_______________________

Name:
_
3.3.8 Tolerances
_______________________
Class:
_

_______________________
Date:
_

Time: 24 minutes

Marks: 24 marks

Comments:

Page 1 of 8
Q1.
Give two safety precautions that are necessary when using the following equipment.

(a)     Craft knife

Precaution 1 _______________________________________________________

Precaution 2 _______________________________________________________
(2)

(b)     Aerosol spray

Precaution 1 _______________________________________________________

Precaution 2 _______________________________________________________
(2)
(Total 4 marks)

Q2.
Describe two ways computers are used to ensure that manufactured products are always
the same.

1. _____________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(3)

2. _____________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(3)
(Total 6 marks)

Q3.
Quality is important in Product Design.

(a)     Describe a quality control test a manufacturer might use when manufacturing

Page 2 of 8
 products in large quantities.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(2)

(b)     Explain why manufacturers perform such tests.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(3)
(Total 5 marks)

Q4.
Explain the importance of tolerance when manufacturing components.

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(Total 4 marks)

Q5.
(a)     During the production of aprons, some are checked for faults.

Describe three faults that could be found in an apron.

Fault 1 _____________________________________________________________

___________________________________________________________________

Fault 2 _____________________________________________________________

___________________________________________________________________

Fault 3 _____________________________________________________________

Page 3 of 8
 ___________________________________________________________________
(3)

(b)     Give two reasons why it is important to make quality control checks.

Reason 1 __________________________________________________________

___________________________________________________________________

Reason 2 __________________________________________________________

___________________________________________________________________
(2)
(Total 5 marks)

Page 4 of 8
Mark schemes

Q1.
Craft knife.
Award 1 mark for each correct answer:

Using a cutting mat / self-healing mat

Using a safety rule (Maun)
Carry either on a cutting mat or blade down
Keep spare hand behind the craft knife
Cut away from yourself
Retractable blade or lid or lock
Do not accept gloves, metal rule, keeping hands away, don’ cut yourself.
2
Aerosol spray.
Award 1 mark for each correct answer:

Use a spray booth or well ventilated room

Use outside
Use away from a naked flame
Wear a mask
Use extractor
2
[4]

Q2.
Monitor automated manufacturing processes to identify components / products which do
not conform to preset standards / measurements and eject from process. Communication
between designers and manufacturing to quickly update designs when improvements
have been made. Greater accuracy in quantity manufacture using CAD / CAM. Less
human interface therefore less likelihood of errors. Repeat designs, copy and paste using
CAD CAM. Save and store designs for later use.

A concise and detailed response showing an understanding of quality processes

and the part computers play, with one point fully explained and another mentioned.
3 marks

A sound response showing a basic understanding of quality processes and the part
computers play, with one point briefly explained and another mentioned or two
points mentioned briefly.
2 marks

A simplistic statement which mentions one point only.

1 mark
2 × 3 marks
[6]

Q3.
(a)     E.g. quality control checks – selecting a product every so many made,
measurements against tolerance limits, testing for flammability, strength / load
failure, wear / durability tests, wash tests. Testing to ensure product performs to
users expectations, is safe in use.

A detailed response showing an understanding of quality control testing and

Page 5 of 8
 types of tests carried out.
2 marks

A simplistic statement which mentions one point only.

1 mark

(b)     Manufacturers perform QC tests to ensure the quality of their products and to

conform to quality standards such as BSI and CE. These give consumers
confidence and therefore help manufacturers to sell their products. Tests also
help manufacturers to minimise costs due to faulty products / materials /
components as they highlight problems early.

A concise and detailed response showing a good understanding of reasons for

QC with two or more points mentioned.
3 marks

A sound response showing a basic understanding of QC with one point

explained or two points mentioned briefly.
2 marks

A simplistic statement which mentions one point only.

1 mark
[5]

Q4.
Award one mark each for details relating to the importance of tolerance when
manufacturing components.

•        Very difficult to make a component exactly correct

•        Easier to make a component within tolerances
•        This is the maximum and minimum sizes a component can be
•        Manufacturer knows that if a product is within tolerances then it will work.
4 × 1 mark
[4]

Q5.
(a)     Pocket, ties, frill, apron wrong size, stitching in wrong place, coming undone, wrong
thread, bias binding or fabric, pocket in wrong position, frill incorrectly gathered,
stain / damage during production, fabric faults, fraying, loose threads, parts /
components missing from apron.

1 mark for every correct and different fault.

No to ‘not very good’, just ‘size’ or ‘stitching’ unless further explanation, to pins
in apron but accept broken needles.
Accept ‘size of apron / strap / pocket etc
(Max 3 marks)

(b)     To ensure quality assurance, product safety, fitness for purpose, apron won’t
fall apart, meets the standard, conforms to product description, consumer has
a right to expect a safe and functioning product, to check if there are any
faults.

1 mark for any correct answer.

No to waste of fabric and time, best quality.
Accept ‘to make sure apron is correct’.
(Max 2 marks)

Page 6 of 8
 [5]

Page 7 of 8
Examiner reports

Q1.
This question was generally answered well, although some responses were too generic to
give a mark. For example 'keep away from young children or don’t spray in your mouth'.

Q2.
Poorly answered by many. The better responses identified the uses of CAD and CAM and
how these can achieve reproducibility in manufacturing due to saving, storage and
accuracy achieved in the process.

Q3.
The majority of candidates appeared to have very limited knowledge of this topic.

(a)     Most candidates could name a quality control test but few described how it would be
carried out. Frequent answers referred to weight, durability and dimensional
checking.

(b)     Most answers were good – it was generally known why tests were carried out.

Q4.
The candidates’ knowledge of the term ‘tolerance’ when applied to the manufacturing of
components was lacking. Few candidates gained marks on this question. Many incorrectly
referred to ‘taking your time’ and ‘being patient’.

Q5.
(a)     Candidates had prepared well for this question and could give a range of different
possible faults.

(b)     The second part of the question was more challenging and those that referred to
quality assurance demonstrated a greater subject knowledge and generally gained
higher marks.

Page 8 of 8