Manufacturing Engineering Apprenticeship

Program Overview

The program is targeted toward individuals who are already in Production Operator or Technician roles and wish to advance in a manufacturing or engineering field. Upon completion, apprentices will have a solid grounding in the engineering and manufacturing fields.

Program Outline

Degree Overview:

This is a three year, Level 7 Apprenticeship, with 70% of time spent in the workplace, and 30% in TUS. This course will suits individuals who are existing Production Operators/Technicians who want to train or retrain in the engineering and manufacturing sectors, and progress to a level 7 qualification.

Outline:

Year 1

• Engineering Mathematics 1 (Credits: 10)
• This module will provide students with a solid mathematical foundation relevant to a manufacturing engineer.
• Learning Outcomes:
• Manipulate symbolic statements and expressions according to the transformational rules of mathematics.
• Solve a range of equations and applied problems using mathematical methods from algebra, trigonometry and basic calculus.
• Formulate and use mathematical representations (symbolic, numeric, graphical, visual, verbal) and identify their relations, advantages and limitations
• Communicate orally and in written form the reasoning and procedure for solving a mathematical problem.
• Engineering Science (Credits: 10)
It covers atomic models, chemical equations, basic mechanical concepts (mass, density, pressure, forces), gas laws, heat transfer, statics and kinematics.
• Learning Outcomes:
• Distinguish and explain basic mechanical concepts such as mass, density, pressure, forces, energy, power and explain the relationship between them.
• Explain basic concepts of the atom, molecule, chemical equation, polymer.
• Perform algebraic manipulations and substitutions of physical formulae to solve simple problems using appropriate units.
• Solve problems of pressure, temperature and volume using the gas laws.
• Carry out practical laboratory experiments in a safe and ethical manner; make appropriate analyses, using graphs and/or calculations,
of measured and recorded experimental data, and communicate the results effectively.
• Electrical Sciences (Credits: 5)
• This module will cover the fundamental principles of electrical sciences and instrumentation.
Students will learn to design, build, analyse and trouble-shoot basic electrical and instrumentation circuits through both theory and practical applications.
• Learning Outcomes:
• Analyse basic circuits using the fundamental laws of electrical science.
• Explain the technology and use of common electrical and electronic components, including common sensors and actuators.
• Explain the basic principles of electrical power generation.
• Apply basic safety principles.
• Specify, select, build and troubleshoot basic electrical and instrumentation circuits.
• Industry Module 1 (Credits: 15)
• Learning Outcomes:
• Comply with company’s procedures and policies, and describe the company’s ethical guidelines relating to the workplace, customers and the environment.
• Operate manufacturing processes within the relevant environment.
• Operate in the relevant regulatory environment.
• Describe and explain manufacturing processes available in the work place.
• Undertake a basic technical project, to investigate a process, and communicate findings.
• Integrate in the company work place, communicating and contributing as an individual and team member, and describe the company’s organisational structure.
• Reflect on their experiential learning
• Manufacturing Engineering 1 (Credits: 5)
• Manufacturing Engineering 1: Aims to produce environmentally responsible engineers, who will conduct manufacturing activities with due regard to the environment, regulatory and legal requirements.
The module introduces the learner to the basic skills required to be a manufacturing engineer. It is envisaged that the learners will have the capability to understand, analyse, design and/or select the machinery, tooling and processes necessary for the production of components. The practical element of this module will enable the learners to have the practical skills required to safely operate workshop equipment to produce component to a desired specification. Upon completion of this module the learners will have obtained the basic necessary skills to gain employment working in a manufacturing engineering environment.
