Unit 16: Advanced Manufacturing Technologies



Unit 16:

Advanced Manufacturing

 

 

Technologies


Unit code:
D/601/1505

QCF level:
5


Credit value:
15






Aim

This unit develops learners’ understanding of advanced manufacturing technologies and the safety and technical requirements of producing goods economically.

Unit abstract

In a competitive market, companies aim to produce products of the highest quality at the lowest cost in order to maximise profitability. Companies employ engineers to identify the most efficient equipment and processes necessary to achieve this. This can best be achieved when engineers have a broad knowledge and experience of the technologies that are available.

There have been major advances in manufacturing techniques both in terms of plant and processes. Information and communication technology (ICT) and computer-aided design and computer-aided manufacture (CAD/CAM) technologies are used widely in the machinery used to produce parts. There has also been much analysis of how people and plant interact in production to optimise effectiveness in terms of Kanban and work-flow systems.

This unit introduces advanced manufacturing technologies and the safety and technical requirements of producing goods economically. The function, purpose and economic evaluation of different manufacturing technologies and strategies are investigated. Manufacturing options for single piece, small, medium and large batch production are considered. Flow line production is considered as well as non-traditional and emerging technologies. Specialised machining technologies such as electro-discharge and ultrasonic machining are also examined.

Learners will achieve an understanding of key issues in implementing suitable strategies and adopting suitable advanced technologies.

Learning outcomes

On successful completion of this unit a learner will:

1       Understand health and safety requirements in the manufacturing workplace

2       Understand the function and purpose of existing Advanced Manufacturing Technology (AMT) installations

3       Be able to analyse benefits and drawbacks to building flexibility into the manufacturing process

4       Know the applications of special manufacturing processes.

Unit content


1      Understand health and safety requirements in the manufacturing workplace

Health and safety within the company: organisation levels; people involved; responsibilities of the employer and individual employees; appointment and role of safety representatives and safety officers; safety inspection procedures and legal requirements

Safety in automated areas: guarding of unmanned equipment and areas; safety in the design of a flexible manufacturing cell (FMC) and a flexible manufacturing system (FMS)

2      Understand the function and purpose of existing Advanced Manufacturing Technology (AMT) installations

AMT installations: CNC turning centres; multi-head/turret machines; sliding head and single/multi spindle autos; gantry loading machines; industrial robots for materials handling and assembly operations; CNC machining centres, multi-pallet systems; CNC mill-turn centres – C axis turning, Y axis lathes; live tooling; automatic tool change systems for milling and turning; probe systems for work and tool setting (spindle and bed mounted probes, turret mounted probes); adaptive control system; block tooling and replacement sister tooling; part programming for multiple fixtures

Manufacturing strategies: high volume production techniques; transistor lines; flexible transfer lines; group technology (GT); FMS; FMC; low-volume and small, medium and large-batch production techniques; one-off and prototype production


3      Be able to analyse benefits and drawbacks to building flexibility into the manufacturing process

Benefits and drawbacks: economics of machining; economic batch sizes; break-even charts; costs of setting; operating; training; maintenance; machine specifications; hardware and software specification; cost of software/hardware upgrades; assessment of ‘intangible’ and ‘unquantifiable’ benefits; calculation of cycle times; CAM layouts for autos


4      Know the applications of special manufacturing processes

Manufacturing processes: chemical machining; electro discharge machining (die sinking, wire cutting); laser machining; water jet cutting; PCB routing and drilling; ultrasonic machining; rapid prototyping; flame cutting; plasma cutting; emerging technologies; economics of non-traditional manufacturing processes

Learning outcomes and assessment criteria




Learning outcomes

Assessment criteria for pass



On successful completion of

The learner can:



this unit a learner will:














LO1 Understand health and

1.1
explain how health and safety is catered for within an


safety requirements in the



organisation


manufacturing workplace

1.2
assess the legal requirements and procedures for health










and safety inspections




1.3
discuss the safety requirements and features which






should be included in the design of automated areas








LO2 Understand the function

2.1
review the use of a range of Advanced Manufacturing



and purpose of existing


Technology (AMT) installations



Advanced Manufacturing

2.2
evaluate the benefits of different manufacturing



Technology (AMT)






strategies



installations
















LO3 Be able to analyse benefits

3.1
calculate break-even points and identify suitable


and drawbacks to building



processes for given quantities


flexibility into the

3.2
calculate cycle times for given components using


manufacturing process






specified equipment










3.3
specify CAM layouts for single spindle autos




3.4
make decisions based on the initial costs and running






costs of Flexible Manufacturing Systems (FMS), Flexible






Manufacturing Cells (FMC) and stand-alone machinery







LO4 Understand the applications

4.1
explain the technical requirements, uses and applications


of special manufacturing



of special manufacturing processes


processes

4.2
discuss the benefits and drawbacks of special










manufacturing processes




4.3
identify the mix of manufacturing process equipment






required to produce given components and assemblies






economically.













Guidance
Links

This unit may be linked with Unit 13: Application of Machine Tools, Unit 18: Advanced Machine Tools and Unit 31: Value Management.

Essential requirements

Learners will need access to a range of advanced manufacturing technology installations.


Employer engagement and vocational contexts

Centres should try to work closely with industrial organisations in order to bring realism and relevance to the unit. Industrial visits to view existing production facilities would be of great advantage.



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