GCSE Engineering: Single Award Specimen Assessment Materials

Transcription

1 GCSE Engineering: Single Award Specimen Assessment Materials For first teaching from September 2009 For first assessment from Summer 2010 For first award in Summer 2011 Subject Code: 0009

2 Foreword The awarding bodies have prepared new specifications to comply with revised GCSE criteria. The specimen assessment materials accompanying new specifications are provided to give centres guidance on the structure and character of the planned assessments in advance of the first assessment. It is intended that the specimen assessment materials contained in this booklet will help teachers and students to understand, as fully as possible, the markers expectations of candidates responses to the types of tasks and questions set at GCSE level. These specimen assessment materials should be used in conjunction with CCEA s GCSE Engineering: Single Award specification.

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4 GCSE Engineering: Single Award Specimen Assessment Materials Contents Specimen Papers 1 Paper 1: Unit 3: Engineering Technology 3 Paper 2: Unit 3: Engineering Technology 21 Paper 2: Pre-Release Materials 29 Mark Schemes 33 General Marking Instructions 35 Paper 1: Unit 3: Engineering Technology 39 Paper 2: Unit 3: Engineering Technology 49 Controlled Assessment 53 Guidance on Controlled Assessment 55 Unit 1: Engineering Design and Graphical Communication 57 Unit 2: Engineering Production 61 Assessment Criteria and Mark Bands 67 Unit 1: Engineering Design and Graphical Communication 68 Unit 2: Engineering Production 70

5 Subject Code QAN /4618/4 A CCEA Publication 2008 You may download further copies of this publication from

6 Specimen Papers 1

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8 Centre Number 71 Candidate Number General Certificate of Secondary Education 2010 Engineering Paper 1 Unit 3: Engineering Technology [CODE] SPECIMEN PAPER TIME 1 hour INSTRUCTIONS TO CANDIDATES Write your Centre Number and Candidate Number in the spaces provided at the top of this page. Write your answers in the spaces provided in this question paper. Answer all ten questions. INFORMATION FOR CANDIDATES The total mark for this paper is 80. Figures in brackets printed down the right-hand side of pages indicate the marks awarded to each question or part question. For Examiner s use only Question Marks Number Total Marks 3

9 Answer all questions 1 (a) All the products shown below belong to a manufacturing sector. Circle two products shown below that belong to the mechanical fabrication sector. You must only circle two products. If you make a mistake you must clearly show which two products you have chosen Jupiterimages Corporation Jupiterimages Corporation 2008 Jupiterimages Corporation Draper Tools Ltd [2] 4

10 (b) All the products shown below belong to a manufacturing sector. Circle two products shown below that belong to the engineering fabrication sector. You must only circle two products. If you make a mistake you must clearly show which two products you have chosen Jupiterimages Corporation Christian Darkin/Science Photo Library Jerry Mason/Science Photo Library 2008 Jupiterimages Corporation 2008 Jupiterimages Corporation 2008 Jupiterimages Corporation [2] 5

11 2 The pictures below and on the next page show some of the tools and equipment used in the manufacture of products. Complete the table by labelling the appropriate picture with the correct name from the list shown. The first one has been done for you. Bandsaw Centre Punch Bench Grinder Bench Mounted Drill Milling Machine Dividers Tool/Equipment Name Milling Machine 2008 Photograph courtesy of Warco, Chillingford,Surrey GUB 4TD Axminster Power Tool Company Ltd [1] 2008 Jupiterimages Corporation [1] 6

12 Axminster Power Tool Company Ltd [1] Draper Tools Ltd [1] Draper Tools Ltd [1] 7

13 3 Explain the function of the following mechanical components. (a) Nut and bolt 2008 Jupiterimages Corporation [1] (b) Cotter pin Tasman Industries Ltd [1] (c) Try square 2008 Jupiterimages Corporation [1] 8

14 4 Products in the engineering fabrication sector are manufactured using a range of different materials and components. (a) Name a product from the engineering fabrication sector and identify a material used within it. Give one physical and one mechanical property of the material identified. Product Material Physical property [1] Mechanical property [1] (b) Give two applications which your selected material is ideally suited for. Application 1 [1] Application 2 [1] 9

15 5 Products in the engineering sector are often made from either thermoplastic or thermosetting plastic. (a) State one feature, characteristic or property of the following two groups of plastics: Thermoplastic [1] Thermosetting [1] (b) State two properties which make plastic suitable for such a wide range of applications in the engineering sector. Property 1 [1] Property 2 [1] 10

16 6 Cell production is when employees in a factory work in teams to produce parts of the same product. (a) Give two advantages of cell production for the manufacturer. Advantage 1 [1] Advantage 2 [1] (b) (i) Explain what is meant by the term quality control. [3] (ii) Give two examples of quality control checks. Check 1 [1] Check 2 [1] (c) Give two advantages to a consumer of quality control being carried out on a product. Advantage 1 [1] Advantage 2 [1] 11