• Learning Outcomes:
• Recall and implement the safety procedures to put in place in an engineering workshop with due regard to the environmental, regulatory and legal requirements
• Describe sustainable manufacturing processes and technologies appropriate to a range of applications.
• Identify and use various types of cutting tools and metrology equipment, including drill bits, turning tools, milling machine tools, vernier calipers, micrometers, dial gauges etc)
• Manufacture artefacts according to a process plan using a range of workshop machines/equipment that incorporate sustainable manufacturing technologies/processes.
• Computer Aided Design (Credits: 5)
• This module provides students with a broad introduction into 2-dimensional and 3-dimensional Computer-Aided Design (CAD) and modeling with a focus on manufacturing specific applications.
students will also learn to communicate through technical drawings.
• Learning Outcomes:
• Read and interpret 2D and 3D drawings, and communicate through drawing documents.
• Produce and explain orthographic and multiview 2D drawings from 3D solid model
• Create 3D solid models and part assemblies using the relevant procedure.
• Use standards parts libraries for the selection of appropriate standard components in the design / assembly process.
• Academic and Professional Skills (Credits: 5)
• The aim of this module is to empower students with the skills to be successful in third level education and the workplace.
This module combines online learning activities and small group workshops to focus on areas such as academic writing and integrity, creative thinking, problem solving, communications, career planning, report writing, innovation, technology and presentation skills.
• Learning Outcomes:
• Compile a reflective logbook relating to laboratory, practical or project work, taking into account the ethical responsibilities of the engineer and technician in relation to business goals, sustainability and wider society.
• Appraise different learning styles and apply appropriate learning and time management strategies;
• Engage in critical thinking, logical and creative problem solving and work as an effective group member;
• Deliver effective oral presentations and apply communication skills.
• Quality 1 (Credits: 5)
• This module will give in an introduction to the concept of Quality.
It will deal with the Quality Assurance systems and quality management principles needed in manufacturing and service organisations.
• The module will deal with the tools and techniques used to measure, analyse and control quality on a manufacturing line.
• This course will provide students with an introduction to the regulations and regulatory agencies that are specific to the medical devices industry.
The course will cover both European Union (EU) and US regulations and related agencies. Topics will include the laws covering the regulation of medical devices, regulations related to the development, manufacturing and approval of medical devices, regulatory agencies and bodies responsible for implementing the regulations, how the regulations affect the marketing of medical devices.
• Learning Outcomes:
• Discuss and compare philosophies and new trends in quality management and their place in today’s manufacturing and service environments including Total Quality Management (TQM).
• Analyse and apply a range of statistical tools to measure quality.
Select appropriate methodologies of quality improvement and apply various tools and techniques for analysis of quality.
• Describe the functions of the GMP, EU and US authorities, departments, agencies and other bodies responsible for developing and implementing the laws and associated regulations for Quality and high-tech industry; and describe their Regulatory Requirements, which affect the development, manufacturing and quality of products, e.g.
medical devices.
• Determine the classification of a medical device.

