Diploma in Mechanical Engineering

College of Engineering

MANUFACTURING PROCESSES
(Date of document: June 2021)

Course Code : MEFD1013

Course Status : Core
Level : Diploma
Semester Taught : 1
Credit : 3
Pre-requisites : -
Assessments : Quizzes 10 %
Assignment 10 %
Test 40 %
Group Lab Project 40 %
Total 100 %

Lecturers : Zainudin Yahya

Room: BN-3-55, ext.: 2141
Email: [email protected]
Muhammad Hanif Abdul Karim
Room: TA-3-214F Ext 1821
Email: [email protected]

Course Description : This course provides the scientific basis of manufacturing processes in
many aspects. This course focuses on material properties and further
expands to the different types of manufacturing application
processes. A brief overview on the different types of machining
processes example lathe, milling, grinding with its associated
calculation are being focused. A general overview on welding
process, grinding process, and press working was introduced. Apart
from traditional manufacturing processes as mention previously
other types of non-traditional machining processes example
Ultrasonic machining (UM), electric discharge machining (EDM) was
introduced. The syllabus concluded with the final finishing processes
and industrial practices example the application of ISO 9001 and
ergonomic methods of work handling.

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 Diploma in Mechanical Engineering
College of Engineering

Course Objectives : The aims of this course are to:

1. Educate students with fundamental of manufacturing processes that

changes the raw materials to create products or output
2. Analyse the processes and machines element based on materials
properties

Course Outcomes (CO)

- what students to achieve and to be assessed upon completing this course

No. Upon completion of this course, the student should be able to:

CO1 Describe conventional and non-conventional manufacturing processes

CO2 Describe welding processes

CO3 Conduct analysis related to machining and manufacturing processes

CO4 Able to describe how work completed and problem encountered

CO5 Work in a team

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 Diploma in Mechanical Engineering
College of Engineering
Diploma of Mechanical Engineering
College of Engineering

Course Outcomes :

MQF
MQF Domain  MQF1  MQF2  MQF2  MQF2  MQF5  MQF5  MQF5  MQF3b,c  MQF3b,f  MQF4a  MQF4b 
3a,d,e 
Course Outcome PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12

CO1 X
CO2 X
CO3 X
CO4 X
CO5 X

Assessment-Course Outcomes Matrix :

MQF Domain MQF1 MQF1 MQF1 MQF3b,c  MQF3d
PO1 PO1 PO2 PO9 PO10
Assessments CO1 CO2 CO3 CO4 CO5
Quizzes (10%) 70 30
Assignment (10%) 80 20
Group Lab Project (40%) 50 50
Test (40%) 70 10 20

PO emphasis:

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 Total
Current Coverage (%) 50.0 10.0 0.0 0.0 0.0 0.0 0.0 0.0 20.0 20.0 0.0 0.0 100

Bloom's Coverage (%) :

Cognitive
Psychomotor Affective Total
Low Med Hi
Current Coverage (%) 50 10.0 0.0 20.0 20.0 100
Diploma in Mechanical Engineering
College of Engineering

Course Outline/Syllabus:

Topic 1: INTRODUCTION TO MANUFACTURING SYSTEM

 Course introduction
 Introduction to manufacturing
 Design, material and production
Topic 2: NATURE AND PROPERTIES OF MATERIAL

 Classification of materials
 Engineering properties of materials
Topic 3: FOUNDRY PROCESSES

 Sand casting and moulding processes

 Gating system and solidification characteristics
 Patterns
 Sand technology
 Composites
Topic 4: CONTEMPORARY CASTING PROCESSES

 Die casting
 Permanent mould casting
 Centrifugal casting
Topic 5: METAL CUTTING

 Metal cutting theory

 Metal cutting tools chip shape and formation
 Coolants
 Machinability
 Tool life
Topic 6: MACHINING CUTTERS, PERFORMANCE AND OPERATIONS

 Turning tools
 Drills
 Reamers
 Milling cutters
Topic 7: GRINDING AND ABRASIVE PROCESSES

 Grinding and abrasive practice

 Grinding process
 Abrasive, grinding wheel and stones
Diploma in Mechanical Engineering
College of Engineering

Topic 8: WELDING AND JOINING PROCESSES

 Arc welding
 Oxyfuel gas welding
Topic 9: HOT WORKING OF METALS

 Hot rolling
 Hot forging
Topic 10: COLD WORKING OF METALS

Topic 11: PRESS-WORKING AND OPERATIONS

 Bending and forming

 Shearing
 Drawing
Topic 12: NON-TRADITIONAL PROCESSES

 EDM, ECM, USM, LBM, EBM

 Powder metallurgy (p/m)
Topic 13: FINISH PROCESSES

Topic 14: QUALITY SYSTEMS

 The quality improvement system

 Process variation
Topic 15: COMPUTER NUMERICAL CONTROL SYSTEMS

Main Reference(s)

1. Manufacturing Engineering and Technology 7th Edition, Serope Kalpakjian & Steven Schmid,
Pearson, 2013.

Additional Reference(s)

th
1. Manufacturing Processes and Systems. Philip F. Ostwald & Jairo Munoz, 9 Edition, John
Wiley & Sons, 2008
Diploma in Mechanical Engineering
College of Engineering

Course Schedule

LECTURE

WEEK TOPIC ASSESSMENT

10

11

12

13

14

15-16 FINAL EXAM

 Diploma in Mechanical Engineering
College of Engineering

What is Programme Educational Objectives (PEO)?

PEO are objectives that UNITEN graduates should achieve after five (5) years of graduation.

What are Programme Outcomes (PO)?

