How technology-based systems are used by designers, manufacturers, retailers and consumers.

Resources → Subject Notes → Design and Technology → Lesson Plan

Industrial Practices – Technology‑Based Systems (Cambridge AS & A Level Design & Technology 9705)

Learning Objective

Explain how digital and electronic systems are used by designers, manufacturers, retailers and consumers to develop products, improve production efficiency, extend market reach and enhance the user experience.

1. Service‑Sector Chain (Syllabus 13.1)

Cambridge defines six stages that constitute the modern service‑sector chain. The chain links directly to the design, development, production and post‑sale stages required for AO3 and AO4 assessments.

Stage Typical Activities Key Stakeholder(s)
1. Raw‑material extraction & processing Mining, refining, polymerisation, metal casting Suppliers, manufacturers
2. Design & development Concept generation, CAD modelling, prototype testing Designers, design engineers
3. Production & assembly CAM, CNC machining, additive manufacturing, robotic assembly Manufacturers, production managers
4. Marketing & sales (retail) Omnichannel retailing, e‑commerce, POS, demand forecasting Retailers, merchandisers
5. Distribution & after‑sales service Logistics, RFID tracking, warranty, repair Retailers, service engineers
6. End‑of‑life & recycling Product take‑back, material recovery, circular‑economy initiatives Manufacturers, waste‑management firms

2. Professional Roles in Industrial Practice (Syllabus 13.1)

  • Designer / Design Engineer – creates product concepts, produces CAD data, evaluates ergonomics and aesthetics.
  • Production / Manufacturing Manager – plans the manufacturing route, selects CAM strategies, monitors productivity.
  • Quality Assurance Officer – defines inspection criteria, uses statistical process control, ensures compliance with standards.
  • Retail Operations Manager – oversees stock levels, integrates POS & e‑commerce, analyses sales data.
  • After‑sales Service Engineer – provides repair, maintenance and upgrades, feeds reliability data back to designers.
  • Health, Safety & Environmental (HSE) Officer – ensures legal compliance, risk assessments and sustainability reporting.

3. Hand‑Made vs. Automated Production (Syllabus 13.2)

Aspect Hand‑Made (Craft/Manual) Automated (Machine‑Based)
Speed Low – dependent on skilled labour High – continuous operation, cycle times in seconds
Initial Cost Low – minimal tooling High – CNC machines, robots, software licences
Per‑Unit Cost Higher – labour intensive Lower – economies of scale, reduced labour
Quality Consistency Variable – depends on artisan skill Very consistent – repeatable programmes
Design Flexibility Very high – easy to modify on the spot High but requires re‑programming or new tooling
Sustainability Low material waste if skilled; often higher energy per unit Optimised material usage (e.g., nesting), energy monitoring, but higher embodied energy in equipment

4. Business & Commercial Practices (Syllabus 14)

4.1 Product Life‑Cycle

  • Stages: Research & Development → Introduction → Growth → Maturity → Decline → (possible) Re‑launch.
  • Technology‑based systems (CAD, PLM, ERP, e‑commerce) support every stage, from rapid concept modelling to after‑sales data collection for redesign.

4.2 Market Research Methods

Method Purpose Typical Digital Tool
Surveys (online questionnaires) Identify consumer preferences, price sensitivity Google Forms, SurveyMonkey, data‑analysis dashboards
Focus Groups (virtual) Explore attitudes, test concepts Zoom/Teams with screen‑sharing of CAD renders
Observation & Usage Tracking Understand real‑world interaction IoT usage logs, mobile‑app analytics

4.3 The Marketing‑Mix (4 Ps)

  • Product: Feature set defined in PLM, supported by CAD visualisations.
  • Price: Cost modelling (TCO) and market‑research data inform pricing strategy.
  • Place: Omnichannel distribution – physical stores + e‑commerce platforms.
  • Promotion: Digital advertising, AR product demos, influencer reviews.

4.4 Product‑Extension Strategies

Example – a smart‑speaker line:

  • Line Extension: New colours and finishes (managed via configurator).
  • Feature Extension: Adding a built‑in display (CAD redesign, BOM update in PLM).
  • Market Extension: Launching in a new country using localized e‑commerce site and RFID‑enabled logistics.

