Name: P Jones Tutor Group: 13D

DT Class: 11B

Litter Bin

INTRODUCTION/SCENARIO:It has been agreed by Harchester Council to invest in a new approach in ensuring that the town is kept clean. This is very important to them as they wish visitors to get a good impression. Part of the project is to replace the existing set of litter bins with a new range. The main area around the central zone will have their bins emptied quickly. It is intended to use a small fleet of dustcarts, the size of a small van, to undertake the task and shop waste will be emptied at night by the same fleet. The Council intends to pave areas within the town to help and make create people friendly zones

CLIENT: Harchester Council

TASK:To design and make a range of litter bins which will reflect the new and modern style of Harchester. They will be free-standing and they will have a liner which will be made of galvanized steel and which can be removed quickly. Any material can be used for the main body if you feel it is appropriate. It is advised that you look at some existing products.

INITIAL SPECIFICATION1. It must hold litter2. It must enable people to put litter in easily3. It must stop rubbish being blown out4. The client is Harchester Council5. They must make a good impression6. It will be used in the centre of the town 7. It must be able to be emptied quickly8. They must be a range9. It must look new and modern10. It will have a galvanised liner11. The main body can be any material12. It must be waterproof13. It must be hard wearing14. It must be vandal proof15. It must be lockable

MATERIALS 1Materials for Model Wood

Pine 20 x 100 20p per. 100mm

£2.00p per. metre

50 x 50 20p per. 100mm

75 x 75 60p per. 100mm

25 x 50 10p per. 100mm MDF 12mm 100 x 100 8p

300 x 300 72p

6mm 100x100 4p

300x300 36p

Hardboard 100 x 100 2p

300 x 300 18p

Dowel 6mm 4p per 100mm

12mm 8p per 100mm

Plastic Vacuum Forming Machine Size 1.90pHIP – 2mm 254x458Full Sheet £3.80

508x458 Acrylic/Perspex 100x100x3mm 30p

300x300x3mm£2.70

MATERIALS 2Materials for Bin

Casings

Plastic Durapol A very tough material, a very weather and vandal proof plastic which can take knocks and collisions. It is chemical resistant and can cope with a wide range of outdoor temperatures.

Medium Density Polyethylene (MDPE)

Easily moulded through the process of rotational moulding, shapes need to be basic, but it is a cheap process, or injection moulding, which is expensive to set up, so only useful for mass production. 100% Recyclable

Metal Stainless Steel Great Appearance, Prevents rusting and hard wearing, but very expensive and not easy to work, can cost as much as 4 times more than bins made with other materials

Cast Iron Traditional. Heavy but hard wearing, can be brittle, but very solid and stable. Good against bad weather. Lasts up to 100yrs. Can add features to the surface, such as logos during casting

PROCESSES 1Model Available EquipmentRange of Hand toolsElectric Hand Drills and JigsawsPillar DrillsVacuum FormerLine HeaterWorkshop Facilities

Staff machinesBand SawCircular SawPlanner & ThicknesserWelding Equipment

ProcessesCutting Tenon Saw - Straight Cut Coping Saw – Curved CutJr Hacksaw – Small items

FixingGlue - Wood Epoxy Resin - For different materialsNails – Permanent FixingScrews - Temporary FixingJoints – Strengthening structures

ShapingFilesSurf Forms

PROCESSES 2Litter BinInjection MouldingThis is the main process used to make complex plastic items, the moulds are expensive and can be more than the machine as they have to resist the pressure of the plastic being injected into them which can be up to 50,000lbs

Rotational MouldingRotational moulding is a process that is ideal for the moulding of hollow products. These include tanks holding liquids, flower pots, rainwater tanks, footballs, road cones, fenders, luggage trays. Polyethylene and Polypropylene are ideal polymers for this moulding process. It is particularly suitable for the manufacture of batches from 100 to 5000 units. The mould are cheap to make as normal steel or aluminium can be used.

CastingCast iron is a ferrous metal which has been heated until it liquefies at around 1200oC, and is then poured into a mould to solidify. It is usually made from pig iron.

