Explain the hierarchy of control for reducing risk.

The most effective control is to eliminate the hazard, then to substitute something safer. Guards and other engineering controls come next, followed by safe systems of work and, last, PPE.

Why is PPE described as the last line of defence?

PPE protects only the wearer, and only if it fits and is worn correctly. A hazard that is removed or guarded protects everyone and does not depend on behaviour.

What are the main risks when turning metal on a centre lathe, and how are they minimised?

The main dangers are entanglement, flying swarf and a chuck key left in the chuck. Guards, eye protection, tied-back hair and a self-ejecting chuck key reduce them.

CCEA A-Level Technology and Design 8900

Material Selection and Wood

Topic overview Material selection criteria Physical and mechanical properties Hardwoods, softwoods and timber stock sizes Pine, ash, beech, oak and mahogany Manufactured boards Wood finishes, veneers and laminates

Metals

Topic overview Ferrous and non-ferrous metals and alloys Metal stock forms and sizes Aluminium, copper, brass and zinc Carbon steels and stainless steel Finishes for metals

Plastics

Topic overview Thermoplastics and thermosetting plastics HDPE, LDPE and PET Polystyrene and PVC Acrylic, nylon and ABS Melamine-formaldehyde and epoxy resins

Composite and Emerging Materials

Topic overview Thermochromic and photochromic materials Phosphorescent pigments, reflective films and holograms Liquid crystal displays PEEK, PPSU and graphene

Processing Materials

Topic overview Wasting with hand tools Manual and CNC machine tools Rolling, blanking, press forming and forging Injection and blow moulding Rotational moulding and vacuum forming Sand casting, die casting and extrusion

Product Analysis and Design Communication

Topic overview Form, function, performance and aesthetics Cost, materials, manufacture and environmental issues Target audience, anthropometrics, culture and safety Design briefs, research and specifications Creativity, innovation and sustainability in design Freehand sketching and mixed media

Design for Manufacture, Quality and Safety

Topic overview CAD modelling, virtual imaging and rapid prototyping CAM and CIM Factor of safety and tolerances Testing and inspection of products Risks in workshop and manufacturing processes

Electronic Control SystemsOption A

Topic overview Control systems, feedback and electronics safety Resistors, Ohm's law and power ratings Capacitors and RC timing Potential dividers, sensors and comparators Switches, pull-up and pull-down resistors Output devices and LEDs Transistors, Darlington pairs and thyristors Logic gates, truth tables and flip-flops 555 monostable and astable timers

Microelectronic Control SystemsOption A

Topic overview Microcontroller systems, ADCs and DACs Strain gauges and bridge circuits Optical switches, encoded discs and Schmitt triggers Op-amp amplifiers and gain Zener diodes and voltage regulators Karnaugh maps and binary counters Seven-segment, LCD and dot matrix displays PIC flowcharts and programming DC motors, stepper motors and driver circuits

Mechanical and Pneumatic ComponentsOption B

Topic overview Open and closed loop mechanical and pneumatic control Safe working with compressed air and mechanisms Levers, linkages and moments Gear types and gear trains Pulleys, belts, chains and shaft fixings Cams, cranks and converting motion Compressed air supply and pneumatic valves Cylinders, shuttle valves, restrictors and reservoirs Pneumatic circuits for logic, timing and speed control

Mechanical and Pneumatic SystemsOption B

Topic overview Hydraulics, system limitations and plant safety Torque, work, power and air consumption Vacuum handling, proximity sensors and 5/3 valves Sequential and cascade pneumatic circuits Cam profiles and follower displacement diagrams Gear geometry, pulley blocks and ratchets Toggles, treadles, shafts and couplings Friction, brakes and clutches Bearings, lubrication and seals

