Portland Community College | Portland, Oregon

This course will provide the student with an introduction to the concepts and technologies  from a designer's viewpoint of the principal manufacturing processes utilized by industry.  Discussion subjects include the manufacturing system and its operating principles, casting, forming, material removal, welding, quality control, and advanced manufacturing processes, in a lecture/lab environment..  Manufacturing Processes is a required course in the Mechanical Engineering Transfer Degree.  Manufacturing Processes covers -The interaction of design with industrial materials and processes is considered in connection with technical and economic feasibility, trade-offs and automation.

Upon completion of this course, students should be able to:

1. Recommend appropriate part manufacturing processes when provided a set of functional requirements and product development constraints.
2. Recommend cost-effective material options based upon net part shape, expected loading, operating environment, cost constraints, and life expectancy.
3. Fabricate basic parts and assemblies using powered and non-powered machine shop equipment in conjunction with mechanical documentation.
4. Ascertain product and process quality levels through the use of precision measurement tools and statistical quality control charts.
5. Mitigate production problems using risk management and root cause analysis tools.
6. Communicate effectively with industry personnel by developing a manufacturing-centric vocabulary.

Student performance measurements are based on typical business/industry performance standards. They are grouped into performance competencies (specific skills) and knowledge competencies (understanding specific subjects). The various areas of study during the course will be evaluated by a variety of activities.  Typical of those activities are the following:
Home Work Assignments - Participation in individual or team structured problem exercises. The emphasis will be to provide introduction to the appropriate areas of study presented/discussed during the class and listed in the course content guide.
Examination - A take home examination in the form of multiple choice, true/false, matching, short answer structure that addresses the subject areas presented/discussed during the class and listed in the course content guide. The typed responses are to be turned in at the next to last class meeting.
Attendance at all scheduled class meetings is strongly encouraged and may be considered in the final grade assignment.  The following schedule of weight will apply to the evaluation activities for this course.
     Final Examination        35%
     Home Work Assignments    35%
     Laboratory Assignments    30%

General Introduction to Manufacturing
   1. What is Manufacturing?
   2. Examples of Manufactured Products.
   3. The Design Process and Concurrent Engineering
   4. Design for Manufacture and Assembly (DFM&A)
   5. Properties of Materials
   6. Heat Treatment
   7. Ferrous Metals and Alloys
   8. Nonferrous Metals and Alloys
   9. Nonmetallic Materials: Plastics, Elastomers, Ceramics, and Composites
  10. Material Selection
  11. Selecting Manufacturing Processes
  12. Computer Integrated Manufacturing
  13. Quality Assurance and Total Quality Management
  14. Global Competitiveness and Manufacturing Costs
  15. Lean Production and Agile Manufacturing
  16. Environmentally Conscious Design and Manufacturing
  17. Product Liability
  18. Organization for Manufacture
Casting Processes
   1. Fundamentals of Casting
   2. Expendable - Mold Casting Processes
   3. Multiple - Use - Mold Casting Processes
   4. Powder Metallurgy
Shaping Process for Plastics
   1. Extrusion
   2. Injection
   3. Blow Molding
   4. Thermoforming
Shaping Processes for Polymer Matrix Composites
   1. Materials
   2. Open & Cold Mold Processes
   3. Other Processes
Forming Processes
   1. The Fundamentals of Metal Forming
   2. Hot - Working Processes
   3. Cold - Working Processes
   4. Forming of Plastics, Ceramics, and Composites
Material Removal Processes
   1. Chip Type Machining Processes
   2. Cutting Tools for Machining
   3. Turning and Boring and Related Processes
   4. Drilling and Related Hole Making Processes
   5. Milling
   6. Broaching, Sawing and Filing
   7. Abrasive Machining Processes
   8. Work Holding Devices
   9. Machining Centers
  10. Tread Manufacturing
  11. Nontraditional Machining Processes
  12. Superabrasives
Joining Processes
   1. Gas Flame Processes: Welding, Cutting, and Straightening
   2. Arc Processes: Welding and Cutting
   3. Resistance Welding
   4. Other Welding and related Processes
   5. Brazing and Soldering
   6. Adhesive Bonding and Mechanical Fasteners
   7. Manufacturing Concerns in Welding and Joining
Measurement and Quality Assurance
   1. Measurement and Inspection
   2. Nondestructive Inspection and Testing
   3. Process Capability and Quality Control
Electronics Manufacturing
   1. Integrated Circuits
   2. Assembly & Packaging
Processes and Techniques Related to Manufacturing
   1. Surface Treatments and Finishing
   2. Manufacturing Systems and Automation
   3. Production Systems
   4. Integrated Manufacturing Production Systems