MSc Advanced Manufacturing: Technology & Systems

This module aims to provide a series of strategic frameworks for managing high-technology businesses. The main focus is on the acquisition of a set of powerful analytical tools which are critical for the development of a technology strategy as an integral part of business strategy. These tools can provide a guiding framework for deciding which technologies to invest in, how to structure those investments and how to anticipate and respond to the behaviour of competitors, suppliers, and customers. The course should be of particular interest to those interested in managing a business for which technology is likely to play a major role, and to those interested in consulting or venture capital.

At the end of this module students will be able to:

• Demonstrate a comprehensive understanding of the role and importance of technology in business strategy formulation process
• Develop the ability to critically assess concepts, tools and techniques of managing technology for both stable and turbulent business environments
• Evaluate complexity and develop appropriate technology strategy models for specific cases

Grades will be determined by class participation assessed through four two-page papers on case studies, which may be written in groups of 4 people (40%), and an individual final technology strategy report based on an in-depth exploration of technology strategy in an assigned industry (60%). There is no final exam.

This module aims to introduce students to the concepts and basic technology of manufacturing automation and to be able to select suitable applications and specify the type of automation to be used in specific cases.

The module covers: Automation in manufacturing industry, why and where; Industrial robots, automation and typical applications; Open and closed loop control; Problems in robot design and control; Types of motion control; Control system functions; Advantages and disadvantages of electric and fluid power systems; Types of electric motors and their control techniques, simple actuators for hydraulic and pneumatic systems; Methods of programming robots; Relative economics of human labour, reprogrammable and hard automation and Safety considerations for industrial robots and other automated systems.

At the end of this module students will be able to:

• Demonstrate knowledge and understanding of why manufacturing automation is used
• Describe the conditions under which manual and/or automated production methods would be applied
• Analyse the configuration and technical specifications of an automation system suitable for a specified task
• Synthesise a manufacturing task suited to a specified automated system
• Analyse and understand the technological elements of drive and control, and machine vision, systems
• Critically appreciate the kinematic and dynamic problems associated with the control of automated systems
• Understand the implications of applying automation in human terms
• Demonstrate knowledge of safety factors that must be considered when installing automation

Assessment and feedback is in the form of one coursework submission showing technical analysis of an aspect of automation and critical thinking on the design of systems (40%), an exam (50%) and in-class participation (10%).

This module aims for the student to acquire: (1) knowledge of the fundamentals of micro- and nano-products and of the manufacturing of such products (MEMS, micro-fluidic devices, micro-medical devices, micro-motors, microrobots, MOEMS, etc.), size-effects, material/interface behaviour at the micro-/nano-scale, challenges to manufacturing at low length-scales, etc.; (2) knowledge of micro-/nano-materials processing methods, techniques, industrially-viable processes, etc. and (3) experience and skills in the design/selection of micro- /nano-manufacturing processes, tools and equipment for real-world products.

It covers material behaviour, challenges, processes (subtractive, additive, deformation, replication, joining, hybrid processes including mechanical, thermal, chemical, electrochemical, electrical methods) and tools, machines and manufacturing systems.

At the end of this module students will be able to:

• Explain key techniques used in the processes for the manufacture of micro-products
• Correctly select technologies for specified products and materials
• Demonstrate calculations of forming/cutting forces involved and analysis of stresses/temperatures involved in tools/machine-frames/workpiece as appropriate
• Deliver a machine design (either for micro-machining or micro-forming) with detailed analysis and module designs, including a cost analysis on the machine designed.

Assessment and feedback is in the form of coursework (40%) and a project (60%), including a group project presentation and project report and individual assignment.

This module aims to provide students with knowledge and understanding of the underlying principles of the metal forming theory and practice as applied to modern metal forming machines, tools and processes.