Year 2

• Engineering Mathematics 2 (Credits: 5)
• This module will provide students with a solid foundation in statistics and probability relevant to a manufacturing engineer.
• The module will develop the students’ ability to analyse, solve and understand problems using relevant data in various applications in Manufacturing Engineering.
• Learning Outcomes:
• Implement suitable analytic procedures in problems involving discrete and continuous random variables and probability distributions.
• Perform statistical analysis by hand and with appropriate software and interpret the results.
• Identify, formulate and solve applied problems using relevant industry based data sets.
• Communicate their knowledge of statistics and probability both orally and in writing.
• Metrology (Credits: 5)
• Learning Outcomes:
• Explain the concepts of metrology and use the language and systems of measurement.
• Explain the basic features of measurement, gauging, and tolerances.
• Apply the process of measurement with various measuring devices.
• Explain of the purpose of critical dimensions in manufacturing and apply inspection, gauging and checking systems.
• Analyse parts for dimensional and tolerance accuracy and functionality..
• Manufacturing Automation (Credits: 10)
• The student will study valves, actuators and all aspects of air production, conditioning and distribution.
Electro-pneumatic circuits will be designed, including multi-actuator sequences. The student will specify and size components based on system requirements.
• The student will analyse basic pneumatic/hydraulic manufacturing applications and develop automated solutions using Programmable Logic Control (PLC) technology.
PLC ladder logic programmes will be designed, developed and tested in accordance with industrial safety standards.
• Learning Outcomes:
• Outline the working principles of electro-pneumatic components
• Describe the components of pneumatic and hydraulics actuation.
• Simulate basic and multi-actuator pneumatic and electro-pneumatic circuits.
• Specify, size and select suitable pneumatic components for industrial applications
• Construct ladder logic programmes using Boolean Logic, IOs, timers, counters, sequencing
• Design and test PLC programs
• Identify and implement safety measures in the design of automated systems
• Manufacturing Engineering 2 (Credits: 5)
It broadens the learners experiences in both the theoretical and practical elements of Manufacturing. This module also extends to the learners experience in industry.
• Learning Outcomes:
• Explain the basic physical, mechanical properties of engineering materials and main testing techniques used in industry.
• Describe sustainable manufacturing processes and technologies appropriate to a range of applications
• Generate/Write a CNC Programme for 2 Axis Turning and 3 Axis Milling using a simulator/CAM software
• Analyse and interpret CNC program for basic CNC turning and milling operations
• Demonstrate practical application of manufacturing engineering methodologies through the correct identification, selection and use of manufacturing processes using laboratory equipment or workshop machinery.
• Industry Module 2 (Credits: 15)
• Learning Outcomes:
• Select the appropriate tools, methodologies and techniques to solve manufacturing problems, and design and implement solutions.
• Analyse, measure performance and continuously improve manufacturing processes with innovative technical solutions.
• Communicate findings to teams and management, and work effectively as a team member.
• Describe and communicate how the regulatory constraints affect the operations of the company, and how ethical considerations affect their conduct as a technician.
• Apply management skills within their occupation as a technician.
• Reflect on their experiential learning, and their ability to solve problems using a structured technical approach, and identify gaps.
• Manufacturing Design of Fixtures (Credits: 5)
• This module in delivered in 2 parts: Theory and Practical.
The students are introduced to the importance of standard parts – integrating standard components, fasteners, clamps, dowels etc. 2D working drawings are also addressed. It also introduces the role and application of CAD relating to the manufacture of products in the context of working holding and automated manufacturing and the role of metrology therein.
