Hello and welcome to today's lesson.

My name's Mrs. Taylor.

I'm really pleased you can join me.

Today's lesson is wasting manufacturing processes.

And this is part of the unit principles of materials and manufacturing.

The outcome.

I can identify and select appropriate wasting processes for different materials.

We have four key words.

Wasting, abrasion, quantity, and risk assessment.

In today's lesson, we have three learning cycles.

Wasting manufacturing processes, choosing wasting processes, and wasting processes health and safety.

Here we begin with wasting manufacturing processes.

There are different types of manufacturing processes.

These can be grouped into four categories.

Wasting, which means to remove material.

Fabricating, which is joining material.

Deforming, which is changing the material shape but not the state.

And reforming, changing the material's shape and the state.

Here we have a check.

Which manufacturing process removes material? Is it A, deforming; B, fabricating; or C, wasting? Pause the video and have a go.

Brilliant.

Let's look.

That's right.

It's C, wasting.

There are many different ways to remove material.

Here are some examples of tools which cut.

Scissors, a craft knife, and a junior hacksaw.

The scissors are used to cut straight or curved cuts.

The material could be paper, thin board, fabric, or thin polymer sheet.

Here we have a check.

Which materials can scissors cut? A, metal sheet such as aluminium; B, polymer sheet such as thin PVC; or C, fabric such as cotton calico.

Pause the video and have a go.

Let's look.

That's right.

The answers are B and C.

Scissors can cut polymer sheet when it's thin and an example would be PVC.

And scissors can cut fabric such as cotton calico.

Well done.

Here is a craft knife which can create straight cuts in paper, thin board, and thin polymer sheet.

Andeep reminds us that a craft knife must always be used in conjunction with a safety rule and cutting mat.

A junior hacksaw can be used to cut straight cuts in timber, polymer, and metals.

And Sofia reminds us that if you are cutting timber, you must use a bench hook with the junior hacksaw.

If it is a polymer or a metal, you must use a vice.

Here are some examples of machines which cut.

Here is a pillar drill and a fretsaw.

You may know this as a scroll saw.

Here is a pillar drill.

The pillar drill is used to cut circular holes in timber, polymer, or metal.

Andeep reminds us that the material must be securely clamped in place before drilling.

The operator must be trained, and wear goggles and an apron.

Here we have a check.

What is a pillar drill used for? A, to cut straight lines in timber, polymer, or metal; B, to create circular holes in timber, polymer or metal; or C, to cut curved lines in timber, polymer, or metal.

Pause the video.

Great.

Let's check.

That's right.

It's B, to create circular holes in timber, polymer and metal.

Well done.

Here is a fretsaw.

A fretsaw can be used to create straight or curved cuts in timber or polymer.

Sofia reminds us that fretsaws are also called scroll saws.

The operator must be trained, wear goggles and an apron.

Here are some examples of tools or equipment which are used for abrasion.

Abrasion is the removal of surface material by friction.

For example, grinding or rubbing.

A belt sander, glasspaper, and files.

Here we have a check.

True or false? Wasting material always involves cutting.

Pause the video.

Well done.

Let's check.

That's false.

Glasspaper and files are also used to remove material.

However, they are abrasive rather than cutting techniques.

The belt sander is used for abrasion with timber.

Andeep reminds us that belt sanders are sometimes called band facers.

The operator must be trained, wear goggles, and an apron.

Glasspaper is also used for abrasion of timber.

Sofia tells us glasspaper is supplied in different grades.

Some feels much rougher than others.

You begin with rough and move on to the finer grades to give you a fine finish on the timber.

We have a check.

Glasspaper can be used to abrade the surface of which materials? A, timber; B, polymers; and C, metal.

Pause the video.

Well done.

Let's look.

That's right.

It's timbers.

Files are used for abrasion on polymers or metals.

Andeep tells us that files come in different shapes.

They can be round, half round, triangular or flat.

We now move on to task A.

Please complete this table.

Look at the tools or equipment on the left and identify whether they are to cut or for abrasion.

