Principal Learning. Manufacturing and Product Design. Mark Scheme for June OCR Level 3 Principal Learning Unit G312: Quality in manufacturing

Transcription

1 Principal Learning Manufacturing and Product Design OCR Level 3 Principal Learning Unit G312: Quality in manufacturing Mark Scheme for June 2012 Oxford Cambridge and RSA Examinations

2 OCR (Oxford Cambridge and RSA) is a leading UK awarding body, providing a wide range of qualifications to meet the needs of candidates of all ages and abilities. OCR qualifications include AS/A Levels, Diplomas, GCSEs, OCR Nationals, Functional Skills, Key Skills, Entry Level qualifications, NVQs and vocational qualifications in areas such as IT, business, languages, teaching/training, administration and secretarial skills. It is also responsible for developing new specifications to meet national requirements and the needs of students and teachers. OCR is a not-for-profit organisation; any surplus made is invested back into the establishment to help towards the development of qualifications and support, which keep pace with the changing needs of today s society. This mark scheme is published as an aid to teachers and students, to indicate the requirements of the examination. It shows the basis on which marks were awarded by examiners. It does not indicate the details of the discussions which took place at an examiners meeting before marking commenced. All examiners are instructed that alternative correct answers and unexpected approaches in candidates scripts must be given marks that fairly reflect the relevant knowledge and skills demonstrated. Mark schemes should be read in conjunction with the published question papers and the report on the examination. OCR will not enter into any discussion or correspondence in connection with this mark scheme. OCR 2012 Any enquiries about publications should be addressed to: OCR Publications PO Box 5050 Annesley NOTTINGHAM NG15 0DL Telephone: Facsimile: publications@ocr.org.uk

3 1 Continue to produce quality products 3 1 mark for each way Set standards that are considered high by its customers/the industry Continuously monitor the quality of its output and make changes if quality is seen to be falling Use quality materials Provide supporting/independent evidence of quality 2 Business will lose reputation (1) as word gets around that goods are poor quality (1) or not as good as they used to be and sales start to suffer (1) Products will not perform/function as customers expect (1) customers get dissatisfied (1) start to try products from other manufacturers/competitors (1) and finally switch permanently (1) Quality falls below standards of competition (1) customers have no reason to continue buying poor quality product (1) so they switch to competitor (1) and sales just disappear (1) 3 This is an examination of the quality system, carried out by an internal team (1) it is a key part of ISO 9000 (1) and is used to provide evidence that required standards are being met and maintained (1) This is a regular check on quality standards that is carried out by people that work for the business (1) it is designed to confirm that standards/quality system established by the regulatory body for the industry eg the Food Standards Agency are being met (1) and that the business continues to meet these standards over time (1) 4 Award (1) mark for any consequence that could realistically occur or 1 mark for consequence marks for description and development of consequence 3 Award (1) mark for description of internal quality audit or 1 mark for description of internal quality audit marks for description and development of how internal quality audit can help meet regulatory standards 1

4 Question Answer Marks Guidance 4 In the design specification at Ali Windows, the lengths of extrusion are measured in millimetres (1) the cutting tolerance is expressed as +/- 10mm over a 2000mm length (1) but only +/- 5mm on a or 1000mm length (1) this is because the window fitters can fill any gaps/overcome any tolerance in the lengths with a sealant (1) Tolerances in the design specification for plastic bowls at the Jolly factory are expressed in terms of weight as well as dimensionally (1) the weight is +/- 15g on a standard bowl, any more and it uses too much plastic, any less and the bowl will be too flimsy (1) the dimensions have a greater tolerance +/- 10mm (1) as the shrinkage rate will depend on the temperature of the mould, the colour of the plastic and the speed at which the bowls are moulded (1) 4 Award (1) mark for stating how tolerances are defined (maximum 2 marks) 1 mark for stating how tolerances are defined marks for explaining more fully and applying to a design spec. 5 What you buy should be able to do the job that it was made for (1) it should not fail or break down (1) if you buy a toaster (1) it must be capable of producing toasted bread (1) Goods should be fit for any specific purpose you agreed with the seller at the time of sale (1) for example, if you were looking to buy a screen monitor (1) and you asked the seller if it would work with your computer (1) then that advice has to be correct. (1) 4 Award 1 mark for example of what is meant by goods being fit for purpose (maximum 2 marks) marks for explanation of what is meant by goods being fit for purpose 2

5 Question Answer Marks Guidance 6 Bread could be overwrapped (1) this will prevent it from drying out (1) and means that a baker can keep it on sale longer before it has to be removed from sale (1) 3 Understanding of shelf life may be implied. Fresh fruit juice could have a preservative added (1) this will stop it oxidising (1) of being affected by yeasts or bacteria (1) or Ready mixed tile grout could have a fungicide added (1) this will stop it going mouldy (1) which means that there will be fewer product returns (1) Award (1) mark for realistic suggestion of how shelf life can be improved 1 mark for stating realistic suggestion of how shelf life can be improved marks for description or understanding of how shelf life relates to the functionality of a product 3

