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MECH5660: Foundations of Manufacturing Engineering (2014 - Semester 1)

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Unit: MECH5660: Foundations of Manufacturing Engineering (6 CP)
Mode: Normal-Day
On Offer: Yes
Level: Postgraduate
Faculty/School: School of Aerospace, Mechanical & Mechatronic Engineering
Unit Coordinator/s: Mr Briozzo, Paul
Session options: Semester 1
Versions for this Unit:
Campus: Camperdown/Darlington
Pre-Requisites: MECH5400.
Brief Handbook Description: The unit aims to teach the fundamentals of manufacturing processes and systems in mechanical, mechatronic and biomedical engineering, including traditional and advanced manufacturing technologies.

This unit aims to develop the following attributes: to understand the fundamental principles of manufacturing technologies for the above mentioned engineering areas; to gain the ability to select existing manufacturing processes and systems for direct engineering applications; to develop ability to create innovative new manufacturing technologies for advanced industrial applications; to develop ability to invent new manufacturing systems

At the end of this unit students will have a good understanding of the following: merits and advantages of individual manufacturing processes and systems; principles of developing new technologies; comprehensive applications and strategic selection of manufacturing processes and systems.

Course content will include:

Manufacturing Processes: Common processes and their science (machining, casting, powder metallurgy, metal working, welding); merits and limitations; CNC and CAM;

Manufacturing Systems: Economics in manufacturing; flexible manufacturing; group technology; materials selection and requirements planning; quality control; introduction to new technology; introduction to e-manufacturing; human factors; plant layout.
Assumed Knowledge: None.
Lecturer/s: Mr Briozzo, Paul
Dr Chang, Li
Tutor/s: Peter Lok - Tutor

Kazi Rizwana Mehzabeen (Pauline) - Tutor

Edwin Soh - Marker
Timetable: MECH5660 Timetable
Time Commitment:
# Activity Name Hours per Week Sessions per Week Weeks per Semester
1 Laboratory
2 Lecture 2.00 1 13
3 Tutorial 2.00 1 13
4 Independent Study 5.00 13
T&L Activities: Laboratory:

1. CNC Laboratory demonstration will provide experience in hands-on CNC machining. Each student will be allocated one session of demonstration.

2. Clubman Laboratory will provide exposure to mechanical hardware which has been manufactured using methods described in the lectures and tutorials. Each student will be allocated one session of demonstration.

Attributes listed here represent the key course goals (see Course Map tab) designated for this unit. The list below describes how these attributes are developed through practice in the unit. See Learning Outcomes and Assessment tabs for details of how these attributes are assessed.

Attribute Development Method Attribute Developed
Design of manufacturing processes. Design (Level 3)
Understanding of the common manufacturing processes and essential skills in planning the manufacture of a product. Engineering/IT Specialisation (Level 3)
Participation in team assignments. Project and Team Skills (Level 3)

For explanation of attributes and levels see Engineering & IT Graduate Outcomes Table.

Learning outcomes are the key abilities and knowledge that will be assessed in this unit. They are listed according to the course goal supported by each. See Assessment Tab for details how each outcome is assessed.

Design (Level 3)
1. Ability to determine function requirement of an engineering design in terms of application and suitability, etc.
2. Ability to determine the basic manufacturing considerations necessary to realize the design functions, including the selection of materials and the manufacturing method, taking into account the strength and reliability.
3. Ability to analyse the merits and disadvantages of individual manufacturing method.
4. Ability to explore the major problems in the current manufacturing practice and your appraoches to ingor improving them (highly encouraged to undertake an investigation, e.g., visit a manufacturer by yourselves).
Engineering/IT Specialisation (Level 3)
5. Understanding the fundamental principles of manufacturing technologies for mechanical, mechatronic and biomedical engineering.
6. Familiarity with use of CNC machining in manufacturing.
Project and Team Skills (Level 3)
7. Ability to contribute to effective team processes.
Assessment Methods:
# Name Group Weight Due Week Outcomes
1 Quiz 1 - CNC Machining / Automation No 20.00 Week 5 1, 2, 3, 4, 5, 6,
2 Quiz 2 - Manuf. Processes /Automation No 20.00 Week 9 1, 2, 3, 4, 5,
3 Quiz 3 - Composite and Nano Manufacturing No 20.00 Week 13 1, 2, 3, 4, 5,
4 Design for Manufacturing Project Yes 20.00 Week 9 1, 2, 3, 4, 5, 6, 7,
5 Manufacturing Research Proposal Yes 10.00 Week 13 1, 2, 3, 4, 5,
6 CNC Laboratory Exercise No 5.00 Multiple Weeks 5, 6,
7 Clubman Laboratory Group Report Yes 5.00 Multiple Weeks 1, 2, 3, 5, 7,
Assessment Description: Quizzes: Three Quizzes that examine; 1. Quiz 1 CNC - Machining and Automation, 2. Quiz 2 - Manufacturing Processes and Automation and Quiz 3 - Composite and Nano Manufacturing as shown in Syllabus/Schedule below. Quiz material is derived from course notes, tutorials and lectures.