17 7 (a) State what the abbreviation CNC stands for. [1] (b) CNC devices are extensively used in the engineering sector to manufacture products. Give two reasons why CNC is an effective way of manufacturing products in the engineering sector. Reason 1 [2] Reason 2 [2] (c) Explain two disadvantages a manufacturer may face after installing CNC machines in their workplace. Disadvantage 1 [2] Disadvantage 2 [2] 12

18 8 The photograph below shows robotic welding stations on a car assembly line. KUKA (a) Give three ways that the introduction of a new robotic system, like the one pictured above, would impact on a car assembly factory with regards to: (i) Production time [3] (ii) Workforce [3] 13

19 (b) (i) CAD and CAM systems contribute to the development of Computer Integrated Manufacture (CIM). This is an automated production process, with every aspect of the manufacture controlled by a computer. State two types of equipment that could be linked to a CIM system. 1 [1] 2 [1] (ii) Explain two advantages of CIM for the manufacturer. Advantage 1 [2] Advantage 2 [2] (c) A robotic work station controlled by a computer through CIM is unable to react to problems during production in the same way a human operator could. Describe two limitations of a robotic work station when faults occur. 1 2 [2] [2] 14

20 9 Composites and smart materials have aided the development of new products. (a) (i) Explain what is meant by the term composite. [2] (ii) Give two examples of composite materials. Example 1 [1] Example 2 [1] (b) Select one of the composite materials you stated above. Composite Describe two properties of this composite material and give one application for each property. Property 1 Application [2] Property 2 Application [2] (c) (i) Explain what is meant by the term smart material. [2] 15

21 (ii) Give three examples of smart materials. Example 1 [1] Example 2 [1] Example 3 [1] (c) (iii) Select one of the smart materials you stated in the answer to c (ii). Smart material Describe one of its properties which give it an advantage over another material. [4] 16

22 10 (a) (i) State one manufacturing process which you think could be potentially harmful to a manufacturing employee and explain two ways it could affect them. Manufacturing process [1] Explanation [2] (ii) Describe one modern manufacturing process which could eliminate the problem stated above. [2] 17

23 (b) Explain two ways that a manufacturer could reduce their factory s impact on the environment. Impact 1 [2] Impact 2 [2] Total [80] 18

24 THIS IS THE END OF THE QUESTION PAPER 19

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26 Centre Number 71 Candidate Number General Certificate of Secondary Education 2010 Engineering Paper 2 Unit 3: Engineering Technology [CODE] SPECIMEN PAPER TIME 1 hour INSTRUCTIONS TO CANDIDATES Write your Centre Number and Candidate Number in the spaces provided at the top of this page. Write your answers in the spaces provided in this question paper. Answer all parts of the paper. The paper should be answered in relation to the pre-release materials. You will be provided with a new copy of the pre-release. You should not bring any of the material previously issued, or any notes made in to this examination. INFORMATION FOR CANDIDATES The total mark for this paper is 40. Figures in brackets printed down the right-hand side of pages indicate the marks awarded to each question or part question. For Examiner s use only Question Marks Number 1 a b c d e f g Total Marks 21

27 Answer all parts of the question. There is one question in this paper which relates to the pre-release materials. You should draw on the knowledge gained from the pre-release task and also Unit 3: Engineering Technology. The photographs below show a folding bicycle. This product is at the forefront of bicycle design. Its strong frame and patented technology make it one of the best folding bikes on the market. Its features are listed below: The frame is constructed exclusively from tubular aluminium. The seat adjusts up and down the stem to accommodate different heights of cyclist. The drive train kevlar belt drive is rated up to 50,000 miles. The bicycle has injection moulded wheels. The tyres can be changed without removing the wheels. The bicycle folds easily, quickly and fits in small places. The bicycle has folding handlebars. 1 (a) The frame of the folding bicycle is constructed from tubular aluminium. Name one other suitable material that could be used to manufacture the frame of the bicycle. [1] (b) State two characteristics of the bicycle frame which would make it appeal to consumers. 1 2 [2] 22

28 (c) The component sections of the rear shelf on the back stem of the folding bicycle are cut out using modern technology. (i) State two methods of control technology used to remove the component parts from stock sheet material. 1 2 [2] (ii) Give four advantages to the manufacturer when using the control technology stated above. Advantage 1 [1] Advantage 2 [1] Advantage 3 [1] Advantage 4 [1] (d) (i) Give two reasons why tubular section aluminium is an appropriate material to manufacture the main frame of the folding bicycle. Reason 1 Reason 2 [2] (ii) Give two reasons why powder coating is an appropriate surface finish for the main frame of the folding bicycle? 1 2 [2] 23

29 (e) (i) Below is a diagram which shows a hot extrusion machine and a list of five parts of this machine. Ram Bullet Dummy block Extrusion Die Identify the five parts of the machine labelled 1 5 using the list above. You should write your answer on the lines provided at the bottom of this page. CCEA [5] 24

