COURSE OUTLINE
FACULTY OF
MECHANICAL ENGINEERING
AUTOMOTIVE PRODUCTION
(SKMV 4792)
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PRE-REQUISITE
EQUIVALENCE
:
:
LECTURE HOURS
:
Dr. Richard Foo Jin Hoe
:
:
:
:
F
1st Sept 2010
25th July 2011
3
SKMV 3012, SKMM 2713
2 Hours Lectures
Lecturers
1.
5
E-Mail
Room No.
Phone No.
jinhoe@fkm.utm.my
C23-408
07-5534703
Synopsis :
This course introduces students to manufacturing processes involved in automotive production as well as
some of the major issues related to automotive manufacturing. It will emphasize on casting and forming
processes employed in the automotive industry. A brief review on machining and joining processes is also
given. The course will also highlights some of the challenging issues such as Quality, Group Technology,
Lean Manufacturing and Automation.
PREPARED BY :
CERTIFIED BY :
Name
: Assoc. Prof. Dr. Hamidon Musa
Name
:
Signature
:
Signature
:
Date
: 3rd March 2010
Date
:
Head of Department
3rd September 2012
COURSE LEARNING OUTCOMES
By the end of the course, students should be able to :
No.
1
2
3
Course Learning Outcomes
Explain geometrical
accuracies and surface finish
of automotive components.
Describe methods of
measurement for geometrical
accuracies and surface finish
of automotive components
Outline the relevant
processes and materials in
automotive production.
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Programme
Learning
Outcome(s)
Addressed
Learning
Taxonomies
&
Generic Skills
Assessed
Assessment
Methods
PO1
C2
T, F
PO1
C2
T, F
PO1
C2
T, F
COURSE OUTLINE
FACULTY OF
MECHANICAL ENGINEERING
AUTOMOTIVE PRODUCTION
(SKMV 4792)
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1st Sept 2010
25th July 2011
3
Determine process
parameters in selected
production processes.
PO1
P4, C3
T, F
5
Identify the main issues
related to quality, automation
and lean manufacturing in the
automotive industry.
PO1
P2, C2
T, F
6
Seek relevant information and
apply them appropriately.
PO9
P2, A3
[LL1-LL3]
A
4
Note : (T – Test ; PR – Project ; Q – Quiz; HW – Homework ; A – Assignment; Pr – Presentation; F – Final Exam)
STUDENT LEARNING TIME
No.
Teaching and Learning Activities
Teaching and Learning Activities
Student Learning Time
(hours)
Student Learning Time
(hours)
1. Face-to-Face Learning
a. Lecturer-Centered Learning
i. Lecture
24
b. Student-Centered Learning (SCL)
i. Laboratory/Tutorial
0
ii. Student-centered learning activities – Active
Learning, Project Based Learning
4
2. Self-Directed Learning
a. Non-face-to-face learning or student-centered learning
(SCL) such as manual, assignment, module, e-Learning,
etc.
8
b. Revision
28
c. Assessment Preparations
12
3. Formal Assessment
a. Continuous Assessment
2
b. Final Exam
2
Total
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80/40=2.0
COURSE OUTLINE
FACULTY OF
MECHANICAL ENGINEERING
AUTOMOTIVE PRODUCTION
(SKMV 4792)
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1st Sept 2010
25th July 2011
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TEACHING METHODOLOGY
Lectures and Active Learning
WEEKLY SCHEDULE
Week
Lecture
Topic / Content
Introduction
1
2
1
Course requirement and general information
2
Overall stages and processes in automotive manufacture
3
4
3
Geometrical accuracy (including surface finish)
Methods of measuring geometrical accuracy
5
Basic casting processes for automotive parts
6
Casting allowances, shrinkage cavities and methods to control
shrinkage cavities
Casting alloys and their applications in automotive industry
4
7
Material selection and substitution
8
Sand resin-bonded processes for cores and moulds
9
Review of sheet metal stamping processes (blanking, piercing,
drawing)
5
Forces and press capacity for blanking and piercing
10
11
6
Forces, press capacity, number of draws and blank sizes in deep
drawing
Forces, spring back and blank development for bending
12
Die clearances, and punch and die dimensions for blanking and
piercing.
13
Review of bending
14
Forces, spring back and blank development in bending
7
8
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MID SEMESTER BREAK
COURSE OUTLINE
FACULTY OF
MECHANICAL ENGINEERING
AUTOMOTIVE PRODUCTION
(SKMV 4792)
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25th July 2011
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WEEKLY SCHEDULE
Week
Lecture
Topic / Content
Presses for sheetmetal stamping
15
9
Presses and hammers for forging and extrusion
16
Press brake
17
10
18
Process documentation
- Process Sheet, Operation Sheet, Standard Operation
Procedure, Assembly Operation Standard, and Process
Control Plan
Overview of Malaysian automotive industry
Issues and challanges in Repair and Maintenance, Tooling, and
Process Improvement
11
19,20
Automation and its application in the automotive industry
12
21,22
Automation and its application in the automotive industry
13
23,24
Quality in the automotive industry
14
25,26
Quality and Lean Manufacturing
15
27,28
Lean Manufacturing
16-18
REVISION WEEK AND FINAL EXAMINATION
REFERENCES
1.
Phillip Ostwald and Jairo Munoz, "Manufacturing Processes and Systems," John Wiley & Sons, 1997
2.
Mikell Groover, "Automation, Production Systems, and Computer-Integrated Manufacturing,"
Prentice Hall, 2001
3.
HMT, "Production Technology", Tata McGraw Hill, 1987
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COURSE OUTLINE
FACULTY OF
MECHANICAL ENGINEERING
AUTOMOTIVE PRODUCTION
(SKMV 4792)
Page : 5
of
5
Revision
Date of issue
Last Amendment
Edition
:
:
:
:
F
1st Sept 2010
25th July 2011
3
GRADING
No.
Assessment
Number
% each
% total
1.
Test 1
1
20
20
2.
Test 2
1
20
20
3.
Assignments
1
15
15
4.
Assingment(Life-Long
assessment)
1
5
5
5.
Final Exam
1
40
40
Learning
Overall Total
100
ATTENDANCE
The student should adhere to the rules of attendance as stated in the University Academic Regulation :1.
Student must attend not less than 80% of lecture hours as required for the subject.
2.
The student will be prohibited from attending any lecture and assessment activities upon failure to
comply the above requirement. Zero mark will be given to the subject.
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