And then in the third column, identify which materials are suitable for each tool or equipment.

Pause the video.

Have a go.

Well done.

Let's have a look at some of the answers you may have come up with.

Here we go.

Scissors are used to cut paper, board, fabric, or polymer.

A craft knife can cut paper, board, or thin polymer sheet.

A junior hacksaw can cut timber, polymer, or metal.

A belt sander can abrade timber.

Glasspaper can also abrade timber.

Files are used for abrading polymer or metals.

The pillar drill can cut timber, polymer, or metal.

And a fretsaw can cut timber or polymer.

Well done.

We move on to our second learning cycle, choosing wasting processes.

When manufacturing a product, there are several considerations which determine the suitable wasting process.

Shape, size, material, and quantity.

Shape, the shape is considered because some wasting process are suitable for cutting straight lines and some are suitable for curved shapes.

To cut a straight line in a piece of softwood such as pine, you could use a tenon saw and a bench hook.

A tenon saw has a wide and rigid blade.

Here we can see a picture of a tenon saw and a bench hook.

And here a gif showing the tenon saw being used with the bench hook to cut a piece of solid timber, a piece of softwood pine.

If a curved shape is required, you could use a coping saw.

This has a thin and flexible blade.

Here is a coping saw.

And here is a gif of the coping saw cutting a curve in a piece of solid timber, a piece of pine, a softwood.

You can also see that the timber is held securely in a vice.

Here we have a check.

Which saw has a wide and rigid blade? Is it A, fret saw; B, tenon saw; C, coping saw? Pause the video.

Let's have a look.

That's right.

It's B, tenon saw.

Well done.

A fret saw can be used to cut both straight and curved shapes in sheet material.

A craft knife can cut straight shapes.

Here is a gif showing the fret saw being used.

Note that the operator's hands are far away from the blade.

And here we have a gif showing a craft knife being used in conjunction with a safety rule and a cutting mat.

Here we have a check.

True or false? Shape determines which wasting process is suitable.

Pause the video.

Brilliant.

Let's have a look.

It is true.

Because some tools are better at cutting straight lines and others are better at cutting curves.

Well done.

Size, the size and thickness of the item is considered because some wasting processes are suitable for cutting large or thicker pieces of material, and some are limited to smaller sizes and thicknesses.

Plywood sheets can come in sizes as large as 2,440 millimetres by 1,200 millimetres.

And softwood planks can come in sizes 25 millimetres by 100 millimetres.

The maximum thickness a fret saw can cut is determined by the distance from the bed to the moving blade arm.

The size is also limited to the operator's arm span.

Here we have a check.

What limits the size of material which can be cut to using a fret saw? A, the size of the workshop, B, the space between the blade and the bed of the machine, or C, the operator's arm span.

Pause the video.

Let's have a look.

That's right.

It's B and C.

The space between the blade and the bed of the machine and the operator's arm span.

Well done.

Material, some processes are suited to some materials and not others.

Scissors can cut curves in corrugated card but not timber.

Here we have a check.

Which materials cannot be cut using scissors? A, metal; B, polymer; C, paper; and D, textiles.

Pause the video.

Brilliant.

Let's have a look.

That's right.

Metal and polymer cannot be cut using scissors.

It is possible to use scissors to cut some thin polymer sheet such as acetate or thin PVC.

Quantity, quantity means how many.

Manufacturers may make one product known as one-off production or a number of products known as batch production.

Quantity, carving a shape from timber is a specialised skill and would be made by one person, one at a time.

Polymer storage boxes are made in a batch, as the injection moulding process can be easily and accurately repeated using machinery.

Here we can see one person carving a timber item.

This case it's a violin.

And an example of a storage box, which would be made in batch.

Here we have a check.

Batch production is A, one product; B, a number of products; or C, continuous production of products.

Pause the video.

Great.

Let's have a look.

That's right.

It's a number of products.

Here we have task B.

Part 1 is to select a suitable wasting process for the material and the shape required.

And Part 2 is to explain why you chose each wasting process for the material and the shape.