30 (ii) Hot extrusion is used to form different types of metal. Name two other forming methods. 1 2 [2] 25

31 (f) The bicycle has a unique folding system which reduces the space it takes up during storage. Using notes and sketches in the box below, design a modification to the folding bicycle that would allow it to be carried comfortably when not in use, e.g. on a train journey. Marks will be awarded for: Suitability of the design [4] Quality of sketches [3] Detailed notes [3] [10] 26

32 (g) Using notes and sketches in the box below, show a method of adjusting the height of the seat on the folding bicycle. Marks will be awarded for: Suitability of chosen method [4] Quality of sketches [3] Detailed notes [3] [10] Total [40] 27

33 THIS IS THE END OF THE QUESTION PAPER 28

34 General Certificate of Secondary Education 2010 Engineering Paper 2 Unit 3: Engineering Technology [CODE] SPECIMEN PRE-RELEASE MATERIALS 29

35 Engineering Guidance for Candidates This pre-release material is provided in advance of the external assessment for Paper 2. Paper 2 will include a range of general questions relating to this pre-release and also to Unit 3: Engineering Technology. Candidates should research the given product and produce appropriate study materials but will not be able to bring these notes in to the examination. Clean copies of the pre-release materials will be issued with the examination. Guidance for centres To prepare for Paper 2, candidates should have studied and have knowledge and understanding of the stages involved in making a range of mass-produced products belonging to and used by the Engineering Fabrication sector. The actual products studied may be selected by the centre, but these should not include the research product described in this specimen pre-release. 30

36 Pre-release task You should also carry out research into mass-produced Evolved Cycles. You should investigate the impact and use of the following technologies in the design and production of Evolved Cycles : ICT, including: handling information, designing and manufacturing techniques and process control, designing and manufacturing techniques such as CAD and CAM. Modern materials, including: polymers, metals and composites. Control technology, including: process/quality control, automation, computer integrated manufacture (CIM), computer integrated engineering (CIE) and robotics. Your investigation should include the stages in making the product. 31

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38 33 Mark Schemes

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40 General Certificate of Secondary Education Engineering GENERAL MARKING INSTRUCTIONS 35

41 General Marking Instructions Introduction Mark schemes are intended to ensure that the GCSE examinations are marked consistently and fairly. The mark schemes provide markers with an indication of the nature and range of candidates responses likely to be worthy of credit. They also set out the criteria which they should apply in allocating marks to candidates responses. The mark schemes should be read in conjunction with these general marking instructions. Assessment Objectives Below are the assessment objectives for GCSE Engineering. Candidates must: recall, select and communicate their knowledge and understanding of engineering in a range of contexts (AO1); apply skills, knowledge and understanding, including quality standards, in a variety of contexts, and plan and carry out investigations and tasks involving a range of tools, equipment, materials and components (AO2); and analyse and evaluate products, make reasoned judgements and present conclusions (AO3). Quality of candidates responses In marking the examination papers, examiners should be looking for a quality of response reflecting the level of maturity which may reasonably be expected of a 16-year-old which is the age at which the majority of candidates sit their GCSE examinations. Flexibility in marking Mark schemes are not intended to be totally prescriptive. No mark scheme can cover all the responses which candidates may produce. In the event of unanticipated answers, examiners are expected to use their professional judgement to assess the validity of answers. If an answer is particularly problematic, then examiners should seek the guidance of the Supervising Examiner. Positive marking Examiners are encouraged to be positive in their marking, giving appropriate credit for what candidates know, understand and can do rather than penalising candidates for errors or omissions. Examiners should make use of the whole of the available mark range for any particular question and be prepared to award full marks for a response which is as good as might reasonably be expected of a 16-year-old GCSE candidate. Awarding zero marks Marks should only be awarded for valid responses and no marks should be awarded for an answer which is completely incorrect or inappropriate. Types of mark schemes Mark schemes for tasks or questions which require candidates to respond in extended written form are marked on the basis of levels of response which take account of the quality of written communication. Other questions which require only short answers are marked on a point for point basis with marks awarded for each valid piece of information provided. 36

