_______________________

Name:
_
3.3.9 Material management
_______________________
Class:
_

_______________________
Date:
_

Time: 86 minutes

Marks: 75 marks

Comments:

Page 1 of 26
 Q1.
You are making one tent as shown in the picture.

(a)    Assume no material is wasted when cutting and that the material used will be
purchased to the nearest full metre.

Cotton is sold by the metre length. The width of the materials is fixed but it can be
cut at different lengths.
 
Stock form

Cost per
Material Roll width
linear metre

Cotton 5 metres £18

The table below shows the sizes of the material pieces to make one tent.
 
Cotton fabric required for one tent

Part Pieces
Length (m) Width (m)
description required

Tent roof 1 3.0 2.0

Tent front 1 1.8 1.5

Tent back 1 1.8 1.5

Tent sides 2 2.0 0.5

Using the diagram below, show the position of each piece of the tent using the least
amount of material as possible.

Do not include the groundsheet in your drawing.

The position of the front of the tent has been drawn to help you.

Page 2 of 26
  
(5)

(b)    You find that 1.95 m2 of the piece you have to buy is not actually used.

Calculate how much material is not used as a percentage.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(2)
(Total 7 marks)

Q2.
Using the diagram below, calculate the height of the tent poles required.

Page 3 of 26
  
* Diagram not drawn to scale

Use the space below to show your calculation and working.

You may use either trigonometry or drawing in your answer.

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_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

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Page 4 of 26
  
(Total 4 marks)

Q3.
(a)     When packaging is cut out ‘nesting’ is used to ensure that minimal material is
wasted.

A piece of material measures 60mm by 40mm. A triangle pattern measures 18mm

(height) by 18mm (base).

The first triangle has been placed on the material. Repeat the triangle pattern to
ensure that as many as possible fit on the material.

Page 5 of 26
  
(1)

(b)     Calculate the amount of material wasted when producing the shapes you have
drawn in question (a).

Assume no material is wasted when cutting.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(3)
(Total 4 marks)

Q4.
When manufacturing in batches the following aids can be helpful.
 
Templates Jigs Moulds Formers Dies

Choose three of the aids given above. Use notes and / or sketches to explain their use.
 
Manufacturing aid choice:

Page 6 of 26
 Explanation:

Manufacturing aid choice:

Explanation:

Manufacturing aid choice:

Explanation:

(Total 9 marks)

Q5.
Explain why many products are manufactured in mass production using Computer Aided
Manufacture (CAM).

Page 7 of 26
 Give examples of products to explain your answer.

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(Total 8 marks)

Q6.
Describe two ways computers are used to ensure that manufactured products are always
the same.

1. _____________________________________________________________________

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_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(3)

2. _____________________________________________________________________

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Page 8 of 26
 _______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________
(3)
(Total 6 marks)

Q7.
Quality is important in Product Design.

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

products in large quantities.

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________

___________________________________________________________________
(2)

(b)     Explain why manufacturers perform such tests.

___________________________________________________________________

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___________________________________________________________________
(3)
(Total 5 marks)

Q8.
Two designs for a sports trophy are shown below.

Both of them could be made in a school workshop.

Choose one of the sports trophies and tick the appropriate box. You will be asked how
you would make a batch of ten of your chosen sports trophies.
 

Plastic sports trophy with wooden base

Metal sports trophy with wooden base

Page 9 of 26
 Wooden sports trophy with wooden base

 
A plastic or metal sports trophy     A wooden sports trophy
 
with wooden base          with wooden base

Use clear notes and sketches to show how you would make a batch of ten of your chosen
sports trophies in a school workshop.

At each stage, name all the tools, equipment or software you would use.
 
Stage 1: Marking out or CAD (Computer Aided Design)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 2: Cutting and shaping or CAM (Computer Aided Manufacture)
 
 
 
 
 

Page 10 of 26
  
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 3: Bending or joining
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 4: Applying the surface finish
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(2)

Page 11 of 26
 
Stage 5: Producing the text that says ‘1st’
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(2)
(Total 16 marks)

Q9.
Two designs for a kitchen roll holder are shown below.
Both of them could be made in a school workshop.

Choose one of the kitchen roll holders and tick the appropriate box.
 
Plastic kitchen roll holder

Metal kitchen roll holder

Wooden kitchen roll holder

A plastic or metal kitchen roll holder                A wooden kitchen roll holder

Use clear notes and sketches to show how you would make a batch of ten of your chosen

Page 12 of 26
 kitchen roll holders in a school workshop.

At each stage, name all the tools, equipment or software you would use.
 