• The Theory aspects of the module aims to impart the workpiece holding and orientation as considered in modern automated manufacturing techniques.
The theory element also imparts designing fixtures with operational considerations, maintenance and repair and design for manufacture elements.
• Learning Outcomes:
• Explain the fundamentals of part orientation and principles of workholding.
• Describe the design of systems for part orientation & holding
• Select the relevant method of actuation of fixturing systems
• Describe specific fixturing system types
• Use CAD to design and implement a fixture related project
• Maintenance and Safety (Credits: 5)
• Identifying the reasons for and methods of performing Risk Assessments is central to the first section of this course.
The learner will understand the concepts, processes and legislation for Risk Management, performing and updating Risk Assessments and Health and Safety Management such as Safety Statements.The learner will be able to identify and select maintenance practices such as Breakdown, Planned, Preventative Maintenance: which are appropriate for a variety of real workplace scenarios and distinguish their respective impacts on system reliability. Maintenance practices such as Total Productive Maintenance (TPM) and Reliability Centred Maintenance will be covered in detail: how they can benefit industry (company, customer and worker) and the steps that are followed for implementing these practices. A 25% project applying the concepts of TPM to a real workplace is central to this understanding.
• Learning Outcomes:
• Recognise the risks and hazards associated with machinery, equipment and workplaces, identify control measures necessary for Health and Safety management, and prepare relevant safety documentation
• Analyse and compare different Maintenance Management strategies such as breakdown, planned and preventive maintenance techniques and apply them to appropriate workplace situations.
• Illustrate the reasons for and benefits of maintenance systems such as TPM (Total Productive Maintenance) and RCM (Reliability Centred Maintenance) in a workplace environment
• Develop an implementation plan for a new workplace maintenance system and schedule and appraise a maintenance system currently in place
• Assess equipment effectivenss, maintenance economics, work scheduling and reliability, and FMEA (Failure Mode and Effects Analysis)
• Quality 2 (Credits: 5)
It will also introduce Process Validation, and Corrective and Preventive Action.
• Learning Outcomes:
• Describe the purpose of a quality management system and explain the 8 principles of quality management.
• Explain the purpose, content and interrelationship of quality management standards ISO9000, ISO13485, auditing and assessment standards ISO9004, ISO19011 and sustainability standards ISO14000, ISO15001 and ISO2600.
• Explain Risk Management, how to identify and quantify risks, decide on the acceptability of those risks and re-evaluate risks following corrective actions.
Explain the impact that ISO14971 Risk Management has on the decision-making process in the medical device industry.
• Apply various risk assessment methodologies such as FMECA, Fault Tree Analysis and HAZOP.
• Explain the context of Process Validation within the quality management system and describe the steps needed to conduct a Process Validation.
• Identify and distinguish between a correction, corrective action and preventive action and identify a process to implement corrective/preventive actions.
• Lean Manufacturing (Credits: 5)
Lean manufacturing, originally developed by Toyota, is widely practiced in Irish industry and is vital for its continued competitiveness.
• Learning Outcomes:
• Perform data analysis in MS Excel to solve Lean Engineering problems.
• Review and comment on lean case studies
• Perform lean manufacturing analysis (Value Stream mapping, Overall Equipment Effectiveness, Takt Time Calculation, Process Throughput measurement, 5S) to identify areas for improvement, and solve problems

