MSc Design Engineering with Sustainability

This module aims to prepare students with the knowledge, skills and experience to become competent members of global/distributed design teams.

It covers the nature of distributed design, including:

• benefits and issues relating to distributed design, design methodologies
• extended supply chains (design and manufacture)
• distributed team structures
• comparison of co-located and distributed design teams
• design to manufacture, distributed design expertise, different distributed design scenarios, e.g. cross-site, cross-company, national, international, etc.

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

• demonstrate knowledge of distributed design by explaining the concepts of distributed design engineering by discussing how the benefits and issues related to distributed design compare to those of co-located design
• demonstrate understanding of the management of distributed design projects by describing management tools and techniques for successfully managing distributed design, applying these tools and techniques to carry out distributed design project work and showing how these tools and techniques can overcome issues relating to distributed design
• describe appropriate technology and how it can be used to support distributed design by applying the use of technology to successfully carry out distributed design project work

Assessment and feedback is in the form of coursework submissions (70%) and project presentations (30%).

This module aims to enable students to select and apply appropriate design methods as a part of the design process.

The selection and use of design methods within the context of modern design practices and the new product development process will be explored. Emphasis will be placed on recently developed product independent design methods and their application within industrial environments.

Specific topics include:

• the design process management frameworks
• user understanding methods
• product specification methods
• creative methods
• design for production and cost methods
• design for safety and reliability methods
• design for the environment

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

• select and apply appropriate design methods for a design project to solve product design oriented problems by understanding specific design methods and recognising their strengths and weaknesses
• integrate appropriate design methods into a design process to ensure fitness of purpose of all aspects of the problem/context by demonstrating how manufacture, costing, environmental, disposal and customer needs may be addressed in the design process through design methods
• analyse literature sources to identify design methods suitable for a particular situation by undertaking a critical literature review to identify current developments in design methods in research and practice and synthesise the results of the literature review into a report

Assessment and feedback will be in the form of an exam (60%), a report (35%) and a presentation (5%).

This module aims to enable students to understand the concepts of virtual product modelling and techniques used to visualise products before they are fully designed and manufactured.

The module covers:

• an introduction to basic modelling, visualisation and evaluation techniques creating models, parts and assemblies
• the representations that underpin modern CAED systems (wireframe, surface, CSG and BRep), basic computer graphics (homogeneous transformations), data exchange, information integration, product data management, economics of CAD/CAM systems (cost breakdown, potential benefits, improving cost/benefit ratio), basic systems selection and justification and organisational impact and system management

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

• demonstrate the ability to use a commercially available CAD system by creating 3-D product models and appropriate visualisations for evaluation
• demonstrate knowledge and understanding of product modelling and visualisation by demonstrating an ability to provide 2D/3D part and assembly drawings, and a variety of sectioned/dimensioned views of part/assembly models
• demonstrate knowledge and understanding of product evaluation techniques by identifying and describing suitable product evaluation techniques such as FEA and utilise for evaluation
• describe and discuss the functionality and benefits that CAED systems can bring to product development by identifying and justifying a CAED solution for an industrial problem

Assessment and feedback is in the form of coursework (100%).

This module provides a structured introduction to the Design Management process, issues and tools.

The module covers: Different approaches and aspects to design development including concurrent engineering, team engineering, product management, design management, distributed design, and decision support, the design activity, methods and process models including role of the market, specification, conceptual and detail design, basic team and management structures (organisation), key issues related to design complexities and the key aspects of design coordination, design performance and innovation.

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

• appreciate and understand the role of design within an organisation and the organisational structures required for effective design by articulating the impact of early product delivery with regards to quality, cost and market sales and by describing the different main organisational structures and their impact on the design activity
• appreciate the role of design models, approaches and methods by appreciating of the different strengths and weaknesses of models, approaches and methods
• appreciate the role of innovation in design and know how to measure design performance by highlighting the key factors in design performance and how they relate as well as the nature and different types of innovation in relation to design

Assessment and feedback is in the form of coursework (100%), there will be no exam.