Stage 1: Marking out or CAD (Computer Aided Design)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 2: Cutting and shaping or CAM (Computer Aided Manufacture)
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(4)
 
Stage 3: Bending or joining
 
 
 
 
 
 
 
 
 

Page 13 of 26
  
 
 
 
 
 
 
 
(4)
 
Stage 4: Applying the surface finish
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(2)
 
Stage 5: Producing the ‘kitchen roll’ text
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(2)
(Total 16 marks)

Page 14 of 26
Mark schemes

Q1.
(a)    1 mark for correct number of parts drawn.

1 mark for positioning of the pieces with least possible waste.

1 mark for correct use of scale and proportions.

1 mark for showing that 15 square metres / 3 full metres of fabric will be required per
tent.

1 mark for indication of no waste when cutting i.e. touching parts of the product
when cutting.

 
5

(b)    1 mark for the correct subtraction of area required for tent pieces from total area
available on a 4 metre long piece of fabric. 1 mark for correct percentage waste to
two decimal places.

Calculation

Step 1:
3 x 5 = 15 square metres for minimum quantity of material required

Step 2:
inserting of total fabric area and waste area into formula 1.95 / 15 x 100 = 13.066

Step 3:
percentage waste to two decimal places is 13.07%

NB if a student has assumed a value other than 15 square metres but calculated the

Page 15 of 26
 correct percentage of waste using the waste value provided in the question do not
double penalise and award full credit.
2
[7]

Q2.
Students may respond:

•   By calculating the height of the tent poles using trigonometry

•   By drawing out the required height of the tent pole graphically.

Trigonometry:

1 mark for use of tangent formula:

e.g. tan A = opposite / adjacent.

1 mark for correct substitution of values:

eg tan 30 degrees = 0.75 / adjacent.

1 mark for correct transposition:

eg adjacent (Tent pole) = 0.75 / tan 30 degrees or 0.75 / 0.58

1 mark of correct tent pole length:

eg 1.30 metres plus 0.5 metres = 1.8 metres.

Graphic:

1 mark for accurate construction of 30 degree angle in correct location.

1 mark for scaled drawing measured lengths.

1 mark for identifying portion on the pole in the sloping roof to be 1.3 m scaled length.

1 mark for answer i.e. adding calculated drawn vertical height and 0.5 m together: accept
1.79 m or 1.8 m.
[4]

Q3.
(a)     1 mark awarded for showing how ten triangles could fit on the grid (given that one
triangle is already provided on the grid).

An example of the possible layout is shown below. Other correct responses should
be rewarded.

Triangles do not need to be drawn accurately but it must be clear how they fit on the
grid.

Page 16 of 26
  
1

(b)     1 mark for calculating the area of a rectangle.

1 mark for calculating the area of a triangle.
1 mark for adding the areas of the triangles together and subtracting from the area
of the rectangle to find wastage.

Please note if students has not answered question (a) correctly they will be unable
to obtain the third mark.

Calculation

Area of rectangle:        60 × 40 = 2400

Area of triangle:           ½ × 18 × 18 = 162

Area of 10 triangles:    162 × 10 = 1620

Material wasted:          2400 – 1620 = 780mm2

3
[4]

Q4.
Templates:
A shape made from a durable material which can be lined up and drawn / cut around
to reproduce the original shape e.g. dress pattern, cake decoration, sheet
metalwork, block pattern, pottery templates.
Accept:
•        3 valid points
or
•        2 valid points with an example.
N.B. Accept stencils as a form of template
3

Jigs:
A device you line material up to accurately repeat an operation accurately time after
time e.g. for sawing, cutting, drilling, punching.
Accept:
•        3 valid points
or
•        2 valid points with an example.
Think of lining up paper on a photocopier.
3

Page 17 of 26
 Moulds:
A shaped cavity used in which a liquid can be poured until it solidifies or cools e.g.
jelly making, aluminium casting, slip casting
Accept:
•        3 valid points
or
•        2 valid points with an example.
3

Formers:
A construction used to help with shaping operations e.g. laminating, vacuum
forming, acrylic bending, felt blocking, dressmaker’s dummy, drop moulding & drape
forming in clay.
Accept:
•        3 valid points
or
•        2 valid points with an example.
3

Dies:
Used to produce a consistent cut out on paper, card, leather, plastics & foams.
Can also be used for creating perforations on packaging, punching euro slots and
creasing card for folding.
Knife blades for cutting
Rounded blades for creasing
Accept:
•        3 valid points
or
•        2 valid points with an example.
Ink dyes = 0
Pastry cutters = 1
Reference to extrusion e.g of plastic or piping bag = 1
3
[9]

Q5.
CAM manufacturing more efficient - accurate and much faster than manufacture by
hand. Materials purchased in bulk much cheaper than in smaller quantities.
Products nested to make maximum use of material in stock form. Once prototype
developed to be suitable for mass manufacture, CAM makes every product the
same within pre determined tolerances; hand made products often bespoke to
customer requirements, time taken in design of each one off product, hand skills
slower than machine. Less people involved in manufacture by CAM – less cost in
terms of workforce.

