Year 10 Industrial Products - The Bottle-Opener Project


The Task

A local gift shop wishes to stock quality pieces of merchandise based upon a theme. You are required to design and make a mild steel bottle opener to sell in the shop. You are to consider that the bottle opener may be mass-produced.

Requirements

1. You must analyse a variety of bottle openers and comment on;
· The way in which they were made.
· The materials used.
· The shape.
· The finish.
· The type of people that may buy them.
2. To make an accurate perspex/card template of the bottle opener before shaping the mild steel.
3. To accurately mark out, cut and make a bottle opener out of mild steel.
4. To test and evaluate your product. You will need to find out other people's thoughts about your finished bottle opener.

You will learn the following skills;
· How to accurately mark out and the use of wastage.
· Chain drilling.
· Dot punching.
· Edge treatment(use of buffing machine)
· The use of engineer's blue, scribers and centre punches.
· How to accurately cut and shape mild steel.
· How to apply a variety of finishes e.g. paint, plastic coating and lacquer,
· How to use brazing techniques.
· Turning skills on the centre lathe.

Programmes Of Study References

1c To design for manufacturing in quantity;
3f To determine the degree of accuracy required for the product to function as planned, taking account of critical dimensions and tolerances in determining methods of manufacture;
3l To ensure that the quality of their products is suitable for intended users.
4b To use tools and equipment accurately and efficiently to achieve an appropriate fit and finish and reliable functioning in products that match the specification;
4d The difference between quality control and quality assurance;
4e How products are manufactured in quantity, including the application of quality control and assurance techniques;
4k To apply and devise test procedures to check the quality of their work at critical points during development, and to indicate ways of improving it;
4l To ensure through testing, modification and evaluation, that the quality of their products is suitable for intended users.
5a How materials are cut, shaped and formed to designated tolerances;
5c How materials are prepared for manufacturing, allowing for waste and fine line finishing;
5d About a variety of self-finishing and applied finishing processes, and to appreciate their importance
For aesthetics and functional reasons;
Product analysis
7a The intended purpose of the product;
7b The components available for use in the product;
7c The choice of materials and components and the way in which they have been used;
7d The process used to produce them;
7e The application of scientific principles;
7f The market for which the product is intended;
7g The range of alternative products and solutions.
Quality
Pupils should be taught to distinguish between the quality of design and quality of manufacture, and use further criteria and techniques that help them judge the quality of a product including:
8a How far it meets a clear need;
8b Its fitness for the purpose;
8c Whether it is an appropriate use of resources;

Technical Knowledge and Understanding

Processes and Equipment needed

· Accurate cutting and wastage(chain drilling and filing)(dot punching, edge treatment, buffing mops)
· Accurate marking out techniques( use of engineers blue, scribers, marking gauge
· Application of finishes(paint, plastic coating, lacquer)
· Use of brazing techniques and lathe if required.
Tools and Equipment Needed
· Pillar Drill and drill bits and hand vices
· Hand files
· Engineers blue, scribers, centre punches
· Hack saws, junior hacksaws
· Metal vices
· Buffing wheels
· Brazing hearth, brazing rod, flux
· Centre lathe and cutting tools
· Fluidising bath(plastic coating)
· Mild steel plate and Hammerite paint

Using Mathematics

· Geometry, how to mark centres of bars, constructing radii, Accurate marking out.

Using I.T

· Draw package to create an accurate working drawing of the bottle opener.
· Isometric Drawing of the bottle opener.
· Questionnaire to create market research.

Using Science

· Properties of metals( ferrous and non-ferrous metals)

Using Other Subjects

· Art- sketching, rendering

Using Economic And Industrial Understanding

· Mass production, quality control and quality assurance. Product analysis.

Year 10 - Engineering Bottle Opener

The Task
To analyse a variety of bottle openers. To design and make a mild steel bottle opener. To consider how the bottle opener would be made in school and in industry( mass production). Pupils are required to make a perspex template before making the mild steel bottle opener.

Setting The Task
A local gift shop wishes to stock quality pieces of merchandise based upon a theme. You are required to design and make a mild steel bottle opener to sell in the shop. You are to consider that the bottle opener will be mass-produced.

Main Aims
1. To be able to analyse a variety of products, considering manufacture, finish aesthetics and ergonomics.
2. To design for manufacturing in quantity and to make a quality steel product using wasting and edge treatment techniques.
3. To understand the importance of accurate templates and accurate marking out techniques.
4. To learn of a variety of surface treatments.
5. To be able to evaluate a product based upon their own specifications and to understand the difference between quality control and quality assurance.

Values
Technical
· Product analysis Economics
· Cutting, forming and wastage. The economics of selling one
· Designing for mass production off products as opposed to
· Importance of templates mass produced items.
· Quality control and quality assurance. Market research.
· Evaluation, testing techniques.
· The need for accuracy of marking outs and manufacture.

The Nature Of The Product
· Each pupil will analyse a set of similar products and research similar products. They will comment on the manufacturing techniques, finish, aesthetics, price and size.
· Each pupil will design and make a mild steel bottle opener using a variety of techniques.
· Each pupil will make a perspex template.
· Each pupil will test and evaluate the product.
· Each pupil will learn of mass production, quality control and quality assurance.