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 globalisation and industrialisation 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
• 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, defining and differentiating them and critically discussing their particular advantages and disadvantages in sustainable manufacturing
• identify the product features and characteristics that facilitate and hinder product recovery and be able to technically analyse products’ sustainability 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 (100%) including discussion forums, group seminars and a position paper.

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 develop a detailed understanding of the concept of remanufacture and its industrial application as well as new developments in the area. It explores the potential impact of remanufacture on a circular economy as well as the enablers and barriers.

The module covers:

• remanufacture concepts & significance (including history, drivers, issues, future developments)
• design for remanufacturing
• reverse logistics
• remanufacture disassembly
• lean remanufacture/remanufacture cleaning
• novel remanufacture tool and techniques.

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

• demonstrate an understanding of remanufacturing concepts and its significance (including with respect to a circular economy) plus the major issues in operating remanufacture
• technically analyse products’ status plus remanufacturing operations in order to enhance performance
• demonstrate an understanding of various techniques in sustainable design
• demonstrate understanding of major design-for-remanufacture (DFRem) concepts and approaches and apply these

Assessment and feedback is in the form of two assignments:

• this will be a report written in the format of an academic journal (50%) 
• this project involves the student carrying out a detailed analysis of the remanufacturing approaches within the context of a chosen remanufacturing organisation in order to enhance operational effectiveness (50%) 

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.

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 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 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 develop a critical understanding of operation, structure and implementation issues around enterprise resource planning (ERP) systems as used in industry. Students learn how a typical ERP system works using an up-to-date SAP training package and consider the real-life use of a typical software package within an organisation.

The module covers:

• business excellence
• what is ERP?
• business planning and control
• expected benefits
• how does ERP work?
• ERP pre-requisites
• selecting the right system
• implementation planning

At the end of this module students will have a critical understanding of:

• terminology relating to MRP, ERPII and ERP
• the benefits and limitations of using ERP systems for making operational, tactical and strategic decisions within businesses, including the ways in which ERP systems may support or hinder decision making at different levels
• learning to operate and build a product in a SAP environment
• the scope, implications, logic, critical requirements to facilitate successful implementation of ERP systems, in particular the relationship between ERP systems, other ICT systems, business processes and human factors

Assessment and feedback is in the form of a 40-minute quiz (40%) and one coursework (60%).

This module aims to introduce the basic principles and techniques of engineering risk management and demonstrates the appropriate application of this knowledge within an engineering context.

The module covers: 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 - 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 and Risk legislation and litigation in engineering.

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

• demonstrate awareness of and ability to make general evaluations of risk issues in the context of the particular specialisation, including health & safety, environmental and commercial risk
• demonstrate awareness of relevant regulatory requirements governing engineering activities
• demonstrate ability to work with information that may be incomplete or uncertain, quantify the effect of this on the design and, where appropriate, use theory or experimental research to mitigate deficiencies

Assessment and feedback is in the form of a group coursework to show understanding of the risk management process in practice (100% for group contribution and submission of main reports).

This module aims to provide students with an in-depth understanding of the key principles, concepts, tools and techniques of total quality management and continuous improvement together with an awareness of how these can be used to design and deliver an integrated continuous improvement programme.

It covers:

• an introduction to total quality management including definitions, basic elements and quality costing
• ISO quality management system standards
• quality improvement tools
• reliability engineering and continuous improvement concepts (FMEA, lean methodologies, kaizen, poka yoke, theory of constraints)

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

• understand the key principles, concepts, tools and techniques of total quality management and continuous improvement
• apply key principles, concepts, tools and techniques of total quality management and continuous improvement, including planning for real-life application of tools and techniques
• formulate improvement strategies within a particular context

Assessment and feedback is in the form of one group work (a case study report, 40%) and one individual coursework (a journal article, 60%).

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
• cevelop 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.

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 to develop a theoretical and practical understanding of design form and aesthetics.

