams are made

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Explain the properties of metallic foams.

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How can metallic foams be applied to different products?

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Process, applications, characteristics and advantages/disadvantages of powder metallurgy: powder mixing/blending, pressing/compacting, sintering.

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Topic B3: Modern material processes in engineering

Advantages and Disadvantages of Powder Metallurgy

The process of manufacturing of shaped components or semi-finished products such as bar and sheet from metal powder is called as Powder metallur-

gy.

The technique of powder metallurgy combines unique technical features with cost effectiveness and generally used to produce sintered hard metals

known as ‘carbides’ or ‘tungsten carbides’.

This technique deals with the production of metal and non metal powders and manufacture of components.

Powder metallurgy is generally used for iron based components.

The powders used as raw material can be elemental, pre-alloyed, or partially alloyed.

Elemental powders like iron and copper are more compressible and produce pressed compacts with good strength.

Pre-alloyed powders are harder but less compressible therefore require higher pressing loads to produce high density compacts.

Powder metallurgy technique has many advantage as well as limitation.

Some of the Advantages of Powder Metallurgy are as follows;

1. Powder metallurgy produces near net shape components. The technique required few or no secondary operations.

2. Parts of powder metallurgy can be produce from high melting point refractory metals with less cost and difficulties.

3. The tolerance of components produced by this technique have quite high tolerance, therefore no further machining is not required.

4. This technique involves high Production Rate along with low Unit Cost.

5. It can produce complicated forms with a uniform microstructure.

6. Powder metallurgy has full capacity for producing a variety of alloying systems and particulate composites.

7. This technique has flexibilities for producing PM parts with specific physical and mechanical properties like hardness, strength, density and poros-

ity.

8. By using powder metallurgy, parts can be produced with infiltration and impregnation of other materials to obtain special characteristics which are

needed for specific application.

9. Powder metallurgy can be used to produce bi-metallic products, porous bearing and sintered carbide.

10. Powder metallurgy makes use of 100% raw material as no material is wasted as scrap during process.

Disadvantages of Powder Metallurgy:

1. The production of powder for metallurgy is very high.

2. The products of metallurgy can have limited shapes and features.

3. This technique causes potential workforce health problems from atmospheric contamination of the workplace.

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Applications, characteristics and advantages/disadvantages of the following new technolo-gies used in engineering sectors:

optical fibres as used in the communications sector

hydrogen fuel cells, surface nanotechnology and telematics as used in the automotive sector

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Topic B4: New technologies in engineering

Optical Fibres

Fibre-optic communication is a method of transmitting information from one place to another by

sending pulses of light through an optical fibre. The light forms an electromagnetic carrier wave that

is modulated to carry information. First developed in the 1970s, fibre-optics have revolutionized the

telecommunications industry and have played a major role in the advent of the Information Age. Be-

cause of its advantages over electrical transmission, optical fibres have largely replaced copper wire

communications in core networks in the developed world. Optical fibre is used by many telecommuni-

cations companies to transmit telephone signals, Internet communication, and cable television signals.

Researchers at Bell Labs have reached internet speeds of over 100 petabit×kilometer per second us-

ing fibre-optic communication

Nanotechnology

The basic trends that nanotechnology enables for the automobile are

lighter but stronger materials (for better fuel consumption and increased safety)

improved engine efficiency and fuel consumption for gasoline-powered cars (catalysts; fuel additives;

lubricants)

reduced environmental impact from hydrogen and fuel cell-powered cars

improved and miniaturized electronic systems

better economies (longer service life; lower component failure rate; smart materials for self-repair)

Read more: Nanotechnology in the automotive industry

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Applications, characteristics and advantages/disadvantages of the following new technolo-gies used in engineering sectors:

blended wing bodies as used in the aerospace sector

● bionics as used in the biomedical sector.

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Topic B4: New technologies in engineering

Blended Wing Bodies

A Blended wing body (BWB or Hybrid Wing Body, HWB) is a fixed-wing aircraft having no clear divid-

ing line between the wings and the main body of the craft. The form is composed of distinct wing and

body structures, though the wings are smoothly blended into the body, unlike a flying wing which has

no distinct fuselage. A BWB design may or may not be tailless.

The potential advantages of the BWB approach are efficient high-lift wings and a wide airfoil-

shaped body. This enables the entire craft to generate lift, potentially reducing the size and drag of

the wings. A blended wing body can have a lift-to-drag ratio significantly greater than a conventional

craft, offering improved fuel economy.

Bionics

Bionics is a term which refers to the flow of concepts from biology to engineering and vice versa.

Hence, there are two slightly different points of view regarding the meaning of the word.

In medicine, bionics means the replacement or enhancement of organs or other body parts by me-

chanical versions. Bionic implants differ from mere prostheses by mimicking the original function

very closely, or even surpassing it.

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Characteristics, applications and advantages/disadvantages of Life Cycle Assessment (LCA) at the following stages for engineered products:

raw materials extraction

material production

production of parts

assembly

use

● disposal/recycling.

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Topic C1: Sustainable engineered products

Explain each stage of the life cycle of a product

Raw Materials Extraction

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Materials Production

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Topic C1: Sustainable engineered products

Explain each stage of the life cycle of a product

Production of Parts

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Assembly

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Use

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Characteristics, applications and advantages/disadvantages of minimising waste production throughout the life cycle of engineered products, using the four Rs:

Reduce materials and energy.

