Manufacturing Prototype

1
Manufacturing Prototype

• How do all the aspects of manufacturing come
  together to make a final product?

2
Manufacturing the Big Picture

• Essential Question
• What role does each part of manufacturing play in
  the final manufacturing process?

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Manufacturing Prototype

• You have been contracted by your local TSA
  chapter to produce a product for this years
  Manufacturing Prototype event.
• Revisit the steps of the manufacturing process to
  create a production plan for a product you
  design.
• You should keep notes of each step in your design
  notebook. You will transfer your notes to
  PowerPoint to communicate your design.

4
The Design PROCESS

• The following is an outline of the process and
  steps you should complete.

5
The Design Process

• Define the Problem
• Research the Problem
• Develop Possible Solutions
• Choose the Best Solution
• Create a Prototype
• Test and Evaluate
• Communicate
• Redesign

6
Define the Problem

• Define the problem and list criteria and
  constraints

7
Research the Problem

• Conduct research on the problem including
• What products currently exist in this area?
• What is the cost of products that currently
  exist?
• What materials can be used?
• Ergonomic factors?
• Safety factors?

8
Research your Customer Needs

• Sample Questions
• Who would purchase the product?
• What is the age range of potential customers?
• Like and dislikes of potential customers?
• What do they want from your product?
• What factors would sway them to or away from your
  product?
• What cost would they be willing to pay?
• Create a survey or data sheet and record your
  results in your design notebook.

9
Develop Possible Solutions

• Create 8 solution concepts write a detailed
  description of each solution
• Complete thumbnail sketches of at least 4
  designs.

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Choose the Best Solution

• Using the format to the right, answer the
  following questions
• Does it meet each of your criteria?
• Ergonomics
• Materials
• Aesthetics
• Construction Method
• Health and Safety
• Environmental
• Other

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Create a Prototype

• Create a technical drawing using CAD software of
  your chosen solution. (use color to match your
  design)
• Create a prototype using the materials given and
  any materials you bring from home.

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Test and Evaluate

• Evaluate your solution using the format below

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Communicate

• You should prepare a PowerPoint presentation of
  your design process steps and information.
• Each team will present their presentation to the
  class.

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Redesign

• Using information and feedback from the class
  what do you need to redesign?
• Make any modifications in your design.
• Changes to technical drawing
• Changes to materials

15
The Financial Cost

• The following is an outline of the process and
  steps you should complete.

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The Financial Cost

• Using your prototype and the internet, research
  your materials and figure the cost to manufacture
  your item.
• How much is one product?
• How much are 30 products?
• Where can you purchase the materials most
  economically? (remember shipping costs)
• Prepare a summary report of your findings to
  present to the class. Add this report to your
  PowerPoint presentation.

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Production Planning

• The following is an outline of the process and
  steps you should complete.

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Production Planning - Tooling

• Create the following chart in your design
  notebook
• Part of Product list each part of your game
• Material what materials is each part made from
• Tool Needed what tool will you use to create
  that part
• Tooling Needed we will be learning about this
• Create technical drawing and specifications of
  any tooling that needs to be built.

Part of Product Material Tool Needed Tooling Needed


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Production Planning Facility

• Create a flow process chart like the one below
  for each part.

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Production Planning Facility
PLASTIC CLIP
1. Cut to width
2. Cut to length
3. Drill holes
4. Round corners
5. Assemble to clip
Create an operation process chart for your entire
production map.
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Production Planning

• Add your production planning information to your
  PowerPoint Presentation to present to the class.

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Quality Control

• The following is an outline of the process and
  steps you should complete.

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Quality Control

• Answer the following questions
• Where will you use quality control?
• What methods will you use for your quality
  control?
• Add your quality control to your PowerPoint
  Presentation to present to the class.

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Taking it Further - Adding a Logo

• The following is an outline of the process and
  steps you should complete.

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Logo Design

• Basic rules for a successful logo
• Simple in design
• Easy to understand, even at a distance
• One or two colors are normally used
• Writing is simple and easy to read
• A simple drawing or symbol is sometimes used.

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Logos

• Simple pictures can be altered easily to make
  logos.

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Logos

• Create a mockup design of 3 different logo
  choices for your product and put them in your
  design notebook.
• Add these designs to your PowerPoint presentation.

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Taking it Further - Packaging

• The following is an outline of the process and
  steps you should complete.

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Packaging

• Purpose of packaging
• Protect a product from damage or contamination by
  micro-organisms and air, moisture, and toxins.
• To keep the product together, to contain it.
• To identify the product.
• Protection during transport and ease of
  transport.
• Stacking and storage.

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Packaging Symbols

• Polythene Terephthalate (PET) is used for widely
  packaging, especially for dink containers. It is
  90 recyclable and the symbol reminds the
  consumer to recycle the container.
• International recycle symbol to remind the
  consumer to recycle the packaging.
• Material is recyclable and made from aluminum.
  Look at drink cans and you may find this symbol.
  
• Store package upright

• Card packaging materials used to make package
  were harvested in sustainable forests. Trees are
  managed and replaced when cut down.
• Contents are fragile
• Professional quality control and precision is
  used in manufacturing
• Do not store package in damp conditions
• Store at a particular temperature

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Environmental Issues with Packaging

• Waste ensure minimum waste of materials and if
  possible no waste.
• Why
• wasted materials wasted money
• Helps conserve the environment
• Less energy is needed to run machines
• Recycle as much waste as possible to save the
  environment and money

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Manufacturing Packaging

• Use a straight edge to draw the lines of the
  packaging
• Use design software to design the packaging
  appearance and attach it
• Use a craft knife and straight edge to cut each
  of the outside pencil lines and score each of the
  inside lines.
• Use a ruler to help fold the package into its
  shape

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Example Self Locking Package

• Folds and holds its shape without glue

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Example Hexagonal Packages

• The top folds and locks into place. The bottom
  has a number of tabs that must be glued.

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Example Box with Handles

• Handles are part of the packaging

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Example Gift Box Small Scale
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Logos

• Using the packaging concepts we have discussed.
  create your own packaging for your product.
• You will need the following
• Template for packaging
• Packaging outside logos and design
• Write a rational for why you choose this type of
  packaging.
• Include all of these items in your design
  notebook.
• Add these designs to your PowerPoint presentation.

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Review of the Problem

• Did you know your problem?

39
Manufacturing Prototype

• You have been contracted by your local TSA
  chapter to produce a product for this years
  Manufacturing Prototype event.
• Revisit the steps of the manufacturing process to
  create a production plan for a product you
  design.
• You should keep notes of each step in your design
  notebook. You will transfer your notes to
  PowerPoint to communicate your design.

40

• Grading Rubric