48663 Advanced Manufacturing
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Credit points: 6 cp
Subject level:
Undergraduate
Result type: Grade and marksRequisite(s): 48650 Mechanical Design 2 AND 48621 Manufacturing Engineering
Anti-requisite(s): 43016 Materials and Manufacturing B
Description
This subject enables students to understand key aspects of manufacturing in modern environments. Students learn about considerations relating to volume, capital investment, modern concepts of quality management, and quality control. Modern metrology equipment and methods are also examined. Students of this subject become conversant with aspects of computer systems and software in relation to modern manufacturing, and gain experience with CAD/CAM for CNC machining. Students also investigate some roles of industrial robots in fabrication, welding and assembly.
Subject learning objectives (SLOs)
Upon successful completion of this subject students should be able to:
| 1. | Identify and explain the design and manufacturing processing of products in various environments ranging from low volume to high volume and with various levels of capital investment in the manufacturing system. |
|---|---|
| 2. | Use modern concepts of quality management to apply process quality control techniques to manufacturing situations (to achieve client requirements). |
| 3. | Apply some of the important techniques of modern metrology to the manufacturing industry. |
| 4. | Demonstrate the use of CAD/CAM in a manufacturing environment. |
| 5. | Apply the concepts of reverse engineering and rapid prototyping. |
| 6. | Investigate the viability of industrial robots in environments such as fabrication, welding and assembly. |
| 7. | Apply contemporary ideas such as Design for Manufacture (DFM) and Just in Time (JIT). |
Course intended learning outcomes (CILOs)
This subject also contributes specifically to the development of the following Course Intended Learning Outcomes (CILOs):
- Socially Responsible: FEIT graduates identify, engage, interpret and analyse stakeholder needs and cultural perspectives, establish priorities and goals, and identify constraints, uncertainties and risks (social, ethical, cultural, legislative, environmental, economics etc.) to define the system requirements. (B.1)
- Design Oriented: FEIT graduates apply problem solving, design and decision-making methodologies to develop components, systems and processes to meet specified requirements. (C.1)
- Technically Proficient: FEIT graduates apply abstraction, mathematics and discipline fundamentals, software, tools and techniques to evaluate, implement and operate systems. (D.1)
Teaching and learning strategies
The student learning development in this subject is through: (1) Preparative work (“pre-work”), (2) “in-class” activities, and (3) “post-class” activities. Of these activities, some are undertaken on-campus and others online.
When students participate in these activities, they will develop an understanding of key advanced manufacturing concepts relating to quality in manufacturing, engineering metrology and measurements, automation, production systems, computer-integrated manufacturing, CNC, CAD/CAM, Additive Manufacturing, PLC and robotics. In addition, students will develop an ability to understand, troubleshoot and solve complex manufacturing problems.
For each of these topic areas, student learning starts with preparatory activities. In most cases, preparatory documents are available on Canvas for students to read prior to the in-class sessions. Second, after students complete their (online) preparatory activities, they will participate in lectures and laboratories. The students will have experience and knowledge exchange through forum, social media applications will be a discussion windows. Third, student competency is further developed through “post-class” problem-based and project-based learning activities including assignments and preparing for the final exam.
An illustrative example follows, showing how these learning strategies are intended to work together to improve learning. During two laboratories, students will use specialised metrology equipment to measure and characterise the dimensions and surfaces of various items and parts. Students already know that manufacturing engineering commonly involves the production of parts or products – and that those parts or products must invariably meet specified requirements relating to size/surface/smoothness etc.
During the two-metrology laboratories, students will gain hands-on experience with different types of metrology equipment. In this way, they will further their understanding of how such measurements are obtained, analysed and interpreted with respect to tolerance and quality. In addition, by participating in such practical activities, students will further-develop competencies relevant to professional manufacturing engineering practice. In tandem with the laboratories, the lectures will help students to develop their understanding of relevant key concepts.
Prior to the in-class activities, students will have engaged with online pre-work that focuses on some introductory concepts and introduces students to “must-know” aspects of the equipment that they will soon use hands-on. Following the labs, students will produce reports that analyse and reflect on the results of the labs. These post-class activities are intended to help students reinforce their learning, encourage students to undertake additional self-directed research and facilitate student engagement with further self-directed problem solving.