Initial cost of machine set up offset by mass quantities of product made.

CAM manufacturing not ‘quick and easyߣ unless sufficiently justified.

A concise and detailed response showing a good understanding of the above

factors. Examples of relevant products used to show comparison of two types of
manufacture and cost implications.
Response well structured with good use of appropriate design and technology

Page 18 of 26
 terminology and showing a good grasp of grammar, punctuation and spelling.
6–8 marks

A sound response showing a basic understanding of the above factors. Examples of

relevant products may be used to show comparison of two types of manufacture and
cost implications.
Response fairly well structured with some use of design and technology terminology
with small number of errors in grammar, punctuation and spelling.
3–5 marks

A simplistic statement which mentions one point only. Response may not include
examples of relevant products or products selected may not be appropriate to
argument. Response poorly structured with little or no use of design and technology
terminology and with numerous errors in grammar, punctuation and spelling.
1–2 marks

No relevant argument presented.

0 mark
[8]

Q6.
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]

Q7.
(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

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

Page 19 of 26
 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]

Q8.
Award marks using the following descriptors

Stage 1: Marking out (traditional)

Candidates may gain marks for giving responses that span both traditional
and CAD areas.

Sufficient detail for most of the design to be marked out, as a one off. Most tools
and equipment given.
1 − 2 marks

Sufficient detail for most of the design to be marked out, in quantity, using a
template. Most tools and equipment given.
3 − 4 marks
or

Stage 1: Marking out CAD

Sufficient detail for the design to be drawn by CAD.

Most tools and equipment given

Look for details relating to:

Computer hardware
Naming software
Net on screen
Use of different coloured lines
1 − 4 marks

Stage 2: Cutting and shaping (traditional)

Sufficient detail for some of the design to be cut and shaped as a one off. Most
tools and equipment given
1 − 2 marks

Sufficient detail for most of the design to be cut and shaped in quantity, using jigs /
templates / systems. Most tools and equipment given.
3 − 4 marks

or

Page 20 of 26
Stage 2: Cutting and shaping CAM

Sufficient detail for the design to be manufactured by CAM. Most tools and
equipment given.

Look for details relating to:

Transfer of data to CAM

Laser cutter / CNC router
Clamping work piece

Power setting / Speed and feed settings

Changing tools / tool selection
Safety
1 − 4 marks

Stage 3: Bending / joining (traditional)

Sufficient detail for some of the design to be bent and joined as a one off. Most
tools and equipment given.
1 − 2 marks

Sufficient detail for most of the design to be bent / joined, in quantity with use of
jigs / formers.
Most tools and equipment given.
3 − 4 marks
or

Stage 3: Joining CAM

Laser cutter / CNC router

1 mark
Transfer of data to CAM
1 mark
Description of how to cut the joints
1 − 2 marks
or

Pewter casting

Sufficient detail for some of the design to cast. Most tools and equipment given
1 − 2 marks
Sufficient detail for most of the design to cast. Most tools and equipment given.
3 − 4 marks

Stage 4: Applying the surface finish (traditional)

Sufficient detail for the design to be finished. Most tools and equipment given.

Look for the following details:

Material preparation

Use of a brush / aerosol / rag

Application of varnish / paint

1 − 2 marks
or

Stage 4: Applying the surface finish (CAM)

Page 21 of 26
 Reference to the fact that a laser cut stand would not need finishing as the laser
produces a good quality finish

or

Reference to improving the quality of laser cut edges by use of wet and dry paper,
‘Brasso’ and polishing / buffing
1 − 2 marks

Stage 5: Producing the text that says ‘1st’ (traditional)

Sufficient detail for the logo to be applied, tools and equipment given

Look for the following details:

Use stencil / template

Application of varnish / paint
1 − 2 marks
or

Stage 5: Producing the text that says ‘1st’ (CAD / CAM)

Reference to the fact that the logo would be etched in by the laser. The candidate
may simply reference back to Stages 1 and 2.

Look for the following details:

The logo being produced on a graphics software package (2D design)

The logo being etched by the laser cutter
The logo being produce by the vinyl cutter
1 − 2 marks
[16]

Q9.
Award marks using the following descriptors

Marking out (traditional)

Sufficient detail for most of the design to be marked out by a third party, as a one
off. Most tools and equipment given
1 – 2 marks

Sufficient detail for most of the design to be marked out by a third party, in quantity,
using a template. Most tools and equipment given.
3 – 4 marks

or

Marking out CAD

Sufficient detail for the design to be drawn by CAD by a third party. Most tools and
equipment given.