5. Quantity Production (Syllabus 15)

5.1 Production Types – Comparison Table

Production Type Typical Volume Lead‑time Flexibility Cost per Unit Sustainability Considerations
One‑off (custom, prototype) 1‑10 Weeks–months Very high – manual or low‑volume CNC/3D‑print High Material waste often higher; low energy per batch
Batch (small series) 10‑1 000 Days–weeks Medium – change‑over required Medium Opportunity for nesting, recycling of off‑cuts
Mass (high‑volume) 1 000 + Hours–days Low – dedicated lines Low Optimised material utilisation, but large energy demand

5.2 Key Production Strategies

  • Just‑In‑Time (JIT) – synchronises material arrival with production, reduces inventory holding.
  • Computer‑Integrated Manufacturing (CIM) – links CAD, CAM, ERP and robotics for seamless flow.
  • Kaizen / Continuous Improvement – regular data‑driven reviews (IIoT dashboards) to cut waste.
  • Cell Production – self‑contained work‑cells that combine machining, inspection and assembly; ideal for medium‑batch automotive components.

6. Materials Processing in Industry (Syllabus 16)

Modern industry employs a range of processing techniques, each supported by specific digital tools.

Process Category Typical Operations Digital Support Example Application
Shaping Turning, milling, drilling, laser cutting CAM toolpath generation, simulation of cutting forces CNC milling of aluminium bicycle frames
Forming Stamping, forging, deep‑drawing, roll‑forming Finite‑Element Analysis (FEA) of stress, die‑design software Sheet‑metal stamping of car body panels
Redistribution Injection moulding, extrusion, blow moulding Mould flow analysis, process‑parameter optimisation Plastic housing for a smart thermostat
Joining Welding, brazing, adhesive bonding, mechanical fasteners Weld‑simulation, torque‑control software, quality‑inspection vision systems Robotic spot‑welding of a chassis sub‑assembly
Finishing Painting, anodising, coating, polishing Colour‑matching software, spray‑robot programming, thickness sensors Powder‑coat finish on a metal office chair
Printing (Additive Manufacturing) FDM, SLS, SLA, metal powder bed fusion Slicer software, material‑property libraries, build‑monitoring IoT 3‑D‑printed custom medical implant

7. Technology‑Based Systems by Stakeholder

7.1 Designers – Digital Design & Collaboration

  • Computer‑Aided Design (CAD) – 3‑D modelling, parametric design, stress & ergonomics simulation.
  • Product Lifecycle Management (PLM) – Centralised data repository, version control, change‑management workflows.
  • Virtual Reality (VR) & Augmented Reality (AR) – Immersive design reviews, client presentations, spatial fit checks.
  • Collaborative Cloud Platforms – Real‑time multi‑user editing (e.g., Autodesk Fusion 360, Onshape) and automatic backup.
  • Regulatory & HSE Checks – Integrated compliance libraries for CE marking, RoHS, REACH.

7.2 Manufacturers – Automation & Data‑Driven Production

  • Computer‑Aided Manufacturing (CAM) – Generates CNC toolpaths, adaptive machining strategies, post‑processor output.
  • Industrial Internet of Things (IIoT) – Sensors on machines collect temperature, vibration, cycle‑time data; feed predictive‑maintenance alerts.
  • Enterprise Resource Planning (ERP) – Links procurement, inventory, scheduling, finance and quality records.
  • Additive Manufacturing (3D Printing) – Rapid prototyping, low‑volume customised production, material‑property libraries.
  • Robotic Assembly & Vision Systems – Pick‑and‑place, quality inspection, real‑time error detection.
  • Environmental Monitoring – Energy‑use dashboards, waste‑tracking software, compliance with ISO 14001.

7.3 Retailers – Omnichannel & Supply‑Chain Visibility

  • Radio‑Frequency Identification (RFID) – Automatic stock counting, loss prevention, real‑time location tracking.
  • Point‑of‑Sale (POS) Systems – Integrated sales, loyalty programmes, real‑time analytics.
  • e‑Commerce Platforms – Digital catalogue, automated order fulfilment, click‑and‑collect.
  • Demand‑Forecasting Algorithms – Use historic sales, seasonality and external data (weather, trends) to predict stock levels.
  • Warehouse Management Systems (WMS) – Optimise picking routes, manage returns and repair cycles.

7.4 Consumers – Personalisation & Feedback Loops

  • Mobile Apps & Wearables – Remote control, usage statistics, over‑the‑air updates.
  • Online Review & Rating Platforms – Structured feedback that can be exported to PLM for design revision.
  • Smart‑Home & IoT Standards – Zigbee, Matter, Wi‑Fi, enabling inter‑device communication.
  • Customization Portals – Web‑based configurators for colour, material, feature selection before purchase.
  • After‑Sales Service Apps – Schedule repairs, request spare parts, log fault codes for reliability analysis.