Pause the video and have a go.

Here we have some of the answers you may have come up with.

Plywood, a straight line could be cut with a fret saw and a curved line, a coping saw.

Corrugated card, a craft knife could be used to cut a straight line.

And scissors to cut the curved line.

Pine, a tenon saw could be used for the straight line, and a coping saw for a curved shape.

Part 2, explain why you chose each wasting process for the material and shape.

Sam says, "The plywood can be cut using different tools and equipment.

I chose to use the fret saw for the straight line as I can move the material evenly through the blade.

I chose to use a coping saw for the curve because my fingers would have to be too close to the fret saw blade.

I would hold the plywood in a vice, and then move the coping saw round, whilst also sawing forward and back, keeping my fingers safe." Sam also says, "The corrugated card can be cut in a straight line using a craft knife with a safety rule and cutting mat.

The curve would be a lot easier and safer to cut using scissors as the safety rule is straight and wouldn't be useful when cutting a curve.

Scissors are safer, but they do crush some of the corrugated sections." Well done.

We're doing so well.

Let's look at the last learning cycle for today's lesson.

Wasting processes health and safety.

Health and safety is the way we ensure everyone remains safe and healthy when manufacturing.

Everyone must take responsibility for this.

Some tools and machinery can be dangerous if not used correctly.

Risk assessments are used to assess the potential dangers and plan to minimise these.

Here we have a check.

True or false? Health and safety is the teacher's responsibility.

Pause the video.

Let's have a look.

That's false.

It's everyone's responsibility.

A fretsaw is used to cut sheet material, timbers, boards, and polymers.

The potential risks include noise, vibration, dust, light levels, the operator not concentrating, and the operator cutting themselves.

Here we have a check.

What is the purpose of a risk assessment? Is it A, to remove all the risks; B, to assess what the potential risks are; or C, to minimise any potential risks? Pause the video.

Let's have a look.

That's right.

It's B and C.

It's both to assess the potential risks and to minimise those potential risks.

Well done.

Here are some ways to minimise the potential risks when using a fret saw.

The operator not concentrating.

We could mark the area around the machine to ensure that only one person at a time is close.

We could also train the operators to concentrate and work individually.

The operator cutting themselves.

We could train the operators to plan the cut to avoid their fingers going close to the blade.

They could also use the guard to cover the blade.

Dust, have appropriate machine and room extraction.

Wear personal protective equipment known as PPE, including an apron and goggles.

Vibration means movement.

Ensure the machine is securely attached to the table or bench.

Use the dropdown foot to ensure the material does not vibrate excessively.

Task C, choose one of these tools or machinery.

And Part 1 is to identify the potential risks this equipment could pose.

And 2, explain what actions could be taken to minimise these.

Pause the video and have a go.

Well done.

Let's have a look at some of the answers you may have come up with.

The potential risks associated with the tenon saw could be dust, dropping the saw, the material moving, getting distracted by a friend, or the operator cutting themselves.

And the actions that we could take to minimise these.

If we were using a tenon saw, we could remove the dust material regularly using a vacuum cleaner with a filter, and we must not blow the dust.

Dropping the saw is a risk and we could always place the saw in the centre of the bench when not in use, and in the back at the end of the lesson.

We must walk carefully holding the blade down towards the floor when carrying it.

There's a risk that the material would move whilst we are cutting, so we could use a bench hook and train the operator to hold the material firmly on the bench hook.

We could get distracted by a friend, so we could take the action to train the operators to concentrate and focus on the task.

And there's a risk that the operator could cut themselves.

To minimise this, we could keep our hands away from the blade.

Well done.

Here we have a summary of today's learning.

Wasting manufacturing processes remove material.

Hand tools or machinery can be used to remove material.

When choosing which wasting process to use, manufacturers consider shape, size, material, and quantity.

When manufacturing, we must consider health and safety.

Risk assessments, identify potential risks and list actions to be taken to minimise these.

Well done.

You've done so well today.

I'm really pleased.

Thank you for joining me.