42 Levels of response Tasks and questions requiring candidates to respond in extended writing are marked in terms of levels of response. In deciding which level of response to award, examiners should look for the best fit bearing in mind that weakness in one area may be compensated for by strength in another. In deciding which mark within a particular level to award to any response, examiners are expected to use their professional judgement. The following guidance is provided to assist examiners. Threshold performance: Response which just merits inclusion in the level and should be awarded a mark at or near the bottom of the range. Intermediate performance: Response which clearly merits inclusion in the level and should be awarded a mark at or near the middle of the range. High performance: Response which fully satisfies the level description and should be awarded a mark at or near the top of the range. Marking calculations In marking answers involving calculations, examiners should apply the own figure rule so that candidates are not penalised more than once for a computational error. Quality of written communication Quality of written communication is taken into account in assessing candidates responses to all tasks and questions that require them to respond in extended written form. These tasks and questions are marked on the basis of levels of response. The description for each level of response includes reference to the quality of written communication. For conciseness, quality of written communication is distinguished within levels of response as follows: Level 1: Quality of written communication is limited. Level 2: Quality of written communication is satisfactory. Level 3: Quality of written communication is excellent. In interpreting these level descriptions, examiners should refer to the more detailed guidance provided below: Level 1 (Limited): Candidates presentation, spelling, punctuation and grammar is limited. The candidate makes a limited selection and use of an appropriate form and style of writing. The organisation of material may lack clarity and coherence. There is little use of specialist vocabulary. Level 2 (Satisfactory): Candidates presentation, spelling, punctuation and grammar is satisfactory. The candidate makes a satisfactory selection and use of an appropriate form and style of writing supported with appropriate use of diagrams as required. Relevant material is organised with some clarity and coherence. There is some use of specialist vocabulary. Level 4 (Excellent): Candidates presentation, spelling, punctuation and grammar is excellent. The candidate successfully selects and uses the most appropriate form and style of writing, supported with precise and accurate use of diagrams where appropriate. Organisation of relevant material is excellent. There is excellent use of appropriate specialist vocabulary. 37

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44 General Certificate of Secondary Education 2010 Engineering Paper 1 Unit 3: Engineering Technology [CODE] SPECIMEN MARK SCHEME 39

45 1 (a) Mechanical fabrication The two correct products are: Foot pump [1] Carjack [1] (AO1 [2]) [2] (b) Engineering fabrication The two correct products are: Bucket [1] Gate [1] (AO1 [2]) [2] 2 Picture 1 Milling machine (example) Picture 2 Centre Punch [1] Picture 3 Dividers [1] Picture 4 Bandsaw [1] Picture 5 Bench Grinder [1] Picture 6 - Bench Mounted Drill [1] (AO1 [5]) [5] 3 (a) Nut and bolt Nuts and bolts are used to create a mechanical fixing between two pieces of material. (AO1 [1]) [1] (b) (c) Cotter pin A cotter pin is a metal fastener with two tines that is secured (after passing through a hole) by splitting the ends apart. (AO1 [1]) [1] Try square A try square is a woodworking or a metal working tool used for marking and measuring (primarily the accuracy of 90 o ). (AO1 [1]) [1] 4 (a) Physical Property For the given product and material candidates must give physical properties such as: Fusibility [1] Density [1] Electrical conductivity [1] Thermal property [1] Any other appropriate response (AO1 [1]) [1] 40

46 Mechanical Property For the given product and material candidates must give mechanical properties such as: Strength [1] Elasticity [1] Plasticity [1] Hardness [1] Durability [1] Ductility [1] Toughness [1] Stability [1] Any other appropriate response (AO1 [1]) (b) Application 1 and 2 Candidates must give suitable applications of their selected material. [1] and [1] (AO1 [2]) [1] [2] 5 (a) Thermoplastic Any one from the following: Thermoplastics can be formed into shapes when heated and can be reformed by reheating [1] Thermoplastics are recyclable and bendable [1] Thermoplastics can be moulded when heated then harden when cooled [1] Any other appropriate response Thermosetting Any one from the following: Thermosetting plastics can be formed into shape, but once they have set they cannot be changed [1] Thermosetting plastics are non-recyclable and rigid [1] Thermosetting plastics when heated become permanently set due to cross linking [1] Any other appropriate response (AO1 [2]) [2] 41

47 (b) Property 1 and 2 Any two from the following: Low density [1] Resistance to corrosion [1] Good strength to weight ratio [1] Very low coefficients of friction [1] Recyclable [1] Easily formed [1] Plastic memory [1] Heat resistant [1] Fire resistant [1] (AO3 [2]) [2] 6 (a) Advantage 1 and 2 Any two from the following: Reduction in product failure [1] Reduction in product recall [1] Improved product quality [1] Less time consuming the summative quality control [1] Any other appropriate response (AO1 [2]) [2] (b) (i) Quality control Candidates are awarded marks for each of the following: Quality control is a series of checks which are carried out on a product as it is made [1] The checks are made to ensure that the product meets a specific standard [1] A tolerance specifies the minimum and maximum measurements for a component [1] Any other appropriate response (AO1 [3]) [3] (ii) Any two from the following: Dimensional accuracy [1] Weight [1] Electrical circuit testing [1] Flammability tests [1] Any other appropriate response (AO1 [2] [2] 42

