A redesign cuts the material cost of a product from £3.20 to £2.72 per unit. How much is saved on a run of 50,000 units?

The redesign saves £24,000 on the run. The working is (£3.20 − £2.72) × 50,000 = £0.48 × 50,000 = £24,000.

A product costs £26 to make and sells to a retailer for £40. What is the profit as a percentage of the selling price?

The profit is 35% of the selling price. The working is (£40 − £26) ÷ £40 × 100 = £14 ÷ £40 × 100 = 35%.

How can changing the manufacturing process improve an existing product?

A better-matched process can cut cost, improve accuracy or allow a new form. A single die casting can replace a welded steel bracket, removing welding and finishing stages.

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

Product Analysis and Design Communication

Cost, materials, manufacture and environmental issues

3 things to know
AS 1 Paper 1

Overview

The elements of manufacturing cost, part reduction and standard components, cost and profit calculations, process and material changes, transport, resin codes and hazardous substances.

What you need to know

Answer each one before you reveal it.

Your recallNot started

Key term

What elements make up the cost of manufacturing a product?

Key term

How can reducing the number of parts in a product lower its cost?

Key term

Why do designers specify standard components, such as stock screws and bearings, in a redesign?

Questions from this subtopic

Each one with the model answer underneath.

1
What elements make up the cost of manufacturing a product?
Model answer
Manufacturing cost includes materials, labour, energy, tooling and overheads such as factory rent. The retailer’s margin, packaging and transport add to the final selling price.
2
How can reducing the number of parts in a product lower its cost?
Model answer
Fewer parts mean less assembly time, fewer fixings and fewer tools to make and maintain. A single moulding with integral clips can replace several parts and screws.
3
Why do designers specify standard components, such as stock screws and bearings, in a redesign?
Model answer
Standard components are made in huge numbers, so they are cheap and readily available. Stock parts also make repair easier because replacements are easy to find.
4
A redesign cuts the material cost of a product from £3.20 to £2.72 per unit. How much is saved on a run of 50,000 units?
Model answer
The redesign saves £24,000 on the run. The working is (£3.20 − £2.72) × 50,000 = £0.48 × 50,000 = £24,000.
5
A product costs £26 to make and sells to a retailer for £40. What is the profit as a percentage of the selling price?
Model answer
The profit is 35% of the selling price. The working is (£40 − £26) ÷ £40 × 100 = £14 ÷ £40 × 100 = 35%.
6
How can changing the manufacturing process improve an existing product?
Model answer
A better-matched process can cut cost, improve accuracy or allow a new form. A single die casting can replace a welded steel bracket, removing welding and finishing stages.

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Material Selection and Wood

Metals

Plastics

Composite and Emerging Materials

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