8. Comparative Overview of Technology‑Based Systems

Stakeholder Key System(s) Primary Benefits Typical Example
Designers CAD, PLM, VR/AR, Cloud Collaboration Rapid iteration, reduced errors, instant stakeholder review Parametric modelling of a bicycle frame in SolidWorks linked to a PLM server
Manufacturers CAM, ERP, IIoT, Robotics, Additive Manufacturing Optimised machining, real‑time monitoring, flexible low‑volume production CNC milling of aluminium brackets with predictive‑maintenance alerts from vibration sensors
Retailers RFID, POS, e‑Commerce, WMS, Forecasting AI Accurate inventory, seamless checkout, wider market reach, reduced stock‑outs Automatic inventory updates via RFID tags in a fashion store linked to an online shop
Consumers Mobile apps, Smart devices, Review platforms, Configurators Personalised experience, direct feedback channel, remote control and updates Smart thermostat app that learns daily temperature preferences and reports usage to the designer

9. Cost Modelling for Technology Adoption (AO4 – Evaluation)

A simple linear model of Total Cost of Ownership (TCO) helps compare competing systems:

TCO = Cfixed + Cvariable × Q

  • Cfixed – Up‑front investment (software licences, hardware, training).
  • Cvariable – Per‑unit operating cost (energy, consumables, maintenance).
  • Q – Quantity of units produced, processed or sold over the analysis period.

Students should be able to:

  • populate the formula with realistic data for a CNC‑machined part versus a 3‑D‑printed prototype;
  • interpret how economies of scale affect the decision to adopt automation;
  • include non‑monetary factors (environmental impact, skill development) in the evaluation.

10. Case Study – Integrated Product Development (AO3 & AO4)

  1. Concept Generation – Designers model a portable electric kettle in a cloud‑based CAD system.
  2. Data Management – The CAD file is automatically stored in a PLM database, creating version 1.0 and a Bill of Materials (BOM).
  3. Prototyping – CAM software generates CNC toolpaths for an aluminium housing; simultaneously, an additive‑manufacturing printer produces a plastic prototype of the lid.
  4. Production Monitoring – IIoT sensors on the CNC machine send temperature and cycle‑time data to the ERP, which updates the production schedule and triggers a maintenance alert after 500 hours.
  5. Logistics & Retail – Finished kettles are fitted with RFID tags; the warehouse management system tracks them to a regional distribution centre and updates the retailer’s online stock levels in real time.
  6. Consumer Interaction – Customers configure colour and capacity on a web portal, purchase online, and later use a mobile app to monitor energy consumption. Usage data is anonymised and fed back to the PLM for the next design iteration.

11. Design Brief – Student Activity (AO3)

Brief: Choose a household product (e.g., a coffee maker, a desk lamp or a portable speaker). Using the technology‑based systems described above, propose a complete digital workflow from concept to consumer. Your proposal should include:
  • The specific CAD, PLM and CAM tools you would use.
  • How IIoT sensors could improve manufacturing quality.
  • An RFID or barcode strategy for retail inventory.
  • A consumer‑facing app or configurator that captures user feedback.
  • A brief TCO analysis comparing a fully automated production route with a hand‑made prototype route.
Deliverables: a schematic flow diagram, a table of system benefits, and a short written justification (300‑400 words).

12. Evaluation Questions – AO4

  • Assess the impact of adopting IIoT on product cost, quality and sustainability. Which indicators would you monitor?
  • Compare the advantages and disadvantages of RFID versus barcode systems for a fast‑fashion retailer.
  • Explain how the TCO model can be used to decide whether a small batch of customised metal brackets should be CNC‑machined or 3‑D‑printed.
  • Discuss how legal and environmental regulations (e.g., REACH, ISO 14001) influence the choice of digital tools in the design stage.

13. Suggested Diagram

Flow of technology‑based systems from raw‑material extraction → design → manufacturing → retail → consumer use → feedback → redesign.

14. Summary Checklist (AO2)

  • Identify the main digital systems used at each stage of the service‑sector chain (13.1).
  • Explain how data flows between designers, manufacturers, retailers and consumers.
  • Use the TCO formula to compare two production approaches.
  • Evaluate hand‑made versus automated processes in terms of speed, cost, quality, flexibility and sustainability (13.2).
  • Describe business & commercial practices (product life‑cycle, market research, 4 Ps, product extension) (14).
  • Distinguish individual, batch and mass production and recognise JIT, CIM, Kaizen and cell production (15).
  • Match material‑processing techniques (shaping, forming, redistribution, joining, finishing, printing) to appropriate digital tools (16).
  • Consider the role of legal, health‑&‑safety and environmental regulations throughout the product life‑cycle.

Create an account or Login to take a Quiz

36 views
0 improvement suggestions

Log in to suggest improvements to this note.