Scales of Production
GCSE — 2.1.2 In-depth Knowledge: Product Design
Scales of production
One-off production
Single products made as prototypes, concepts or bespoke custom-made items.
| Advantage | Disadvantage |
|---|---|
| The user will have an original product unlike any other | Lots of manual labour — no production line set up for one product |
Batch production
Products made in limited numbers at any one time, although this may be repeated.
| Advantage | Disadvantage |
|---|---|
| Small numbers of similar items made at one time to satisfy demand | There may be a delay until the next batch is produced |
Mass production
Identical products made in large volume (normally thousands), with automated machinery for accuracy, efficiency and identical outcomes.
| Advantage | Disadvantage |
|---|---|
| More profit — materials bought in bulk, automated machinery needs fewer workers | Initial set-up costs are high; not much flexibility once production line is set up |
Continuous flow production
Identical products constantly being produced 24 hours a day, 7 days a week, with heavily automated production lines.
| Advantage | Disadvantage |
|---|---|
| Huge numbers produced identically, efficiently and quickly — saving time, energy and labour | One single fault can stop the entire production process and be very costly |
Jigs and repeating activities
Manufacturers use devices to ensure accuracy and consistency when repeating processes:
- Jig — a device used to hold or secure material and guide cutting or drilling tools to ensure accuracy and repeatability
- Pattern — a shape attached to the surface of the material to help shape it
- Template — a tool for marking out a shape repeatedly so it is exactly the same each time
Computer aided manufacture (CAM)
CAM machines are controlled by a computer and offer many benefits:
- Faster than working by hand
- Far more accurate and precise than manual workers
- Repeat tasks consistently and identically
- Support production by making difficult components while others are produced simultaneously
- Produce multiple items in one go
- Save material and reduce waste
- Work without supervision
Producing products using polymers
| Process | Description |
|---|---|
| Blow moulding | A soft plastic tube is inflated to fill a cavity — used for forming bottles |
| Vacuum forming | A sheet of HIPS or acrylic is heated then pulled over a mould by extracting air using a vacuum |
| Press moulding | Polymer sheets are heated, placed over a mould and pressed down to take the shape |
| Compression moulding | Polymer placed into a heated mould cavity, mould closed with a plug and compressed with a hydraulic press |
Producing products in papers, cards and boards
| Process | Description |
|---|---|
| Pre-press printing | Creates a print layout; transforms electronic files onto paper |
| On-press printing | A plate is covered in ink; paper is pressed against the plate then released |
| Die cutting | Metal cutters stamp out the desired shape from the material (like cookie cutters) |
| UV varnishing | Ultraviolet varnish creates a vivid, luxurious or tactile finish on parts of a design |
| Embossing | Stamping a feature into card/paper to raise it above the surface |
| Debossing | Same as embossing but the feature is below the surface |
| Laminating | Adding layers to card or board to protect items packaged inside |
Books, leaflets and magazines can be printed and bound in different ways. Leaflets can be printed and folded into a smaller form. Booklets are several pages bound, bonded or stitched together.