48 (c) Advantage 1 and 2 Any two from the following: Improved product quality [1] Consistency of product quality [1] Assured functionality [1] Assured safety [1] Any other appropriate response (AO1 [2]) [2] 7 (a) CNC: Computer Numerical Control [1] (AO1 [1]) [1] (b) Reason 1 and 2 Any two from the following: Saving on the design, manufacture and storage [1] of jigs and fixtures [1] On lathes, simple single point tools are able to produce complex forms [1], eliminating the need for expensive, specially made form tools [1] Human error and scrap caused as result of operator fatigue [1] are significantly reduced [1] Manufacturing cost [1] is far more predictable [1] Any other appropriate response [1] for brief statement [2] for full reason (AO3 [4]) [4] (c) Disadvantage 1 and 2 Any two from the following: The initial cost of the machines [1] and installation [1] are very high The training of programmers and operators [1] is very expensive[1] Breakdown and part replacement often cannot be resolved on site [1], specialists required [1] Any other appropriate response [1] for brief statement [2] for full explanation (AO3 [4]) [4] 8 (a) (i) Production time Any three from the following: Reduction in production time [1] The automated robotic system can repeat a programmed operation over and over again [1] This level of repetition and increased speed is achieved by the system not requiring breaks, other than occasional maintenance [1] Any other appropriate response (AO2 [3]) [3] 43

49 (ii) Workforce Any three from the following: Upon introduction of such a system into a factory the workforce will be reduced in size [1] Remaining workforce will be in a caretaker capacity overseeing machine function [1] The workforce will need to be retrained in ICT in order for them to competently programme and oversee the automated machinery [1] Any other appropriate response (AO2 [3]) [3] (b) (i) Any two from the following: Milling machine [1] Router [1] Lathe [1] Laser cutter [1] Any other appropriate response (AO1 [2]) (ii) Workforce Any two from the following: All operations are logged [1] and can be tracked [1] Improved fault finding ability [1] which will increase efficiency and accuracy Production line efficiency can be monitored [1] and adjusted [1] where necessary Time saving [1] information goes directly from design to production floor [1] Any other appropriate response [1] for brief explanation [2] for full explanation (AO3 [4]) [2] [4] (c) Limitations Any two from the following: Limited reaction [1] to unscheduled obstruction [1] Must shut down when problem arises [1] and await human intervention [1] Unable to identify if fault is minor or major fault [1] so reacts in the same way to both [1] Cannot stockpile components from other cells [1] without instruction [1] Can only work at set rate when fault solved [1] difficult to catch up [1] Any other appropriate response [1] for brief description [2] for full description (AO2 [4]) [4] 44

50 9 (a) (i) A composite is a combination of different materials [1] to create a new material with different properties [1] (AO1 [2]) [2] (ii) Composite 1 and 2 Any two from the following: Fibre glass [1] Carbon fibre [1] Any other appropriate response (AO1 [2]) [2] (b) Any composite material identified in question 9(a)(ii), for example: Fibre glass Candidates must give two properties and one application for each property. A very strong material [1] Used for boat hulls [1] Can be formed into complex shapes [1] Used for swimming pool water chutes and slides [1] or Carbon fibre Candidates must give two properties and two uses: A very strong material [1] Used for racing car bodies [1] A light weight material [1] Used for bullet proof vests [1] or any other appropriate response (AO1 [4]) [4] (c) (i) A smart material is a material or component which exhibits some kind of useful response to external changes [1], such as light, heat electric current [1] (AO1 [2]) [2] (ii) (iii) Smart materials Any three from the following: Smart wire [1] Thermo colour sheet [1] Polymorph [1] Conductive polymers [1] Any other appropriate response (AO1 [3]) Smart wire By passing a small electric current [1] through the wire [1] it will shrink in length [1], when the current stops it will return to its original length [1] [3] 45

51 Thermo colour sheet A self adhesive sheet material [1] which has been printed with liquid crystal ink [1]. Colour changes occur above 27 degrees [1] used on children s toys, games and temperature indicators on products which heat up [1] Polymorph A tough polymer [1] which becomes easy to mould at just 62 degrees [1]. It can be softened with warm water or a hair dryer [1] and shaped by hand. It hardens to a stiff plastic [1] Conductive polymers A plastic [1] which can conduct electricity [1], providing endless possibilities for sign makers [1], reducing the need to hide circuits and wires [1] Any other appropriate response (AO3 [4]) [4] 10 (a) (i) Any one from the following: Welding [1] Spray painting [1] Any other appropriate response (AO1 [1]) [1] Welding Any two from the following: Eye damage [1] Potential burns [1] Harmful fume inhalation [1] Noise damage [1] Any other appropriate response or Paint spraying Any two from the following: Eye damage [1] Harmful fume inhalation [1] Skin reaction [1] Repetitive strain injury [1] Any other appropriate response (AO3 [2]) [2] 46

52 (ii) Modern manufacturing process Any one from the following: An automated in line <process> system [1] programmed to complete the task of the human operative [1] The entire process can be operated and controlled from a safe distance [1] by a trained operator [1] Any other appropriate response [1] for brief description [2] for full description (AO3 [2]) [2] (b) Impact 1 and 2 Any two from the following: Be more economical [1] by reducing material waste [1] Use less electricity [1] by changing shift patterns to suit off peak hours [1] Reduce noise pollution [1] by using anti-social shift patterns [1] Reduce water pollution [1] by recycling or reusing waste in an environmentally neutral manner [1] Reduce air pollution [1] by investing new and emerging technologies [1] Any other appropriate response [1] for brief explanation [2] for full explanation (AO3 [4]) [4] Total Marks [80] 47