6 Content Levels of response 7 Indicative Content 6 No marks for naming business, this is to provide context only, and to provide Expanded detailed evaluation Name of manufacturing business: Caxton Printers Ltd marker with sufficient information to assess whether answer is realistic. Main products: Printing promotional leaflets and booklets for local businesses Accept any way that the business uses the findings from its internal quality auditing. Mark Band 3 (5-6 marks) There is a high level of understanding of internal quality auditing. Learner uses some good examples of real situations. Evaluation is detailed and in depth. At Caxton Printers they take quality auditing very seriously. They are carried out internally by Mr Esson who has been trained to apply the principles of ISO Every month he systematically works through the production process to make sure that the quality system the business should be using on each job is still being applied. If it is, then the business can be sure that its quality standards are being maintained; if it is not, them Mr Esson has to report to the directors and get things changed or at least make sure that all the employees in the production process are reminded of the quality standards to which they should be working.. Evaluate: Make a qualitative judgement taking into account different factors and using available knowledge/experience Expanded evaluation Mark Band 2 (3-4 marks) There is some understanding of internal quality auditing. Learner uses some real examples. Evaluation is expanded, but with little detail. Basic evaluation Mark Band 1 (0-2 marks) There is a low level of understanding of internal quality auditing. Learner makes a few basic statements, without any depth of evaluation. 4

7 8 (i) Name of business: Perfect Pies 4 No marks for naming business or main product, these are to provide context only, and to provide marker with sufficient Main product: fruit pies information to assess whether answer is realistic. The measuring technique they use is to just add up how many cartons of pies are sold each day (1) they get the numbers by keeping a record of the figures that are phoned in by the sales team (1) using numbers of cartons is better than measuring the value of sales because it is an accurate figure (1) better than recording the value of the sales as the sales team could be giving discounts which reduce the overall value but will not affect the total number of pies sold (1) Award (1) mark for sales monitoring technique or 1 mark for monitoring technique+ 1-3 marks for description or development 5

8 Content Levels of response (ii) Indicative Content 6 No marks for naming business, this is to provide context only, and to Expanded detailed analysis Name of business: Perfect Pies provide marker with sufficient information to assess whether answer Mark Band 3 (5-6 marks) Main product: fruit pies is realistic. The quality management system that Perfect Pies use to monitor the quality of its products is very complex and sophisticated. It needs to monitor quality to make sure that the pies look good, as described in the product design specification. They need to taste consistently good, so samples ate tested regularly and given to approved and expert tasters. They also monitor the biological indicators which confirm that the pies are healthy to eat. They measure the bio factors by sampling the contents of ten pies from each batch that is baked. The contents are cooled rapidly and analysed in their laboratory, where they measure the bacteria levels to make sure that it is below the level at which they could have problems. If they did not do such thorough and regular measuring and monitoring of the bio factors, they could risk making their customers ill, which could result in bad publicity, loss of sales, and the potential that the production lines could be shut down until the problem is sorted. Accept any measuring techniques that could be used to monitor the performance of its sales function. Analyse: Separate information into components and identify their characteristics - should be thorough/complete Learner provides detailed description of the quality management system, and detailed analysis of the measuring techniques and how they are used to monitoring the quality of its products. Expanded analysis Mark Band 2 (3-4 marks) Learner gives a good description of the quality management system, and a good analysis of the measuring techniques and how they are used to monitoring the quality of its products. Basic analysis Mark Band 1 (0-2 marks) Learner provides a basic description of the quality management system, with little analysis of the measuring techniques or how they are used to monitoring the quality of its products. 6

9 Content Levels of response 9 Indicative Content 8 No marks for naming business, this is to provide context only, and to Expanded detailed recommendation Name of business: Sportz Wares Ltd provide marker with sufficient Mark Band 3 (7-8 marks) information to assess whether answer is realistic. Main product: makes kits for sports teams If Sportz wants to improve the quality of materials that it buys it should first of all confirm the new standard of quality for its products. This should be set out in a new design specification. Once this has been set, the buyers should issue the new spec. to its supplies to see if they have any suitable materials, also, they should try to find new suppliers who may have materials to the new spec. Once they have received samples of new materials, Sportz will have to make up shirts and other bits of kit from the new materials and test them to make sure that the materials are suitable. Recommendation should be realistic within the context of the business, the manufacturing sub-sector and generally recognised good practice. Learner makes a detailed and expanded recommendation, with some development; it is realistic in context of named business; there is detailed explanation of how to improve the quality of materials that it buys. eg The manufacturer develops a specification for materials required (1) the specification is then put out to tender (1) so that different suppliers can submit their quotes (1) the manufacturer specifies that the materials must meet the ISO quality standard (1) etc. Developed recommendation Mark Band 2 (4-6 marks) Learner makes a reasonable recommendation, with some development, which is realistic in context of named business; there is some explanation of how this would improve the quality of materials that it buys eg The manufacturer develops a specification for materials required (1) the specification is then put out to tender (1) so that different suppliers can submit their quotes (1) 7

10 Content Levels of response Basic recommendation Mark Band 1 (0-3 marks) Learner makes a basic recommendation, which may not be realistic in context of named business, with little or no explanation of how this could improve the quality of materials that it buys eg The manufacturer specifies materials (1) and tolerances (1) which are better quality than they buy currently (1) 8

11 OCR (Oxford Cambridge and RSA Examinations) 1 Hills Road Cambridge CB1 2EU OCR Customer Contact Centre Education and Learning Telephone: Facsimile: general.qualifications@ocr.org.uk For staff training purposes and as part of our quality assurance programme your call may be recorded or monitored Oxford Cambridge and RSA Examinations is a Company Limited by Guarantee Registered in England Registered Office; 1 Hills Road, Cambridge, CB1 2EU Registered Company Number: OCR is an exempt Charity OCR (Oxford Cambridge and RSA Examinations) Head office Telephone: Facsimile: OCR 2012