Designing and Manufacturing ProductsOption C

Topic overview Research, questionnaires and specifications Idea generation, critiques and computer simulation Manufacturing planning and product evaluation CFRP, GRP, Kevlar and tungsten carbide Smart materials, nanotechnology and biophotovoltaics Isometric, perspective and assembly drawing Laminating, steam bending, cutting and printing processes Risk assessment and product safety law Scales of production, JIT and cell production Quality assurance, ISO 9001 and continuous improvement Design influences and intellectual property rights

Product Design in Industry and SocietyOption C

Topic overview Life-cycle environmental impact and climate change The 6Rs, waste and environmental legislation Sustainable metals, plastics and degradable polymers Product life cycles, consumer types and relaunches CAD, CAM, 3D scanning and quick-change moulding Market pull, technology push and market strategy Price, place and promotion Jigs, fixtures and ICT in quality control Design for maintenance, inclusion and scale production Rendering, typography and presentation Dyson, Baylis, Memphis and Apple

Product Development

Topic overview Choosing a product to redesign Analysing the function and fitness for purpose of existing products Materials, manufacture and sustainability of existing products Ergonomic and aesthetic analysis Redesign modifications, sketching and viability Modelling, testing and evaluating a redesign

Product and System Design and Manufacture

Topic overview Clients, end users and design briefs Researching existing solutions and writing a specification Generating and appraising design proposals Developing a concept with numerical analysis, ergonomics and aesthetics Working drawings and planning manufacture Testing and evaluating a prototype

Design for Manufacture, Quality and Safety

Risks in workshop and manufacturing processes

3 things to know
AS 1 Paper 1

Overview

Hazard and risk, health and safety law in Northern Ireland, COSHH, the hierarchy of control and PPE, and the risks of lathes, drills, chisels, dust, laser cutting, casting, soldering and presses.

What you need to know

Answer each one before you reveal it.

Your recallNot started

Key term

What is the difference between a hazard and a risk?

Numbers

Which law places health and safety duties on employers and employees in Northern Ireland?

Key term

What do the COSHH regulations require of an employer?

Questions from this subtopic

Each one with the model answer underneath.

1
What is the difference between a hazard and a risk?
Model answer
A hazard is anything with the potential to cause harm, such as a rotating chuck. Risk is the likelihood that the harm will occur, combined with how severe it would be.
2
Which law places health and safety duties on employers and employees in Northern Ireland?
Model answer
The Health and Safety at Work (Northern Ireland) Order 1978 sets these duties. The equivalent law in Great Britain is the Health and Safety at Work etc. Act 1974.
3
What do the COSHH regulations require of an employer?
Model answer
COSHH regulations require hazardous substances, such as solvents, resins and wood dust, to be assessed and controlled. Exposure must be prevented or kept to a safe level.
4
Explain the hierarchy of control for reducing risk.
Model answer
The most effective control is to eliminate the hazard, then to substitute something safer. Guards and other engineering controls come next, followed by safe systems of work and, last, PPE.
5
Why is PPE described as the last line of defence?
Model answer
PPE protects only the wearer, and only if it fits and is worn correctly. A hazard that is removed or guarded protects everyone and does not depend on behaviour.
6
What are the main risks when turning metal on a centre lathe, and how are they minimised?
Model answer
The main dangers are entanglement, flying swarf and a chuck key left in the chuck. Guards, eye protection, tied-back hair and a self-ejecting chuck key reduce them.

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Material Selection and Wood

Metals

Plastics

Composite and Emerging Materials

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The output voltage is V.

356

Blank Blitz consolidates the facts

Rapid timed gap-fills on the terms and numbers you need to recall without thinking.

AThe total resistance is 2 kΩ.

BThe parallel pair gives (2 × 2) ÷ (2 + 2) = 1 kΩ.

CThe series resistor adds another 1 kΩ.

Build It trains answer structure

Assemble a full-mark answer from its marking points, in the order an examiner wants them.

Hazard means anything with the potential to cause harm.

TrueFalse

Test It catches misconceptions

Spot the fault in a statement. The traps are the mistakes students actually make.

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