IB Design Technology 4.5 Production Systems Notes

Types of Production Systems

1. Each production system has its own components, advantages, and challenges.
2. Understanding these factors helps designers and manufacturers optimize cost, efficiency, and quality.

1. Craft Production (Handmade, Skilled Labor)

1. What It Is:
   1. Small-scale production based on manual skills and craftsmanship.
   2. Often used for custom furniture, pottery, jewelry, and luxury items.
   3. Common in pre-industrial societies, now associated with high-end, unique goods.
2. Advantages:
   1. Highly customizable to client needs.
   2. Products have higher perceived value.
3. Disadvantages:
   1. Slow production speed, not scalable.
   2. Higher costs due to skilled labor.
4. Environmental Impact:
   1. Uses high-quality materials in lower quantities, reducing waste.
5. Workforce Impact:
   1. Requires long training and expertise.
   2. Craftspeople manage everything, from production to marketing.

2. Mechanized Production (Machines Controlled by Humans)

1. What It Is:
   1. Machines assist workers in production, increasing efficiency.
   2. Common in automobiles, furniture, and electronics.
2. Advantages:
   1. Increased productivity and consistency.
   2. Reduces human error, improving quality.
3. Disadvantages:
   1. Training costs for workers using machinery.
   2. Less customization, reducing consumer choice.
4. Environmental Impact:
   1. Increased energy use and pollution from machines.
5. Workforce Impact:
   1. Workers need higher training.
   2. Repetitive tasks reduce job satisfaction.

3. Automated Production (Computer-Controlled Machines)

1. What It Is:
   1. Machines are controlled by computers, not humans.
   2. Uses CAD (Computer-Aided Design) and CAM (Computer-Aided Manufacturing).
2. Advantages:
   1. 24/7 production increases efficiency.
   2. Higher precision, reducing errors.
3. Disadvantages:
   1. High investment costs for machines.
   2. Only profitable at large production scales.
4. Environmental Impact:
   1. Less waste due to precision manufacturing.
5. Workforce Impact:
   1. Lower labor costs but requires highly skilled workers.
   2. Improved safety, as fewer humans operate machines.

4. Assembly Line Production (Step-by-Step Manufacturing)

1. What It Is:
   1. Products move along a conveyor belt, with workers or robots adding parts step by step.
   2. Used for mass production of cars, electronics, and appliances.
2. Advantages:
   1. High efficiency and low production costs.
   2. Economies of scale make products more affordable.
3. Disadvantages:
   1. No room for customization.
   2. Relies on timely part delivery—delays can shut down production.
4. Environmental Impact:
   1. Higher pollution levels due to high production rates.
5. Workforce Impact:
   1. Repetitive tasks increase injury risks.
   2. Lower job satisfaction.

5. Mass Production (Large-Scale Standardized Production)

1. What It Is:
   1. Producing thousands or millions of identical products.
   2. Highly mechanized, used in global manufacturing.
2. Advantages:
   1. Low cost per unit.
   2. Highly efficient.
3. Disadvantages:
   1. No customization options.
   2. High energy consumption.
4. Environmental Impact:
   1. Increased waste and pollution.
5. Workforce Impact:
   1. Fewer workers needed, but job opportunities shift to machine maintenance.

6. Mass Customization (Personalized Mass Production)

1. What It Is:
   1. Mixes mass production with consumer customization.
   2. Uses CNC (Computer Numerical Control) and AI-driven manufacturing.
2. Advantages:
   1. Personalized without high costs.
   2. Shorter product development cycles.
3. Disadvantages:
   1. Short product life cycle—trends change quickly.
   2. Requires advanced logistics to handle custom orders.
4. Environmental Impact:
   1. Less waste since items are made to order.
5. Workforce Impact:
   1. Workers need tech training to handle digital manufacturing.

7. Computer Numerical Control (CNC) (Precision Machining)

1. What It Is:
   1. Machines use G-code to cut, shape, and drill materials.
   2. Works with metals, plastics, and composites.
2. Advantages:
   1. High precision and efficiency.
   2. Customizable to specific needs and materials.
3. Disadvantages:
   1. Expensive equipment and training.
   2. Energy-intensive.
4. Environmental Impact:
   1. Less material waste due to optimized cutting.
5. Workforce Impact:
   1. Higher skills required to operate CNC machines.