The module covers concepts and definitions including stress, yield condition, strain, flow laws, plastic work, evolution equations, meso and micro-scale approaches; limiting phenomena (shape accuracy, plastic flow localisation, fracture, tool strength, friction, microstructure); metal forming machines and tooling; bulk metal forming; sheet metal forming and incremental forming.

At the end of this module students will be able to:

• Describe stress/strain relationship for metals undergoing plastic deformation
• Explain the mechanism of plastic deformation at the meso and micro scale
• Explain the effect of different factors on the net-shape forming capability
• Discuss metal forming problems resulting from material and tool interaction
• Explain limitations of the metal forming technology due to a tool/machine system
• Discuss major elements and challenges for a forging system
• Explain the idea and give examples of incremental metal forming operations

Assessment and feedback is in the form of an exam (80%) and coursework (20%)

This module aims to provide students with an introduction to the fundamentals of advanced materials, characterisation and advanced surface engineering. The module also covers advanced machining processes and technologies and the principles and practices of rapid prototyping and manufacturing.

The module covers: Severe plastic deformation, materials properties and characterisation; Advances in Machining including the machining of hard materials, high-speed machining, precision grinding technology; ultra precision diamond turning and grinding technology; Principles and practice of Layered Manufacturing; Advanced Surface Engineering including physical-chemical functionalisation, electro-deposition, CVD, PVD, tools/mould treatment, nano- and multi-layered coating.

At the end of this module students will be able to:

• Describe processes of materials selection, characterisation, ultra-precision machining, rapid prototyping and advanced surface engineering
• Demonstrate know-how on key processing parameters and show numerical and analytical skills relating to the materials and process selections and parameter setting
• Identify key process parameters/variables in relation to process control and product quality
• Specify machines or manufacturing systems for the manufacture/creation of specified products/models or to propose design solutions for a manufacturing machine/system to address the manufacturing requirements identified

Assessment and feedback is in the form of four pieces of coursework (25% each).

This module aims for students to integrate and apply design, manufacturing and engineering management knowledge and skills to an industry based product and process development project and to develop project management skills.

The module consists of a team-based industrial project where an outline project brief is set by an industrial client. The team is expected to manage all aspects of the project through to a finished solution. This can be a product, system or process depending on the nature of the project. Teams meet with academic staff and industrial clients regularly through the project.

At the end of this module students will be able to:

• Have in-depth understanding and knowledge of products and management practices in industry
• Critically review and evaluate products and management practices of the particular company and the business impact of proposed solution
• Demonstrate knowledge and ability in applying and using various analysis and modelling tools and techniques
• Demonstrate project planning and management, presentation, consulting and team working skills
• Plan, control and lead an industrial project from inception to completion.
• Evidence achieving deliverables which meet the client company requirements.

Assessment and feedback includes a project report, a presentation to the client and any other deliverables specified in the project brief.

The aim of the individual project is to allow students to combine the skills learned in other modules of the course and apply them within a significant project in a specific area of design, manufacture, or engineering management. This will be achieved through students carrying out work into a particular topic relating to their course and preparing a dissertation that documents the project.

On completion of the module the student is expected to be able to:

• Define a valid project in a cutting-edge field of study relevant to the student’s degree – with an appropriate methodology and work plan for the project
• Plan, manage and complete project, involving where appropriate technical analysis and independent critical thinking. This involves giving a thorough, logical and critical review of the subject matter; using appropriate tools, processes and levels of analysis in the project and applying project management techniques to manage a successful project
• Document their project using suitable presentation techniques (such as language, figures, writing, layout, structure etc.); showing clear evidence of the value of the project and its outcomes and describing the project with clarity

Based on the work of a project, a student will submit an individual dissertation that will account for 90% of the final mark for the class. An interim project justification report will account for the remaining 10% of the mark.

The course will provide an introduction to basic CAD modelling and visualisation techniques for product development.

The course will introduce awareness of how CAD systems are used to support design and manufacturing processes in industrial settings.