This subject also includes a major project, where students will gain further hands-on experience while they design, fabricate, implement, troubleshoot and evaluate their own manufacturing equipment. The group-based nature of the major project is also intended to help further-develop student experience in participating in a collaborative manufacturing engineering setting.
Content (topics)
- quality management and tools for quality management metrology, tolerance, CMM
- computer-aided manufacturing and numerical control of machine tools computer-aided process programming industrial robotics
- 3D scanning, additive manufacturing and rapid prototyping
- PLC
- flexible manufacturing systems computer integrated manufacturing
- production planning and control ideas; just-in-time, Toyota, Kanban and group technology
Assessment
Assessment task 1: G-Coding, CNC, CAD/CAM and Additive Manufacturing
| Intent: | Experimental validation of students' knowledge. |
|---|---|
| Objective(s): | This assessment task addresses the following subject learning objectives (SLOs): 1, 2, 3, 4, 6 and 7 This assessment task contributes to the development of the following Course Intended Learning Outcomes (CILOs): B.1 and D.1 |
| Type: | Laboratory/practical |
| Groupwork: | Individual |
| Weight: | 20% |
| Length: | 7-12 pages based on student’s selection to present the calculation and simulation work. |
Assessment task 2: Engineering metrology and measurements
| Intent: | Lab-based work. |
|---|---|
| Objective(s): | This assessment task addresses the following subject learning objectives (SLOs): 2, 3, 6 and 7 This assessment task contributes to the development of the following Course Intended Learning Outcomes (CILOs): B.1 and D.1 |
| Type: | Laboratory/practical |
| Groupwork: | Group, individually assessed |
| Weight: | 15% |
| Length: | Proper lab report include the description of the measurement process and the mathematical analysis of the results (Including graphs and discussion). |
Assessment task 3: Statistical Process Control (SPC)
| Intent: | validation of students' knowledge |
|---|---|
| Objective(s): | This assessment task addresses the following subject learning objectives (SLOs): 3, 6 and 7 This assessment task contributes to the development of the following Course Intended Learning Outcomes (CILOs): B.1 and D.1 |
| Type: | Laboratory/practical |
| Groupwork: | Group, individually assessed |
| Weight: | 15% |
| Length: | Calculation based assessment, no limited length. |
Assessment task 4: Robotics and CAD/CAM Applications
| Intent: | Experimental validation of students' knowledge and creativity. |
|---|---|
| Objective(s): | This assessment task addresses the following subject learning objectives (SLOs): 2, 4, 5, 6 and 7 This assessment task contributes to the development of the following Course Intended Learning Outcomes (CILOs): B.1, C.1 and D.1 |
| Type: | Laboratory/practical |
| Groupwork: | Individual |
| Weight: | 30% |
| Length: | 7-15 pages based on student’s selection to present the calculation and simulation work. |
Assessment task 5: CIM and CAPP
| Intent: | Validation of students' knowledge. |
|---|---|
| Objective(s): | This assessment task addresses the following subject learning objectives (SLOs): 4, 6 and 7 This assessment task contributes to the development of the following Course Intended Learning Outcomes (CILOs): B.1 and D.1 |
| Type: | Report |
| Groupwork: | Individual |
| Weight: | 20% |
| Length: | Calculation based assessment, no limited length. |
Minimum requirements
In order to pass the subject, a student must achieve an overall mark of 50% or more.
Required texts
Reference materials to be available on Canvas.
Recommended texts
- Groover, M.P., Automation, Production Systems, and Computer-Integrated Manufacturing, 4th ed., Pearson, 2015.
References
- Nanua Singh, 1996, Systems Approach to Computer-Integrated Design and Manufacturing, Wiley, ISBN 0-471-58517-3
- Serope Kalpakjian and Steven Schmid, Manufacturing Engineering and Technology, SI edition, ISBN 0-13-197639-7
Other resources
See Canvas for recommended web addresses and reference material.