Stage Process Risk Assessment Action

1. Make base - Glue and nail base together

RISK ASSESSMENT – RM1 Using Small Sharp Edged and Pointed Hand tools

Risk Level – MediumCheck using the correct toolsHammer, Nails & GlueCheck if unsure

2. Decorate sides- Cut to length and glue

RISK ASSESSMENT – RM1 Using Small Sharp Edged and Pointed Hand tools

Risk Level – MediumCheck using the correct toolsSaw, GlueCheck if unsure

3. Cut hole in top- Use hole cutter on Pillar drill

RISK ASSESSMENT – RM2a Using a Drilling machine

Risk Level – MediumMake sure machine is set up correctlyPillar Drill, Hole CutterCheck properly Clamped

4. Assembly Pieces- Glue sides and Top

RISK ASSESSMENT – RM1 Using Small Sharp Edged and Pointed Hand tools

Risk Level – MediumCheck using the correct toolsGlue & TapeCheck if unsure

5. Paint- Paint assembled bin

RISK ASSESSMENT – RM1 Using Small Sharp Edged and Pointed Hand tools

Risk Level – MediumCheck OK with paint, care with handling, especially when cleaning Check if unsure

Health & Safety – Risk Assessment

Litter BinOrthographic Drawing

Part Size No.

Sides 155x80 4

Top & Base

100x90 2

Stand 80x70 2

Strips 6x6 General

Parts List

Stage Process Extras

1 Collect materials4 sides, top & base, stand and fixer

Collect 8 pieces

2 Glue base together 70x80 to the 100x90 on both sides

Only put in 2 nails on this diagonal

3 Cut hole in top on Pillar drill Mark out centre using diagonals

Get correct size hole cutter

4 Start to dress side using 6mm stripsCut strip using junior hacksaw and leave at least 5mm overhang

Get 6mm strips

5 Glue strips to only 2 sidesSort out design

Must leave to dry carefully

6 Cut off overhangUse Junior Hacksaw

Cut overhang off carefully

7 Assembly main carcassUse base to help support

Use masking tape to hold it whilst drying

8 Fix top onGlue and hold with tap

Ensure top in correct position

9 PaintClean of any glue spots

Use white paint for base coat

Production Plan

Week Progress Issues

1 Fixed Base together Had problem with nails as base slipped, had to use G clamp to hold it whilst nailing

2 Worked on sides Worked on design whilst fixing 6mm strips. Pleased with final design, used simple pattern made up of lines

3 Worked on sides Completed, but took much longer than expected, but please with result. Had to be careful when leaving it to dry

4 Cut hole in top Took much longer than expected as it was difficult to set up and ensuring work was clamp correctly

5 Assembled main carcass Use masking tape to hold it. Had to leave it somewhere safe and checked it before leaving lesson

6 Fixed lid on Used tape to hold it. Left it in safe place till next lesson to avoid it being knocked

7 Filled gaps Used filler to fill gapes. Difficult getting it in small areasLeft it to dry in safe place

8 Cleaned down FillerGave bin first coat

Primed bin with white paint, had to be careful to avoid running marks on sides which would cover detail

9 Rubbed down first coat with fine glass paper – 250 grade. Gave second coat

Noticed the using fine glass paper gave to bin a really good finish, need to remember this for next time

10 Rubbed down again and gave final grey coat spreading the paint thinly

Final coat on top of base coats gives a really nice finish. Pleased with the end result

Progress Diary

Alterations

These were the designs I used on my boxes, which a designed during construction

I cut circle out of 6mm MDF using the hole cutter and then stuck them on before painting

Although these are not really alterations these were the changes I made when constructing the bin

Final ModelREFLECTION – Evaluation

1. Does it Answer the Brief?Yes, it is a successful litter bin, I think it looks good and would blend into the town well. It gives the image of a modern and forward looking town

2. Does it answer the specification points?Yes, I have checked it against each point as well as the sizes which was easy as the model was to scale. Some points would be answered when it goes into production.

3. What does the client think?I showed the design to the client , Harchester Council and they were pleased. Discussion followed with regards to colour and this will need to be agreed at a later date

4. How could it be tested?An initial survey would take place to see what people would think as well as tests on the materials to ensure they where suitable and meet the requirements of the specification

5. How could it be developed?It could be developed into smaller units, which keep the same style and shape and these could be fitted to lamp posts or walls around town.