The syllabus will cover the representations that underpin modern CAD systems, the fundamentals of CAD modelling and rendering, workflows to incorporate visualization in the design process, and emerging immersive technologies and optimisation techniques.

This module aims to provide students with a critical understanding of the fundamental building blocks of Supply Chain Management (SCM) and e-Supply Chains from a strategic perspective with a view to developing their capabilities in modelling, analysing, diagnosing and re-designing/improving supply chains.

It covers Understanding the Supply Chain; Strategies alignment; Supply Chain performance; Supply Chain benchmarking; Sourcing decisions; Supply Chain network design; Sustainability in the supply chain and case studies.

At the end of this module students will be able to:

• display an understanding of the fundamental building blocks of supply chains, including terminology; factors associated with SCM (business, technological, logistical and legal factors) and the relationship between traditional management functions and technology (such as marketing, purchasing, IT etc)
• demonstrate a critical understanding of how to analyse and diagnose supply chains from a strategic perspective by modelling supply chains; analysing supply chain practices and performance and drawing up supply chain improvement/development strategies for a chosen business
• display an understanding of sustainability issues in modern supply chains including key concepts; methods to assess sustainability and the ability to propose strategic improvements for the sustainability of supply chains

Assessment and feedback is in the form of 40% individual work and 60% group work.

The module will teach the following:

• introduction to risk definitions and basic risks in engineering
• risk management processes
• reliability: achieving reliability; Reliability, Availability, Maintainability and Safety (RAMS) cycle; failure rate; Mean Time Between Failure; Mean Time to Fail; Mean Life; failure stages within bathtub distribution; downtime; repair time and availability.
• risk classification and their nature in engineering; failure rate; severity and detection; As Low As Reasonably Practicable (ALARP). 
• risk identification: Failure Modes and Affects Analysis; Hazard and Operability Study; Fault and Event Tree Analysis
• risk-based decision-making – uncertainty, decision trees, Pareto optimality, Analytic Hierarchy Process
• examples of application of techniques within Risk Based Design: rule-based design; simulation of safety and impact on decision making. 
• risk legislation and litigation in engineering.

This module aims to introduce students to the principles of Lean and Six Sigma. From Continuous Improvement approaches to organisational requirements, the module covers the critical success factors needed to support sustainable and effective business transformation.

The module covers: an Introduction to Lean Thinking, Six Sigma, and Lean Six Sigma (LSS); Comparing and Contrasting Lean & Six Sigma; DMAIC Continuous Improvement Methodology; LSS project characterisation and selection; Lean and Six Sigma metrics; Overview of basic Lean Tools and Techniques including: affinity diagram, project charter, project selection matrices, SPC, Ishikawa, 5 Why’s, 5S, SMED, DoE, etc.; Evolution of Lean Six Sigma (from manufacturing to service environments and the implications of each).

At the end of this module, students will be able to:

• gain an appreciation for Lean Six Sigma as a Continuous Improvement methodology, and understand the implications of its application in manufacturing, transactional and service processes
• apply the Lean Six Sigma methodology (DMAIC) and basic Continuous Improvement tools to solve real world problems
• evaluate the Critical Success Factors and fundamental barriers in the execution of both Lean & Six Sigma initiatives

Assessment and feedback is in the form of an exam (35%) and an assignment in the form of a project report (60%) and project presentation (5%).

This module covers one of the major challenges of modern industry which is to address the need for sustainable product development and manufacturing. International legislation and increasing costs of fiscal instruments such as the landfill tax now aim to force producers to reduce the environmental impacts of their products and processes. Accelerating globalization and industrialization continues to exacerbate complexity of sustainability. Whilst manufacturers are constantly required to lower their costs and maintain their competitiveness, legislations require them to look at lifecycle costs.

