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NSW HSC 2003 : INDUSTRIAL TECHNOLOGY – Metal and Engineering Industries

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Centre Number Student Number 2003 H I G H E R S C H O O L C E R T I F I C AT E E X A M I N AT I O N Industrial Technology Metals and Engineering Industries General Instructions Reading time 5 minutes 1 Working time 1 hours 2 Write using black or blue pen Draw diagrams using pencil Board-approved calculators may be used Write your Centre Number and Student Number at the top of this page and pages 5, 9, 17 and 21 195 Total marks 100 Section I Pages 2 13 60 marks Attempt Questions 1 3 Allow about 55 minutes for this section Section II Pages 17 23 40 marks Attempt Questions 4 5 Allow about 35 minutes for this section Section I 60 marks Attempt Questions 1 3 Allow about 55 minutes for this section Answer the questions in the spaces provided. Marks Question 1 (20 marks) IND-TECH is a large company situated in the inner city, operating in the metals and engineering industry specialising in high quality products and/or services. For a variety of reasons the company has decided to purchase and relocate to a new site, 200 km from its present inner city site. (a) Identify TWO issues that may have influenced the decision to relocate. 2 ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... (b) Outline TWO environmental responsibilities that must be dealt with when IND-TECH vacates the present site. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 1 continues on page 3 2 2 Marks Question 1 (continued) (c) Discuss TWO factors that IND-TECH should consider when choosing the alternative site. 4 ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... (d) Identify and describe TWO occupational health and safety (OHS) issues that IND-TECH would need to review/develop for the new workplace. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 1 continues on page 4 3 4 Marks Question 1 (continued) (e) Explain the possible environmental and sociological effects on the community of IND-TECH s relocation. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... End of Question 1 4 Board of Studies NSW 2003 8 2 003 HIGHER SCHOOL CERTIFIC ATE EXAMINATION Industrial Technology Metals and Engineering Industries Section I (continued) Centre Number Student Number Marks Question 2 (20 marks) Management at IND-TECH has decided to upgrade the level of mechanisation as part of its relocation. (a) 2 Define the term mechanisation. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... (b) Outline an aspect of IND-TECH s operations that could be investigated for upgraded mechanisation. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 2 continues on page 6 195a 5 2 Marks Question 2 (continued) (c) Describe TWO methods of evaluating the effects of upgraded mechanisation on IND-TECH s operation. 4 ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... (d) Upgraded mechanisation will require staff training. Outline the advantages for IND-TECH and its workers of accessing training programs. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 2 continues on page 7 6 4 Marks Question 2 (continued) (e) Identify and analyse issues that could arise between management and workers as a result of upgraded levels of mechanisation. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... End of Question 2 7 8 BLANK PAGE 8 Board of Studies NSW 2003 2 003 HIGHER SCHOOL CERTIFIC ATE EXAMINATION Industrial Technology Metals and Engineering Industries Section I (continued) Student Number Question 3 (20 marks) Please turn over 195b Centre Number 9 Marks Question 3 (20 marks) (a) The following extract is from a draft report that was produced using computer software. Half-Yearly Production Report January 2003 June 2003 Production rate summary Month January February March April May June Year 2003 2003 2003 2003 2003 2003 Production rate (units) 270 300 325 335 340 370 Growth in production is due to: Improved technology Better training Fewer accidents in the workplace Increased access to raw materials Page 1 (i) Name a computer software application that could have been used to produce this report. 1 ................................................................................................................... (ii) Identify FOUR formatting features that have been used in the production of this report. ................................................................................................................... ................................................................................................................... ................................................................................................................... ................................................................................................................... Question 3 continues on page 11 10 2 Marks Question 3 (continued) (1) Use the information from the production report to: produce a graph that shows the monthly production rate (indicate the months on the horizontal axis); graph the average monthly production rate (January June). 3 (2) Assuming the production trend continues, indicate on the graph the predicted production rate for September 2003. (iii) 2 Production rate 2003 450 Production rate (units) 425 400 375 350 325 300 275 250 Months (b) Materials handling injuries make up 40% of workplace injuries. Describe a procedure IND-TECH could implement to communicate improved materials handling strategies to its employees. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 3 continues on page 12 11 4 Marks Question 3 (continued) (c) In its new location, IND-TECH has an opportunity to reorganise its production system to make use of increased mechanisation and to improve efficiency. Shown below is a sample of a metal pool fence manufactured by IND-TECH. Metal pool fence Based on your study of the metals and engineering industry, use the space provided on page 13 to graphically represent the processes used to produce the metal fence shown. In your answer you should: show the sequencing of the components and/or processes; name each piece of equipment used; state the process carried out with each piece of equipment; indicate where quality control would occur, and what would be checked. Question 3 continues on page 13 12 8 Question 3 (continued) End of Question 3 13 BLANK PAGE 14 BLANK PAGE 15 BLANK PAGE 16 Board of Studies NSW 2003 2 003 HIGHER SCHOOL CERTIFIC ATE EXAMINATION Industrial Technology Metals and Engineering Industries Centre Number Section II Student Number 40 marks Attempt Questions 4 5 Allow about 35 minutes for this section Answer the questions in the spaces provided. Marks Question 4 (20 marks) A sports car chassis, similar to the one shown below, is to be constructed from steel RHS tubing. 30 30 (a) The tubing is described as 30 30 1.6 RHS. (i) What do the letters RHS stand for? 1 ................................................................................................................... ................................................................................................................... (ii) Identify the feature of the tubing described by 1.6. ................................................................................................................... ................................................................................................................... Question 4 continues on page 18 196 17 1 Marks Question 4 (continued) (b) Explain why the tubing has rounded corners and not sharp right-angled corners. 2 ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... (c) To construct the chassis, many identical components need to be cut from the tubing. Identify a machine, and describe how the machine would be set up to cut the components. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 4 continues on page 19 18 4 Marks Question 4 (continued) (d) The components of the tubular chassis are to be welded together. Identify and justify a suitable welding process, and outline the safety precautions that must be observed during the welding operation. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 4 continues on page 20 19 4 Marks Question 4 (continued) (e) For the welding process identified in part (d), describe stages in the preparation, welding and finishing of the chassis prior to coating. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... End of Question 4 20 Board of Studies NSW 2003 8 2 003 HIGHER SCHOOL CERTIFIC ATE EXAMINATION Industrial Technology Metals and Engineering Industries Centre Number Section II (continued) Student Number Marks Question 5 (20 marks) The handle for a machine component is shown below. It is to be machined using a lathe. A B M8 1.5 5 Handle (a) Insert Identify the features labelled by the letters A and B. 2 A ............................................................................................................................ B ............................................................................................................................ (b) Describe how the right hand end of the handle is made square after cutting to size. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 5 continues on page 22 196a 21 2 Marks Question 5 (continued) (c) Identify the adjustments that must be made to the lathe in order to produce feature A, and describe the process of cutting this feature. 3 ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... (d) Describe the process of producing feature B. What safety checks are necessary to ensure the safe operation of the lathe? ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... Question 5 continues on page 23 22 5 Marks Question 5 (continued) (e) The handle has a M8 1.5 threaded insert. Describe the process, naming all the tools, for manually cutting the threads inside the handle and on the insert. ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... ............................................................................................................................... End of paper 23 8 BLANK PAGE 24 Board of Studies NSW 2003

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Additional Info : New South Wales Higher School Certificate Industrial Technology Papers
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