CNC Code Submission: Submission of group (2 members max) CNC code.

Design for Manufacturing Project: The project allows students to concentrate on; 1. CNC Machining, 2. Automation and 3. Manufacturing Processes. (2 members max)

Manufacturing Research Proposal: The research propposal allows students to investigate current papers (scientific and industry based) on; Composities and or Nano Manufacturing. (2 members max)

Laboratory (CNC): Compulsory Attendance of the CNC demonstration held within the School.

Laboratory (Clubman): Group Report of the attempted assembly in the Clubman Assembly Lab held within the School.

Laboratory (Clubman): Compulsory Attendance and participation in the Clubman Assembly Lab held within the School.
Grading:
Grade Type Description
Standards Based Assessment Final grades in this unit are awarded at levels of HD for High Distinction, DI (previously D) for Distinction, CR for Credit, PS (previously P) for Pass and FA (previously F) for Fail as defined by University of Sydney Assessment Policy. Details of the Assessment Policy are available on the Policies website at http://sydney.edu.au/policies . Standards for grades in individual assessment tasks and the summative method for obtaining a final mark in the unit will be set out in a marking guide supplied by the unit coordinator.
Policies & Procedures: See the policies page of the faculty website at http://sydney.edu.au/engineering/student-policies/ for information regarding university policies and local provisions and procedures within the Faculty of Engineering and Information Technologies.
Recommended Reference/s: Note: References are provided for guidance purposes only. Students are advised to consult these books in the university library. Purchase is not required.
Note on Resources: The lecture notes, consisting of three parts, summarize the key issues of the subject and are available in the University’s Photocopy Centre.

Note that the "Weeks" referred to in this Schedule are those of the official university semester calendar https://web.timetable.usyd.edu.au/calendar.jsp

Week Description
Week 1 Lecture/Tutorial: Introduction to Course and CNC Machining
Lecture/Tutorial: Manufacturing Automation
Week 2 Lecture/Tutorial: CNC Machining
Lecture/Tutorial: Manufacturing Automation
Week 3 Lecture/Tutorial: Manufacturing Automation
Lecture/Tutorial: CNC Machining
Week 4 Lecture/Tutorial: CNC Machining
Lecture/Tutorial: Manufacturing Automation
Week 5 Lecture/Tutorial: Manufacturing Automation
Assessment Due: Quiz 1 - CNC Machining / Automation
Week 6 Lecture/Tutorial: Manufacturing Processes
Lecture/Tutorial: Manufacturing Automation
Week 7 Lecture/Tutorial: Manufacturing Processes
Lecture/Tutorial: Manufacturing Automation
Week 8 Lecture/Tutorial: Manufacturing Processes
Lecture/Tutorial: Manufacturing Automation
Week 9 Lecture/Tutorial: Manufacturing Processes
Assessment Due: Quiz 2 - Manuf. Processes /Automation
Assessment Due: Design for Manufacturing Project
Week 10 Lecture/Tutorial: Nano Manufacturing
Lecture/Tutorial: Nano Manufacturing
Week 11 Lecture/Tutorial: Nano Manufacturing
Lecture/Tutorial: Nano Manufacturing
Week 12 Lecture/Tutorial: Nano Manufacturing
Lecture/Tutorial: Nano Manufacturing
Week 13 Lecture/Tutorial: Nano Manufacturing
Assessment Due: Quiz 3 - Composite and Nano Manufacturing
Assessment Due: Manufacturing Research Proposal

Course Relations

The following is a list of courses which have added this Unit to their structure.

Course Year(s) Offered
Master of Professional Engineering (Biomedical) 2010, 2011, 2012, 2013, 2014
Master of Professional Engineering (Mechanical) 2010, 2011, 2012, 2013, 2014

Course Goals

This unit contributes to the achievement of the following course goals:

Attribute Practiced Assessed
Design (Level 3) Yes 68.42%
Engineering/IT Specialisation (Level 3) Yes 27.71%
Professional Conduct (Level 3) No 0%
Project and Team Skills (Level 3) Yes 3.86%

These goals are selected from Engineering & IT Graduate Outcomes Table which defines overall goals for courses where this unit is primarily offered. See Engineering & IT Graduate Outcomes Table for details of the attributes and levels to be developed in the course as a whole. Percentage figures alongside each course goal provide a rough indication of their relative weighting in assessment for this unit. Note that not all goals are necessarily part of assessment. Some may be more about practice activity. See Learning outcomes for details of what is assessed in relation to each goal and Assessment for details of how the outcome is assessed. See Attributes for details of practice provided for each goal.