At the end of this module students will be able to:

• Understand the importance of sustainable product development and sustainable manufacturing and how to establish competitive advantage and appreciate the key legislation affecting modern industry
• Demonstrate an understanding of the engineers’ role in problem & solution to this and how to establish competitive advantage (e.g. via operational efficiency and effectiveness, new opportunities and enhanced enhancing marketing and customer goodwill)
• Describe End- of- Life issues and critically discuss the place of reuse processes in Sustainable Design and Manufacturing, as well as identifying the various reuse processes
• Identify the product features and characteristics that facilitate and hinder product recovery and redesign them for enhanced sustainability
• Identify the fundamental “building blocks” of LCA and describe/illustrate the use of LCA in lifecycle decision making, as well as describing Biomimicry use in product design

Assessment and feedback will be in the form of coursework (70%) and a lab project (30%).

This module aims to introduce students to the theories and principles of Systems Thinking. The module also introduces the methods, tools and techniques for modelling, analysing, improving and designing systems in a variety of organisations including industrial, commercial and public sector.

The module covers: Systems theory, concepts and approaches; Hard and soft systems analysis and systems dynamics; Systems and organisational performance – including leadership in a systems environment and ‘design’ in a systems environment and Practical application of Systems Thinking.

At the end of this module students will be able to:

• show clearer understanding and knowledge of hard and soft approaches and how they can be used to deal with complexity and system behaviour in a business context
• develop understanding of fundamental cybernetic principles that form the foundations of Checkland’s Soft System Methodology and Beer’s Viable System Model
• develop knowledge and skills in systems analysis and business process modelling
• critically evaluate the most appropriate methodology to model, analyse and design engineering/business systems across a range of organisations
• demonstrate an understanding of how to model a business system and to develop a solution to solve a business system problem
• develop an awareness of the importance of system approaches in management interventions

Assessment and feedback is in the form of a group presentation and one coursework in the form of a reflective diary.

Introduction to Total Quality Management (TQM) - Quality definitions and dimensions - Definition of TQM - Basic elements of TQM - Service Quality and Quality Costing ISO Quality Management System (QMS) Standards - QMS requirements - Other related standards Quality improvement tools - Seven Basic Tools - Seven New Tools Reliability Engineering Continuous improvement concepts - FMEA - Lean methodologies - Kaizen- Poka Yoke - Theory of constraints (TOC)

The module will cover the following topics: 

• mechatronic system design process: Product/system design specifications (PDS), concept generation and selection, mechatronic system design and flow chart diagrams.
• sensing and actuation: Sensing theory, sensor selection, drive design, motor control. 
• control systems: Understand and apply control theory in a mechatronic system design.
• hardware design: Processor architecture, embedded computing platforms, interface, I/Os.
• software design: Software design basics, algorithm and code design, programming tools, and software engineering principles.
• prototyping and evaluation: develop skills in selecting methods for prototyping using appropriate tools and means, including rapid prototyping and computer modelling.

This module aims to provide students with skills and knowledge relating to the use of engineering practices in Project Management with particular respect to the project triple constraint: time, cost and quality.

The module covers: project management principles, concepts and processes; organisational influences, project stakeholders and project life cycle; project scoping such as project definition, project objectives, project deliverables, and work breakdown structure; Project planning and scheduling: definition of events, activities and nodes, network diagram, analysis of critical path, PERT method and use of industry standard software packages; Project controlling: cost estimate, budget setting, risk identification and assessment and contingency planning.

At the end of this module students will be able to:

• Demonstrate a good understanding of project management practices and practical skills to manage project scope – including translating project specifications into work packages
• Define and schedule project activities using tools such as critical path and PERT methods; estimate cost and determine budget using analogous and three-point estimating methods; identify and control quality standards using cost of quality and other tools
• Develop a good understanding of the inter-dependency between various project management knowledge areas, such as managing projects under constraints; identifying and assessing risks and developing contingency plans
• Understand the importance of project stakeholders and their impact on project management, including managing stakeholder relationships

Assessment and feedback is in the form of a group report (50%) and an individual project (50%).