Manufacturing in Quantity

This is a skills-based project, enabling students to apply an iterative design approach when designing and manufacturing in quantity, and highlighting the importance of quality control throughout the process

Manufacturing in Quantity

This is a skills-based project, enabling students to apply an iterative design approach when designing and manufacturing  in quantity, and highlighting the importance of quality control throughout the process.

The teaching resources were created from the pilot project delivered to Year 9 students at ACE Academy and supported by Alucast.  They are designed to support teachers who may not have previous experience in this topic and are readily adaptable to suit other year groups.

Project Description

Students  design and make a product that comprises several modular components which are batch-produced using a metal casting process.  Simulating industrial metal casting procedures, the project focuses upon the quality control requirements when manufacturing in quantity and translates these into a classroom environment.  With particular attention to the design and manufacture of the mould, this project allows students to approach the development of the mould through an iterative design process, requiring the production of several mould designs and casts in order to ‘perfect’ the casting process and the end product. Students review what they have learned throughout the project, culminating in a final presentation about their journey and key skills.

Key skills: manufacturing in quantity; quality control procedures; iterative design processes; problem-solving; independent enquiry; self-management.

Course Overview

The project is split into 7 learning activities that cover approximately 18 hours of teaching. Each learning activity comprises a detailed learning outline, to be viewed as a guide, and a range of support resources comprising word documents, PowerPoint presentations, video clips and more to help you work through the complete project.

You can download an overview of the project first or access the whole project, which includes the overview and all learning activities. Alternatively you can download the overview, followed by each learning activity module individually below.

NOTE: Please be aware that some folders are large and may take some time to download.

Download the overview document and the whole project from the related files below.

You can download individual modules separately

  • Module 1: Casting in Industry.

    By exploring the concept of quality control and assurance, students design a quality control procedure into the manufacturing process.

    Time: 2 hours
    Key Material: Learning activity 4.1; ppt; support material folder

  • Module2: An iterative design approach.

    Students examine problems that have occurred with mould designs, exploring design requirements for a quality mould through an iterative design process.

    Time: 2 hours
    Key Material: stand-alone learning activity on modular design; ppt and videos

  • Module 3: Product Development.

    Students develop their CAD/CAM skills (2D Design and laser), testing and developing the solutions using an iterative design approach to development.

    Time: 3-4 hours
    Key Material: CAD/CAM information document; ppt; 2D Design and image folder

  • Module 4: Quality control procedures.

    By exploring the concept of quality control and assurance, students design a quality control procedure into the manufacturing process.

    Time: 2 hours
    Key Material: Learning activity 4.1; ppt; support material folder

  • Module 5: Batch Production.

    Students ensure quality in manufacture using a QA/QC approach based upon an industrial (Alucast) model.

    Time: 4 hours / half-day
    Key Material: ppt

  • Module 6: Product production.

    Working as a team and planning tasks, student teams construct their table centre-piece ready for presentation to client.

    Time: 2 hours
    Key Material: action planning pro-forma; ppt; video clip; examples of students' work

  • Module 7: Evaluating the learning.

    Students present their reflections on the project and key skills' focus, identifying what they have learned and areas for future development.

    Time: 2 hours
    Key Material: ppt; example of student presentation

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