Module Title:   Manufacturing Systems Engineering

Module Credit:   20

Module Code:   ENG3302D

Academic Year:   2015/6

Teaching Period:   Semester 2

Module Occurrence:   A

Module Level:   FHEQ Level 6

Module Type:   Standard module

Provider:   Engineering

Related Department/Subject Area:   School of Engineering

Principal Co-ordinator:   Professor M. Khurshid Khan

Additional Tutor(s):   -

Prerequisite(s):   None

Corequisite(s):   None

To study the concepts of PUSH/ PULL (JIT/lean) methods of planning & control of manufacturing systems. Thereafter, to study the concepts of discrete-event modelling and simulation in the context of these manufacturing systems. To develop modelling approaches and simulation models that address a wide variety of manufacturing environments such as FMS, Cellular and Job Shop systems, Flow and Assembly lines.

Learning Teaching & Assessment Strategy:
The module is taught through a series of lectures supported by reading materials and a video session. Each lecture introduces the concepts of Pull and Push manufacturing Systems (along with their sub-elements) and supported by examples of industrial applications. Concurrently, the learning of modelling and simulation will consist of lectures with hands on building of simulation models in the classroom. There will also be a minimum of one industrial visit and or seminar.

Lectures:   40.00          Directed Study:   150.00           
Seminars/Tutorials:   10.00          Other:   0.00           
Laboratory/Practical:   0.00          Formal Exams:   0.00          Total:   200.00

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

(1) PULL (JIT/Lean) and PUSH (MRPII) manufacturing systems and their constituent parts.
(2) The role of simulation in the manufacturing and applications of discrete-event modelling and simulation.

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

(1) have comprehensive and specialist skills in understanding and implementing both JIT/Lean and MRP II (or a composite of both) manufacturing systems in a practical environment.
(2) create a simulation model for a wide variety of manufacturing environments (batch, line, flow, assembly, FMS). You will also have detailed knowledge on the science behind simulation, in terms of probabilities and statistics.

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

(1) comprehensive understanding about teamwork, leadership skills and change management with respect to their use for implementing new concepts in organisations;
(2) create a simulation model for many environments beyond manufacturing, and use the appropriate software.

  Coursework   30%
  Individual coursework (2000 words) on a specific topic of a manufacturing system.
  Coursework   70%
  Group project (3000 words/student) using Arena software to develop a simulation model of a given manufacturing system

Supplementary Assessment:
As Original

Outline Syllabus:
Concepts of Manufacturing Systems. Just-In-Time (JIT/lean) PULL Manufacturing and its elements: waste elimination, Lean manufacturing, value chain, set-up time and batch reduction, levelled/mixed scheduling, , cellular and flexible manufacturing systems, flow-line and assembly lines, job shops, kanban control, continuous improvement, and supplier management,
Study of Manufacturing Resource Planning (MRPII) PUSH systems: Bill of Materials (BOM), Master Production Schedule (MPS), Materials Requirements Planning (MRP), Rough Cut Capacity Planning (RCCP), Capacity Requirements Planning (CRP), Order Release and Scheduling (OR/OS).
Concept of modelling and simulation. Types of simulation models, definitions of event, activity, entity, process, attributes/etc used in discrete event simulation. Introduction to statistics, probabilities, confidence intervals/confidence levels, probability distributions. Approaches to discrete event simulation, through a `hand` example. The simulation process wrt building a model. Basic modelling concepts and techniques, through building simulation models in classroom lecture/tutorial. Simulation software facilities for animation, presentation, model testing and debugging, execution and result`s analysis. The use of statistical techniques to analyse Input and Output data for terminating and non-terminating manufacturing systems, and to compare/contrast of alterative simulation systems. The use of variance reduction techniques for improving simulation models.

Version No:  1