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54 General Certificate of Secondary Education 2010 Engineering Paper 2 Unit 3: Engineering Technology [CODE] SPECIMEN MARK SCHEME 49

55 1 (a) Any one from the following: Stainless steel [1] Mild steel [1] Any other appropriate response (AO1 [1]) [1] (b) Any two from the following: Compact [1] Unique [1] Light weight [1] Modern [1] Any other appropriate response (AO3 [2]) [2] (c) (i) Any two from the following: CNC [1] Laser cutter [1] (AO1 [2]) [2] (ii) Any four from the following: Increased productivity [1] Improved product quality [1] Perfect component matching due to CNC accuracy [1] More economical planning with materials [1] Any other appropriate response (AO3 [4]) [4] (d) (i) Any two from the following: Light weight [1] Non-corrosive [1] Ease of machining [1] Can be self finished [1] Retains strength after forming [1] (AO2 [2]) [2] (ii) Any two from the following: Hard wearing baked on finish [1] Can resist the elements [1] Makes it more durable than paint [1] Any other appropriate response (AO2 [2]) [2] 50

56 (e) (i) 1 Ram [1] 2 Dummy block [1] 3 Billet [1] 4 Die [1] 5 Extrusion [1 (AO1 [5]) [5] (ii) Any two from the following: Forging Rolling Sheet metal forming Any other appropriate response (AO1 [2]) [2] (f) Suitable sketches showing a carrying system possibly involving a shoulder strap or compact bag and strap [4] Sketch should include any two of the following: A suitable 3-dimensional sketch showing the overall appearance of the finished product [2] Focused detail on how the bike is secured into a ruck sack style canvas bag [2] Focused detail on how the product is to be carried shoulder slung or on the back [2] Focused detail on a security system hidden zips, coded locks [2] (AO2 [4]) Quality of sketch [3] Limited: Basic representation of mechanism; basic sketches [1] Good: Good representation of the mechanism but missing some clarity; good quality sketches [2] Very Good: Clear representation of detailed sketches with high degree of sketching techniques [3] (AO2 [3]) Information contained in notes e.g. details of materials, processes, fasteners and fixings [3] Few notes: [1] The level of accuracy of their spelling, grammar and punctuation is limited. They present their notes using a limited form and style. There is limited reference to specialist terms. Good notes: [2] The level of accuracy of their spelling, grammar and punctuation is good. They present their notes using a good form and style with some appropriate reference to specialist terms. Detailed notes: [3] The level of accuracy of their spelling, grammar and punctuation is excellent. They present their notes using an excellent form and style. Specialist terms are used appropriately. No notes: [0] (AO1 [3]) [10] 51

57 (g) Suitable sketches showing how the seat height is moved using some kind of allen key or other mechanical adjuster [4] Sketch should include any two of the following: A suitable 3-dimensional sketch showing the overall appearance of the finished product [2] Focused detail on how the bracket is locked in more than one point [2] Focused detail on how the bracket may be located into preset heights [2] Focused detail on how the adjustment tools may be stored when not in use [2] (AO2 [4]) Quality of sketches [3] Limited: Basic representation of mechanism; basic sketches [1] Good: Good representation of the mechanism but missing some clarity; good quality sketches [2] Very Good: Clear representation of detailed sketches with high degree of sketching techniques [3] (AO2 [3]) Information contained in notes e.g. details of how the seat gains grip on the stem, the most suitable material for the seat bracket or storage area for the tools [3] Few notes: [1] The level of accuracy of spelling, grammar and punctuation is limited. They present their notes using a limited form and style. There is limited reference to specialist terms. Good notes: [2] The level of accuracy of spelling, grammar and punctuation is good. They present their notes using a good form and style with some appropriate reference to specialist terms. Detailed notes: [3] The level of accuracy of spelling, grammar and punctuation is excellent. They present their notes using an excellent form and style. Specialist terms are used appropriately. No notes: [0] (AO1 [3]) [10] Total Marks [40] 52

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60 General Certificate of Secondary Education Engineering GUIDANCE ON CONTROLLED ASSESSMENT 55

