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To introduce you to the core factors of managing operations and the concept of flow in operations.

• An introduction to manufacturing organisations and functions.

• The theory of operations, flow in manufacturing and what enables/inhibits it.

• Order winners, Order qualifiers, and competitive priorities.

• Key Performance Indicators in manufacturing.

• Product/Process matrix, facility layouts, production strategies, product families.

• Customer Demand and capacity planning, and standardization.

• Process flow diagrams, and value stream maps.

• S&OP, Master Production Scheduling, BOM, and scheduling rules.

• Push vs Pull production.

• Information systems; MRP, MPRll, ERP, and Kanban systems.

• Maintenance management strategies.

• Dimensions of Quality, Quality management frameworks, and the cost of quality.

• Roles of inventory; inventory management systems and measures.

• Lean Manufacturing.

• Class discussion of cases, exercises, and videos to support this syllabus.

On successful completion of this module you will be able to:

1. Discuss the importance of the operations functions of an organisation and how operations performance can impact the success of the whole organisation.

2. Assess production and capacity management strategies that can be deployed to meet customer demand for products and services.

3. Assess the importance of inventory, maintenance, and quality management systems in achieving high levels of operational performance.

4. Determine the role of information in planning, control, and scheduling, including the role of IT systems.

5. Critique the different attributes of the Lean Production System and how they apply to contemporary operational contexts.

The aim of this module is to provide you with an understanding of the microstructures and metallurgical characteristics of Additively Manufactured (AM) structures in a range of alloys, and how the metal and heat source interaction affects microstructure and strengthening behaviour of different alloys.

• Crystal structure of metals.

• Dislocations and strengthening mechanisms.

• Mechanical properties of metals.

• Grain structure and recrystallisation.

• Phase Diagrams.

• Phase transformations: Development of microstructure and alteration of mechanical properties.

• Physical metallurgy of Steel/Stainless Steels/Nickel/Aluminium/Titanium and impact of additive manufacture on microstructure and mechanical properties of these alloys.

• Intermetallic compounds.

• Residual stress.

• Dissimilar AM.

• Corrosion.

On successful completion of this module you should be able to:

1. Demonstrating understanding on crystal structure of some structural and functional alloys, analyse phase diagrams and continuous temperature transformation diagrams to explain the microstructural changes and strengthening mechanism for different alloys.

2. Demonstrate understanding on the impact of deposition processes and in-process working on microstructural characteristics of structural alloys and correlate with their mechanical properties.

3. Evaluate advanced materials such as intermetallic compounds developed by AM process for different applications.

4. Evaluate defects in an AM part and correlate to the processing parameters.

The aim of this module is to cover the fundamental physics of heat-source - material interaction in additive manufacturing, to then introduce various AM techniques (selective laser melting, electron beam melting, wire arc AM, blown powder). The mechanisms of the individual techniques will be explored to include the benefits, challenges, limitations and suitability of each process. Practical examples will be used throughout to enable selection of a suitable process for a particular application.

• Fundamentals of arc processing.

• Fundamental of laser/beam processing.

• Different established AM processes.

• Metal AM processes.

• AM process selection.

• Net and near net shape manufacture.

On successful completion of this module you should be able to:
1. Describe various heat sources and their interaction with different feedstocks.
2. Compare the different AM processes and describe machine architectures.
3. Evaluate the different AM processes for a specific application.
4. Appraise the benefits, challenges and limitations associated with the use of AM techniques.

This module will enable you to design their own additive manufacturing cell (including manipulation equipment, and sensing), or integrate an existing additive manufacturing machine in a broader production line. It also introduces you to experimental design and how to develop suitable parameters for part production.

• Sensors for Additive manufacturing.

• Manipulation.

• Jigs and fixtures.

• Cell design.

• Project planning.

• Factory layout.

• Experimental design.

• Component shielding.

• Thermal management.

• Costing and life cycle analysis.

• Statistical methods towards process control and optimisation.

• Generation of technical reports and research work.