Reuse materials and products where applicable.

Recover energy from waste.

● Recycle materials and products or use recycled materials.

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Topic C2: Minimising waste production in engineering

Reduce – Prevent waste in the first place; by eliminating waste at source through better planning and design

Reuse – Increase creativity on site – Reuse materials waste whenever possible; this is both cost-effective and reduces waste to landfill

Recycle – Secondary material use – Down-cycle if it cannot be reused

Recycle – Ensure a good separation of waste into “one-material fractions” that can be more easily recycled

– Enable segregation of at least 6 fractions: Wood, Concrete,

Gypsum/Plasterboard, Metal, Plastic -soft and hard, Paper/Cardboard

Recover – Energy Recovery can be an alternative, if recycling is not available

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Topic C2: Minimising waste production in engineering

Reduce

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Reuse

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Recycle

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Recover

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How do the 4rs

apply to this motorbike?

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Characteristics, applications and advantages/disadvantages of minimising waste at the pro-duction stage in engineering, using the following lean manufacturing techniques:

Just-in-Time (JIT) ,Kaizen and Poka-Yoke

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Topic C3: Lean manufacturing

JIT Just-in-Time manufacturing

`Just-in-time' is a management philosophy and not a technique.

It originally referred to the production of goods to meet customer demand exactly, in time, quality and quantity, whether the

`customer' is the final purchaser of the product or another process further along the production line.

It has now come to mean producing with minimum waste. "Waste" is taken in its most general sense and includes time and resources as

well as materials. Elements of JIT include:

Continuous improvement.

Attacking fundamental problems - anything that does not add value to the product.

Devising systems to identify problems.

Striving for simplicity - simpler systems may be easier to understand, easier to manage and less likely to go wrong.

A product oriented layout - produces less time spent moving of materials and parts.

Quality control at source - each worker is responsible for the quality of their own output.

Poka-yoke - `foolproof' tools, methods, jigs etc. prevent mistakes

Preventative maintenance, Total productive maintenance - ensuring machinery and equipment functions perfectly when it is required,

and continually improving it.

Eliminating waste. There are seven types of waste:

waste from overproduction, waste of waiting time., transportation waste., processing waste, inventory waste, waste of motion and

waste from product defects.

Good housekeeping - workplace cleanliness and organisation.

Set-up time reduction - increases flexibility and allows smaller batches. Ideal batch size is 1item. Multi-process handling - a multi-

skilled workforce has greater productivity, flexibility and job satisfaction.

Kaizen aims for improvements in productivity, effectiveness, safety, and waste reduction, and those who follow the approach

often find a whole lot more in return:

•Less waste – inventory is used more efficiently as are employee skills.

•People are more satisfied – they have a direct impact on the way things are done.

•Improved commitment – team members have more of a stake in their job and are more inclined to commit to doing a good job.

•Improved retention – satisfied and engaged people are more likely to stay.

•Improved competitiveness – increases in efficiency tend to contribute to lower costs and higher quality products.

•Improved consumer satisfaction – coming from higher quality products with fewer faults.

•Improved problem solving – looking at processes from a solutions perspective allows employees to solve problems continuously.

•Improved teams – working together to solve problems helps build and strengthen existing teams.

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Processes, characteristics, applications and advantages/disadvantages of using the following

renewable sources of energy in engineering:

wind energy using turbines and wind farms

solar energy using photovoltaic cells and solar water heaters

hydro energy using dams, barrages and wave power

● geothermal energy using heat pumps and exchangers.

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Topic C4: Renewable sources of energy in engineering

The Advantages of Renewable Energy

One major advantage with the use of renewable energy is that as it is renewable it is therefore sus-

tainable and so will never run out.

Renewable energy facilities generally require less maintenance than traditional generators. Their fuel

being derived from natural and available resources reduces the costs of operation.

Even more importantly, renewable energy produces little or no waste products such as carbon dioxide

or other chemical pollutants, so has minimal impact on the environment.

Renewable energy projects can also bring economic benefits to many regional areas, as most projects

are located away from large urban centres and suburbs of the capital cities. These economic benefits

may be from the increased use of local services as well as tourism.

The Disadvantages of Renewable Energy

It is easy to recognise the environmental advantages of utilising the alternative and renewable forms

of energy but we must also be aware of the disadvantages.

One disadvantage with renewable energy is that it is difficult to generate the quantities of electrici-

ty that are as large as those produced by traditional fossil fuel generators. This may mean that we

need to reduce the amount of energy we use or simply build more energy facilities. It also indicates

that the best solution to our energy problems may be to have a balance of many different power

sources.

Another disadvantage of renewable energy sources is the reliability of supply. Renewable energy of-

ten relies on the weather for its source of power. Hydro generators need rain to fill dams to supply

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Wind energy using turbines and wind farms

Solar energy using photovoltaic cells and solar water heaters

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Hydro energy using dams, barrages and wave power

Geothermal energy using heat pumps and exchangers.

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List Soft Woods:

List Hard Woods:

List Ferrous Metals:

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List Non-Ferrous Metals:

List Thermo Plastics: List Thermosetting Plastics:

List Hard Woods:

List Man-Made Woods:

Materials

Subcategories

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Aylesford School Sports College

Documents

Sports College - aylesford.kent.sch.uk · neering machines include anything with a moving part within it. Early mechanical ... modern composite materials ... properties of carbon