61 Guidance on Controlled Assessment There are now more controls around internal assessment within GCSEs. Internal Assessment will now be referred to as Controlled Assessment. Levels of control are set for each of the three processes involved in controlled assessment. The three processes are: task setting: ensures that tasks are valid and reliable by making them less predictable and formulaic; task taking: conditions under which tasks are taken addresses issues of authenticity; and task marking: ensures high quality judgments in assessment. For each of the above processes, different levels of control are possible. These are defined as high, medium and limited/low, e.g. a high level of control for each process would be very similar to an existing examination. The result is that within any subject, varying levels of control are likely to be required across the three processes. Process Level of Control What this means Task setting High CCEA set a number of comparable tasks from which the teacher chooses those most appropriate to their students. Task taking Medium All work, except research and the practicing of skills, is done under informal supervision. Task marking Medium Teachers must mark the controlled assessment tasks for both units in accordance with the supplied marking criteria and mark bands. There are two controlled assessment tasks for GCSE Engineering: Unit 1: Engineering Design and Graphical Communication (30% of overall award); and Unit 2: Engineering Production (30% of overall award). The specimen controlled assessment tasks are included to help your students understand, as fully as possible, the types of tasks they may encounter and how marks will be awarded. We provide guidance on word or time limits. Tasks are reviewed every year. Further information on controlled assessment can be found in Section 6 of the specification. 56

62 General Certificate of Secondary Education 2011 Engineering Unit 1: Engineering Design and Graphical Communication [CODE] Controlled Assessment SPECIMEN TASK 57

63 Controlled Assessment Exemplar Task: Unit 1 Engineering Design and Graphical Communication Guidance for candidates You are permitted a total of 25 hours for this task. You must complete your portfolio within the classroom (20 hours). However you can carry out research for the Design Briefs and Engineering Drawings outside the classroom (5 hours). You may also work with other candidates when carrying out research. Quality of written communication will be assessed in this task. Your teacher will provide you with a copy of the marking criteria. This will allow you to understand the distribution of marks for this task. 58

64 Example Brief The principal of your local primary school has introduced a recycling scheme to his pupils. They are being encouraged to use the appropriate bins for paper and other general waste. The principal feels that they could do more by recycling drinks cans. Your task is to design a drinks can crushing station suitable for primary school children to use. The crushing station should reduce the size of the can to maximise storage space and promote recycling among the pupils. An example of one such device is shown below. I Want One of Those.com Ltd 59

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66 General Certificate of Secondary Education 2011 Engineering Unit 2: Engineering Production [CODE] Controlled Assessment SPECIMEN TASK 61

67 Controlled Assessment Specimen Task: Unit 2 Engineering Production Guidance for centres This unit aims to help develop an understanding of the process of designing a product and producing it. Techniques to produce a production plan should be taught along with techniques used to select appropriate materials and components and processes to produce products. Candidates are not expected to have occupational competencies at this level or to be working to commercially accepted standards. The unit introduces candidates to: seven aspects of designing and producing a product; using product specifications; reading and interpreting engineering drawings and diagrams; selecting suitable materials, parts and components for a product; creating a production plan, using processes, tools and equipment, including Computer Aided Manufacture (CAM), required to make an engineered product; checking the quality of their work to ensure it conforms to the standards required; and applying health and safety procedures. Centres should think carefully about the product specification to be given to candidates. It should be designed to suit the materials and resources available to that centre. The specification should reflect the diverse realms of engineered products, for example, by including mechanical and electrical components. Using a wide range of different components will make the engineered product more applicable to the unit range requirements. An example of a brief is given on page 63, and working drawings related to that brief are on pages 64 and 65. Guidance for candidates You are permitted a total of 25 hours for this task. You must complete your portfolio and produce the product within the classroom. However you may practice the required skills outside the classroom. 62

68 Controlled Assessment Specimen Task: Unit 2 Engineering Production Example Brief The owner of a local model toy shop is looking to extend the range of model toys to include more affordable models. They have asked you to produce a minimum of five model steam engines or five model cannons. The client wishes to see at least two different types of materials used. If you can meet the client specification he will make a long term arrangement with you to produce model toys. The working drawings for this brief are on pages 64 and 65. Example photograph of model steam engines Lavery Engineering 63

69 CCEA Model Steam Engine Working Drawing 64

70 CCEA Model Cannon Working Drawing 65

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72 General Certificate of Secondary Education 2011 Engineering [CODE] Unit 1: Engineering Design and Graphical Communication Unit 2: Engineering Production SPECIMEN ASSESSMENT CRITERIA AND MARK BANDS 67