Year 3

• Robotics and Control (Credits: 10)
• Control Theory: This module introduces control in the engineering context and studies mechanical, electrical and fluid systems using block-diagram methodology.
Open loop and closed loop systems are studied. Concepts such as feedback, steady state error, disturbances, ON/OFF controllers, proportional, integral and derivative controllers will be examined to show that proper control system design leads to systems that are efficiently and adequately controlled.
• Industrial Robots: Definition and classification of robots.
Robot anatomy: joints and links, control systems, end effectors, sensors in robotic applications. Robotic maintenance and safety. Application of industrial and materials handling robots. Vision systems
• Robotic Programming: Lead-through Programming, use of Teach Pendant.
Simulation and practical robotic applications
• Learning Outcomes:
• Describe the principle of operation and characteristics of sensors and actuators
• Identify the components of data acquisition including signal conditioning and digital interfacing.
• Use appropriate technologies and software programming packages to measure, analyse and control systems
• Analyse control concepts including open loop, closed loop, relays, motor control, sequential control, process control, PID control.
• Identify the environments in which control systems operate and calculate the steady-state error, stability and speed of response of the system.
• Investigate robotic capability, technology and anatomy
• Develop and execute robotic simulation programmes; and practical training using 5 and/or 6 axis robots.
• Advanced Manufacturing Processes (Credits: 5)
It also has a practical use of CAD/CAM and Mould & Cavity software to generate machine code . It concludes the series modules on Manufacturing Technology.
• Learning Outcomes:
• Summarise the principles of traditional manufacturing processes.
• Summarise the principles of non-traditional manufacturing processes.
• Use CAM software in the generation of G and M codes for the manufacture of components on CNC machine tools, in line with Sustainable Engineering best practices.
• Polymer Processing Technology (Credits: 5)
• The Polymer Processing Module focuses on the materials, processes and tooling used in relation to polymers, particularly the common polymer processes of injection moulding and extrusion and the characteristics of various polymers.
There is also a practical aspect with particular emphasis on the design and manufacture of tooling for these processes.
• Learning Outcomes:
• Explain relevant techniques to manufacture plastic parts, in a Sustainable world.
• Explain the fundamentals of the synthesis of plastic materials
• Explain polymer melts rheology and its effect on polymer processing parameters.
• Use mould cavity software to generate, design and optimise Moulds.
• Use appropriate software to analyse flow and other parameters of the mould.
• Engineering Software Systems (Credits: 5)
• The module delivers the essentials of programming and spreadsheet technology appropriate to the needs of the engineer in employment in manufacturing or related industry.
• Learning Outcomes:
• Describe the core concepts of computer programming.
• Write programmes/codes, incorporating core programming concepts such as sequential, conditional, iterative and control structures
• Design an effective event-based software application incorporating spreadsheets to address basic engineering and production requirements.
• Construct the designed software application using a commercial application development environment.
• Roll out the constructed application, including performing Test, Debug and Demonstration activities.
• Industry Module 3 (Credits: 15)
• Learning Outcomes:
• Lead technical projects and design and implement technical solutions under quality systems and procedures.
• Participate in process planning according to company quality policies and system.
• Investigate, analyse, evaluate and report on the performance of a process plan.
• Undertake a six sigma project and communicate the findings to staff and management.
• Apply management skills within their occupation as an engineer and describe their ethicial obligations as an engineer.
• Reflect on their experiential learning and their ability to solve problems using an engineering approach, identify gaps and devise self-learning strategies.
• Manufacturing Process Planning (Credits: 5)
• The aims of this module are
• to help the students develop an understanding of the underlying knowledge and related methods of Process Planning and Computer Aided Process Planning, and
• to equip the students with the skills required in carrying out the process planning (PP) function.
• Learning Outcomes:
• Describe the process planning functions, the role of process planning in manufacturing, the characteristics of traditional and Computer
Aided Process Planning (CAPP) systems, the structure of typical CAPP systems and Group Technology (GT).
• Implement Manual Process Planning system in consideration of process planning criteria, and industrial considerations.
• Implement Computer Aided Process Planning (CAPP) systems in consideration of process planning criteria, and industrial considerations
• Identify relevant principles of Design for Manufacture and Assembly (DFMA), philosophy, implementation and functionality, assembly systems and costing
• Identify issues relevant to green manufacturing, design for environment and recycling, part life cycle assessment, sustainability.
• Six Sigma Quality (Credits: 5)
• An introduction to Six Sigma, which will both explain the concepts and involve using the tools and techniques of Six Sigma.
• Learning Outcomes:
• Explain the Define, Measure, Analyse, Improve and Control steps in Six Sigma.
• Use ‘Define’ phase tools to decide on the process improvement of a Six Sigma project
• Determine the current performance using a variety of ‘Measure’ tools
• Use the ‘Analyse’ tools, including inferential statistics to determine the issues to be addressed.
• Use the ‘Improve’ tools, to experiment and assess the process optimisation.
• ‘Control’ the process to verify the variances are corrected, select appropriate statistical process control (SPC) techniques.
• Operations Management (Credits: 5)
• This module provide an introduction to key principles, strategies, models and techniques used by organisations in the management of their operations.
• Learning Outcomes:
• Apply the stage gate process and engineering tools to Product, Process and Facility design.
• Use an Enterprise Resource Planning system to perform capacity planning, inventory management and materials requirements planning applying the techniques used in Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES).
• Solve basic operations’ improvement problems of capacity, flow design and job design taking budgetary concerns and commercial principles into consideration.
• Compare and contrast appropriate strategies and competitive behaviour for sustainable organisations.
Factors to include environmental sustainability and corporate social responsibility.
• Project Management (Credits: 5)
• This module introduces students to tools and methodologies of project management.
Students will apply the skills and knowledge gained in the module to the technical project of their Industry module.
• Learning Outcomes:
• Articulate and explain structured approaches to project planning and management.
• Apply the principles, methodologies , tools and techniques of project management, including associated financial analysis.
• Use Project management software to assist in planning and managing projects.
• Define, plan and manage team-based projects
• Communicate effectively throughout the project lifecycle, including all necessary reports and presentations required in project planning and management in a real work environment