On successful completion of this module you should be able to:

1. ​​Design and justify a programme of experiments for producing a simple structure and demonstrate the effect of the main input parameters, and analyse data produced from these experiments so that the relationship between process inputs and outputs is understood.

2. Plan an AM cell for manufacturing a specific AM part that includes selection of a robot, and methods to manipulate the part, fixturing and sensing of the part, equipment for loading and unloading, labour requirements and an estimation of the time to manufacture.

3. Calculate and justify the cost of a typical additive manufacturing operation including labour costs, overhead costs, and consumable costs.

4. Plan a factory layout that incorporates all required operations (feedstock storage, machine preparation, material preparation, AM cell and the finishing operations for the part).

5. Construct a project plan for the installation of the AM system.

Provide both an introduction to the theory underpinning finite element analysis, and hands-on experience using a well-established finite element software package, to understand and apply finite element analysis in the context of metal additive manufacturing.

• Introduction to finite element analysis.
  o Overview of the FEA method.
  o Concepts, procedure and terminology of FEA.
  o Advantages and general applications of FEA.
  o FEA in metal additive manufacturing.
• Theory of FEA method.
  o Mathematical theory for obtaining approximate solution.
  o Finite element formulation for solid mechanics.
  o Finite element formulation for heat transfer.
• Implementation of FEA.
  o Simplification and specification.
  o Solution techniques.
  o Assessment of results.
  o Mistakes, errors, accuracy and limitations.
• Introduction to FEA software ABAQUS
  o Pre-processing.
  o Running job and troubleshooting.
  o Post-processing.
• FEA of metal additive manufacturing.
  o Key phenomena and problems.
  o Thermal analysis.
  o Mechanical analysis.
o Other sophisticated aspects, e.g., molten pool fluid dynamics, solidification, grain growth, and solid state phase transformation.
• Practice: modelling wire arc additive manufacturing of a small metal wall using ABAQUS.

1. Appraise finite element analysis (FEA) method and its applications.

2. Evaluate considerations for applying FEA to the modelling of metal additive manufacturing.

3. Identify and discuss the limitations and errors associated with the use of FEA.

4. Demonstrate and justify a FEA approach for solving a range of mechanical and thermal problems.

5. Create a FEA model to simulate additive manufacturing process and critically assess the results.

The aim of this module is to provide you with an understanding of the fundamentals of quality management related to additive manufacturing, welding, and other processes, including quality systems and non-destructive examination, and to provide you with the knowledge to manage health and safety in the work place.

• Overview of standards and their function.

• Introduction to quality assurance.

• Quality control during manufacture.

• Operator qualification.

• Application of Non-destructive examination (NDE) to characterise different types of defects on AM processes Non-destructive testing methods (dye penetrant, magnetic particle, eddy current, acoustic emission, radiographic inspection, tomography, ultrasonic inspection).

• Destructive testing methods.

• Industrial case studies.

• Health and safety.

On successful completion of this module you should be able to:

1. Appraise the standards and the relationship between standards and a particular application, to achieve the required quality; feedstock characteristics and quality.

2. Assess the different NDT and DT, explain the principles upon which they are based, and interpret their results.

3. Assess the probability of occurrence of the different defect types for a selection of materials and manufacturing techniques.

4. Manage workplace practices to ensure adequate health and safety.

This module will enable you to understand, describe and evaluate the different post processing techniques currently used on AM parts and allow them to select the most appropriate one for a specific AM process and application. It will explore the underlying material science concepts for these processes.

• Post-processing techniques.

• Cold working.

• heat treatments.

• Hot isostatic pressing.

• Machining of near net shape.

• Repair principles and methods.

• Impact of processing on materials.

On successful completion of this module you should be able to:

1. Evaluate the different post processing techniques used on AM parts, including those required for removal of support structures, improvement of surface characteristics and structural integrity. This should include requirements during AM building that a part needs to comply.

2. Appraise the benefits and limitations of each post processing technique with respect to each AM process.

3. Propose the most suitable post processing technique including heat treatment (for stress relieving and ageing) for a specific AM process and application.

4. Assess the benefits of in-process cold work and on the properties and microstructure of parts.