Look for details relating to:

Computer hardware
Naming software
Net on screen

Page 22 of 26
Use of different coloured lines
Power settings
1 – 4 marks

Cutting and shaping (traditional)

Sufficient detail for some of the design to be cut and shaped by a third party as a
one off. Most tools and equipment given
1 – 2 marks

Sufficient detail for most of the design to be cut and shaped by a third party, in
quantity, using jigs / templates. Most tools and equipment given.
3 – 4 marks

or

Cutting and shaping CAM

Sufficient detail for the design to be manufactured by CAM.

Most tools and equipment given.

Look for details relating to:

Transfer of data to CAM

Laser cutter / CNC router
Clamping work piece
Changing tools
Safety
1 – 4 marks

Bending / joining

Sufficient detail for some of the design to be bent and joined as a one off by a third
party. Most tools and equipment given
1 – 2 marks

Sufficient detail for most of the design to be bent / joined, in quantity, by a third
party with use of jigs / formers. Most tools and equipment given.
3 – 4 marks

Applying the surface finish (traditional)

Sufficient detail for the design to be finished by a third party.

Most tools and equipment given.

Look for the following details:

Material preparation

Use of a brush / aerosol / rag

Application of varnish / paint

1 – 2 marks

or

Applying the surface finish (CAM)

Reference to the fact that a laser cut stand would not need finishing as the laser

Page 23 of 26
produces a good quality finish.
or
Reference to improving the quality of laser cut edges by use of wet and dry paper,
‘Brasso’ and polishing / buffing
1 – 2 marks

Producing the ‘kitchen roll’ text (traditional)

Sufficient detail for the logo to be applied by a third party, tools and equipment given

Look for the following details:

Use stencil / template

Application of varnish / paint
1 – 2 marks

or

Producing the ‘kitchen roll’ text (CAD / CAM)

Reference to the fact that the logo would be etched in by the laser

Look for the following details:

The logo being produced on a graphics software package (2D design)

The logo being etched by the laser cutter
The logo being produced by the vinyl cutter
1 – 2 marks
[16]

Page 24 of 26
Examiner reports

Q4.
 
Candidates were able in many cases to pick three manufacturing aids from personal
experience and understanding to respond to this question. More use of sketches to clarify
understanding would have supported higher marks because some candidates were
repetitive in the notes provided for each response.

Q5.
There were very mixed responses explaining the use of CAM, ranging from very poor to
well written responses, with good use of English and grammar. Candidates gained marks
for referring to speed, accuracy, nesting, efficient use of materials and better profits after
initial set up costs. Good examples of products produced this way were often given
although sometimes these were school based products such as clocks and jewellery cut
on the laser cutter rather than commercial mass production. Some responses failed to
score marks as they did not answer the question but talked about how CAD could be used
or computers in general.

Q6.
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.

Q7.
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.

Q8.
Stage 1

The majority of candidates were able to gain 2 of the 4 marks available by giving details of
how they would mark out the sports trophy. Few candidates achieved full marks by
addressing the issue of the kitchen roll having to be being batch produced.

Stage 2

Most candidates were able to gain 2 of the 4 marks available by giving details of how they
would cut and shape the sports trophy. Few candidates achieved full marks by addressing
the issue of the sports trophy having to be being batch produced. Candidates who chose
to use CAM to manufacture their sports trophy tended to give simplistic answers.

Stage 3

Again, the majority of candidates were able to gain 2 of the 4 marks available by giving

Page 25 of 26
 details of how they would bend or join the sports trophy. Fewer candidates achieved full
marks by giving a detailed response.

Stage 4

This part of the question was answered well with many candidates giving correct details of
how to apply a relevant finish to the sports trophy. The use of varnish was the most
common correct response.

Stage 5

Candidates provided a variety of ways in which to produce the ‘1st’ text. Many candidates
correctly chose to engrave the text by a laser cutter.

Q9.
Stage 1
The majority of candidates were able to gain two of the four marks available by giving
details of how they would mark out the kitchen roll holder. Few candidates achieved full
marks by addressing the issue of the kitchen roll having to be being batch produced.

Stage 2
Most candidates were able to gain two of the four marks available by giving details of how
they would cut and shape the kitchen roll holder. Few candidates achieved full marks by
addressing the issue of the kitchen roll having to be being batch produced. Candidates
who chose to use CAM to manufacture their kitchen roll holder tended to give simplistic
answers.

Stage 3
Again, the majority of candidates were able to gain 2 of the 4 marks available by giving
details of how they would bend or join the kitchen roll holder. Fewer candidates achieved
full marks by addressing the issue of the kitchen roll having to be being batch produced.

Stage 4
This part of the question was answered well with many candidates giving correct details of
how to apply a relevant finish to the kitchen roll holder.

Stage 5
Candidates provided a variety of ways in which to produce the ‘kitchen roll’ text. Many
candidates correctly chose to engrave the text by a laser cutter.

Page 26 of 26