73 Assessment Criteria and Mark Bands for Controlled Assessment Tasks Unit 1: Engineering Design and Graphical Communication Skill(s) to be assessed Mark Band 1 At this level, work must show: Mark Band 2 At this level, work must show: Mark Band 3 At this level, work must show: (a) Analyse client briefs AO3 6 marks an analysis of the brief to identify basic client needs, with the identification of some key features of the engineering product; limited spelling, punctuation, grammar and legibility; analysis that uses a limited form and style; analysis that has limited coherence; use of a limited range of specialist terms; 1 3 an analysis of the brief to identify the main client needs, with a description of the main key features of the engineering product; satisfactory spelling, punctuation, grammar and legibility; analysis that uses a satisfactory form and style; analysis that is coherent and organised; use of a satisfactory range of specialist terms; 4 5 an analysis of the brief to explain the main client needs, with a justification of the main key features of the engineering product; excellent spelling, punctuation, grammar and legibility; analysis that uses an excellent form and style; analysis that is coherent and very well organised; use of a wide range of specialist terms; (b) Produce, use and modify design specifications AO2 7 marks a design specification that describes basic details of the product criteria and of the production constraint; limited spelling, punctuation, grammar and legibility; ideas that use a limited form and style; ideas that have limited coherence; use of a limited range of specialist terms; 1 3 a design specification that describes some of the main details of the product and of the production constraints; satisfactory spelling, punctuation, grammar and legibility; ideas that use a satisfactory form and style; ideas that are coherent and organised; use of a satisfactory range of specialist terms; 4 5 a design specification that describes the main details of the product and of the production constraints; excellent spelling, punctuation, grammar and legibility; ideas that use an excellent form and style; ideas that are coherent and very well organised; use of a wide range of specialist terms;

74 Skill(s) to be assessed Mark Band 1 At this level, work must show: Mark Band 2 At this level, work must show: (c) Generate design solutions AO2 12 marks the generation of basic design ideas and the development of simple design solutions; 1 5 the generation of alternative design ideas and the development, in some detail, of design solutions; (d) Read, understand and create drawings AO2 6 marks the selection and use of a limited range of engineering drawing techniques to communicate the final solution; 1 2 the selection and use of a range of engineering drawing techniques to communicate, in some detail, the final solution; (e) Present a design solution AO3 5 marks limited testing against the design criteria to select and outline the final design solution; 1 2 a range of testing against the design criteria to select and describe the final design solution; (f) Respond to client feedback AO2 8 marks limited description of how the final design solution meets the brief and specification, with an identification of some relevant modifications; limited spelling, punctuation, grammar and legibility; a response that uses a limited form and style; a response that has limited coherence; use of a limited range of specialist terms. 1 3 description, in some detail, of how the final design solution meets the brief and specification, describing relevant modifications; satisfactory spelling, punctuation, grammar and legibility; a response that uses a satisfactory form and style; a response that is coherent and organised; use of a satisfactory range of specialist terms. Total marks available: 44 When a candidate has not met any of the above criteria then a zero, 0, mark should be awarded. Mark Band 3 At this level, work must show: 6 9 the generation of imaginative design ideas and the development of detailed and appropriate design solutions; 3 4 the selection and use of an effective range of engineering drawing techniques to communicate, in detail, the final solution; 3 4 objective testing against the design criteria to select and justify the final design solution; 4 5 an explanation, in some detail, of how the final design solution meets the brief and specification, explaining relevant modifications; excellent spelling, punctuation, grammar and legibility; a response that uses an excellent form and style; a response that is coherent and very well organised; use of a wide range of specialist terms

75 Unit 2: Engineering Production Skill(s) to be assessed Mark Band 1 At this level, work must show: (a) Independent use of a production plan limited use of a supplied production plan; AO2 4 marks (b) Independent use of appropriate processes AO1 limited use of a limited range of basic processes demonstrating low level engineering skills; 6 marks (c) Independent application of controls to the accuracy of the product limited application of quality controls demonstrating low level accuracy and precision working to a tolerance of +/- 1.5 mm; AO1, AO2, AO3 12 marks (d) Independent application of controls to the finish of the product AO2, AO3 limited application of quality controls demonstrating low level finishing techniques on the product; 8 marks Mark Band 2 At this level work must show: 1 2 satisfactory use of a supplied production plan; 1 2 satisfactory use of a range of appropriate processes demonstrating a good level of engineering skills; 1 5 satisfactory application of quality controls demonstrating a good level of accuracy and precision quality controls working to a tolerance of +/- 1.0 mm; 1 4 satisfactory application of quality controls demonstrating a good level of finishing techniques on the product; Mark Band 3 At this level work must show: 3 competent use of a supplied production plan; 3 4 competent use of a broad range of challenging processes demonstrating high level engineering skills; 6 9 competent application of quality controls demonstrating high level accuracy and precision when working to a set tolerance of +/- 0.5 mm; 5 6 competent application of quality controls demonstrating high level appropriate finishing techniques on the product;

76 Skill(s) to be assessed Mark Band 1 At this level, work must show: Mark Band 2 At this level work must show: (e) Independent use of tools and equipment AO2 limited use of tools and equipment demonstrating low level engineering skills; 1 2 satisfactory use of a range of appropriate tools and equipment demonstrating a good level of engineering skills; 6 marks (f) Application of health and safety procedures AO2 limited application of health and safety procedures under supervision. 1 2 satisfactory application of appropriate health and safety procedures on instruction. 4 marks Total marks available: 40 When a candidate has not met any of the above criteria then a zero, 0, mark should be awarded. Mark Band 3 At this level work must show: 3 4 competent use of a broad range of appropriate tools and equipment demonstrating high level engineering skills; 3 competent application of appropriate health and safety procedures at all times

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