Papers & Boards — Scales of Production (AQA GCSE Design & Technology): Revision Note
Exam code: 8552
Prototyping in paper and boards
Prototyping means making one or a very small number of models to test an idea before full production
Paper and board prototypes are usually quick, low-cost and easy to alter because the materials can be cut, scored, folded and joined using simple tools
Common methods include:
Hand cutting with a craft knife
Scoring
FoldingGluing,
Printing
Using CAD/CAM such as a laser cutter or digital cutter
Examples include a net for a food package, a card architectural model or a mock-up of a leaflet
Batch production in paper and boards
Batch production makes a set quantity of identical products, where equipment can be changed to produce a different batch
Papers and boards are suited to batch production because templates, cutting dies, digital print files and folding guides can be reused for every item in the batch
Processes can include:
Lithographic or digital printing
Die cutting
Creasing
Folding
Gluing
Examples include 500 invitations to an event, a limited run of presentation folders or seasonal packaging (e.g. Christmas)
Mass production in paper and boards
Mass production makes large quantities of identical products, usually using automated production lines
The high setup costs for essential parts such as print plates, dies and machinery are spread across many products
This reduces the cost per unit
Processes are fast and repeatable, with automated printing, die cutting, folding, gluing and quality control
Examples include cereal boxes, drinks cartons and branded food packaging
Worked Example
Explain why mass production is suitable for cereal boxes.
[2 marks]
Answer
Cereal boxes are required in very large and consistent quantities. Automated printing, die cutting, folding and gluing can produce identical boxes quickly. [1] Although the machinery and cutting dies are expensive, the cost is divided across millions of boxes, making the cost per cereal box low despite the good quality. [1]
Examiner Tips and Tricks
When answering questions relating to scales of production, it is important (unless given) to state an example product in your answer. This will ensure that you gain the second mark.
Continuous production in papers and boards
Continuous production runs without stopping, often 24 hours a day and 7 days per week, to make a product that is in constant demand
Paper is manufactured continuously from pulp on large rollers
This forms a long web that is pressed, dried and wound into rolls
The process uses specialised machinery, high energy and careful monitoring
It produces a very low cost per metre or sheet
Examples include toilet rolls, packaging paper and corrugated cardboard boxes
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