The module covers:

• traditions, evolution and trends in design form and aesthetics in the context of industrial design
• principles and practices: form; colour; surface and texture
• designing form and aesthetics in practice including concept sketching and imaging - advanced freehand sketching, digital tablet sketching, transferring sketching to CAD
• design refinement and digital modelling (Rhino 3D) including surface modelling and curvature, NURBS surface modelling, visual curvature analysis, basic rendering visualisation
• communicating form and aesthetics - techniques for presenting form and aesthetic ideas and concepts to users, development teams and clients

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

• apply design form and aesthetics skills and techniques in project work with a focus on form, colour, surface and texture through the use of freehand sketching, digital and physical modelling. Demonstrate an ability to produce freehand sketches, digital and physical models which clearly show application of form, colour, surface and texture techniques
• demonstrate an understanding of a range of methods for communicating design and form approaches (verbal, graphic and prototype)

Assessment and feedback is in the form of preparing a Design Folio. This will include a mid-project design folio presentation (30%), a final presentation of visuals, prototypes etc. and critique of project work (30%) as well as submission of the design folio detailing stages and outputs of the design process (40%).

This module aims to provide students with theoretical and practical understanding of Human Centred Design (HCD).

The module covers:

• the evolution of HCD and its various approaches including ergonomics, cognition, user-centered design, people-centered design, design emotion, participatory design, co-design, design ethnography and design anthropology
• ontological and epistemological perspectives and assumptions in HCD such as different ‘world-views’ of people, objects and interaction
• research methods for HCD including interviews, focus groups, lab experiments, participant and non-participant observation, critical making/‘provotyping’

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

• apply appropriate HCD tools, methods and operations in design practice
• select and provide rationale for appropriate HCD approaches within a variety of scenarios
• apply and communicate HCD approaches to a research and design project with tangible demonstration of methods in process and practice
• communicate HCD approaches verbally to an audience to convey its value within product development and innovation
• communicate design output visually through the documentation of research, process rationale and solution in design folio

Assessment and feedback is in the form of a project progress presentation in class (30%) and submission of project (70%).

This module aims to provide students with an in-depth knowledge and understanding of those key concepts, methods, tools and techniques that are fundamental to effective and efficient running of supply chain operations from suppliers’ suppliers to customers’ customers.

It covers:

• an introduction to supply chain operations
• demand management
• master planning
• material management
• capacity management
• inventory management
• distribution management
• case studies

On completion the participants will be able to design and manage operational supply chain planning, scheduling and controlling systems for complex and disparate operations. In particular, students will:

• understand the basics of supply chain operations in relation to planning, operating, scheduling and controlling, including knowledge of supply chain operation practices (demand management, master planning, material management, capacity management and inventory management); understanding the impact of supply chain operation practices within commercial and social contexts and global trends in supply chain operation practices
• identify and assess different methods, tools and techniques for managing plans, operations and materials of end-to-end supply chains
• demonstrate the ability to apply those methods, tools and techniques in different contexts, including manufacturing and service sectors, with a critical awareness of drivers and obstacles in real life and the ability to produce sensible solutions to overcome them

Assessment and feedback is in the form of two in-class tests (60%) and one coursework (40%).

This module focuses on innovation implementation. It integrates insights from research and strategy, management control, innovation and technology and organisational behaviour to consider how innovations can be managed. Three main challenges to innovation are explored: resources, organisation and management mechanisms.

The module covers:

• management of innovation including an overview of what makes innovation management complex and three models for how these complexities can be managed
• introduction to Model S for small initiatives
• introduction to Model R for Repeatable Innovations
• introduction to Model C for all other innovations
• build the team
• an overview and division of labour
• assembling the dedicated team and managing the partnership
• creating the innovation strategy
• enabling, running and evaluating disciplined experimentations

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

• demonstrate a comprehensive understanding of managing the innovation process within organisations
• demonstrate how to integrate business strategy with innovating strategies
• develop the ability to critically assess concepts, tools and techniques of managing innovation for both stable and turbulent environments
• develop and contextualise an approach for analysis for a specific case
• develop an innovation roadmap for strategic purposes

Assessment and feedback is in the form of a group presentation (40%) and an individual final report (60%).