PO are the expected traits that UNITEN students should have upon graduation.

Summary of DME Programme Educational Objectives (PEO)

Programme Educational Objectives

PEO
No. UNITEN produces mechanical engineering technician graduates who:
PEO1 Practicing technical assistant in mechanical engineering with the ability to venture into energy or other
businesses.
PEO2 Holding leadership/supervisory responsibilities and/or establish their own enterprises.
PEO3 Pursuing or holding competency qualifications/certifications/higher-level studies in mechanical engineering
related areas.

DME Programme Outcomes (PO)

Programme Outcomes
Students graduating from the Diploma in Mechanical Engineering (DME) programmes will have the
ability to:
PO
PO Statements
No.
Apply knowledge of applied mathematics, applied science, engineering fundamentals and an engineering
PO1
specialisation. DA1 (DK1-DK4) [MQF1]

Identify and analyse well-defined engineering problems reaching substantiated conclusions using codified
PO2
methods of analysis specific to their field of activity. DA2 (DK1-DK4) [MQF2]

Design solutions for well-defined technical problems and assist with the design of systems, components or
PO3 processes to meet specified needs with appropriate consideration for public health and safety, cultural,
societal, and environmental considerations. DA3 (DK5) [MQF2 ]

Conduct investigations of well-defined problems; locate and search relevant codes and catalogues, conduct
PO4
standard tests and measurements. DA4 [MQF2]

Apply appropriate techniques, resources, and modern engineering and IT tools to well-defined engineering
PO5
problems, with an awareness of the limitations. DA5 (DK6) [MQF3a, d, e]

Demonstrate knowledge of the societal, health, safety, legal and cultural issues and the consequent
PO6 responsibilities relevant to engineering technician practice and solutions to well-defined engineering
problems. DA6 (DK7) [MQF5]

Understand and evaluate the sustainability and impact of engineering technician work in the solution of well-
PO7
defined engineering problems in societal and environmental contexts. DA7 (DK7) [MQF5]

Understand and commit to professional ethics and responsibilities and norms of technician practice. DA8
PO8
(DK7) [MQF5]

Communicate effectively on well-defined engineering activities with the engineering community and with
PO9 society at large, by being able to comprehend the work of others, document their own work, and give and
receive clear instructions. DA10 [MQF3b, c]
 Diploma in Mechanical Engineering
College of Engineering

Programme Outcomes
Students graduating from the Diploma in Mechanical Engineering (DME) programmes will have the
ability to:
PO
PO Statements
No.

PO10 Function effectively as an individual, and as a member in diverse technical teams. DA9 [MQF3b, f]

Recognise the need for, and have the ability to engage in independent updating in the context of specialised
PO11
technical knowledge. DA12 [MQF4a]
Demonstrate knowledge and understanding of engineering management principles and apply these to one’s
PO12 own work, as a member or leader in a technical team and to manage projects in multidisciplinary
environments. DA11 [MQF4b]
 Diploma in Mechanical Engineering
College of Engineering

Malaysian Qualifications Framework (MQF) 2nd Edition

The Malaysia Education Blueprint 2015-2025 (Higher Education) or the MEB (HE) (Ministry of Higher Education,
2015) is formulated based on the vision and aspiration of the 11 th Malaysia Development Plan (2015 – 2020).

In 2017, a revision to the current Malaysian Qualifications Framework (MQF) by the Malaysian Qualifications
Agency (MQA) was done in response to the call by Malaysians to make the framework more responsive to better,
higher quality and relevant post-secondary education. The MQF 2 nd Edition remains as an overarching framework
for all qualifications from diverse sectors which is based on, and maintains, the structure of the previous framework.

With the 11th Malaysian Development Plans (2015-2020), the scope of MQF refers to qualifications types from two
sectors, i.e., academic and Technical and Vocation Education and Training (TVET) sectors. The Framework, a single
and unifying framework of all qualifications in Malaysia, describes the levels of learning, generic learning outcomes,
level descriptors, credits and single qualification title for each level to be applied in both academic and TVET type
qualifications.

Malaysian Qualifications Framework (MQF) 2 nd Edition

Cluster of Learning Outcome
Cluster Learning Brief Description On Learning Descriptor for Level 4:
Outcome Outcomes Diploma
1 Knowledge and A systematic understanding of facts, Demonstrate systematic comprehension
understanding ideas, information, principles, (understanding) of a broad range of complex technical
concepts, theories, technical and theoretical knowledge and skills to undertake
knowledge, regulations, numeracy, varied, complex, routine and non-routine tasks/ study
practical skills, tools to use, processes within a field/discipline.
and systems.
2 Cognitive skills The thinking or intellectual Identify, interpret, apply and evaluate general
capabilities and the ability to apply concepts, theory and/or operational principles within
knowledge and skills. a well-defined context of a subject/discipline and/or
work with minimal supervision.
Solve problems of a common and well-defined kind as
well as those others of a non-routine nature.
3 (a) Practical In study context, it may include study Apply a limited range of practical skills, essential
skills skills and preparations, undertaking tools, methods and procedures to perform
procedures, scientific skills, designs, required tasks/work.
research and so forth.
Reflect and make adjustments to practices and
processes, as necessary, related to routine or
non-routine tasks.
(b) A range of skills which, amongst Communicate clearly, both orally and in writing, ideas,
Interpersonal others, include interactive information, problems and solutions, to others
skills communications; relationships and including peers, experts and non-experts.
collaborative skills in managing Interact effectively, individually or as member of a
relationships in teams and within the team with supervisors, peers and subordinates.
organizations, networking with Demonstrate a high level of proficiency in at least one
people of different cultures, as well as other language besides the national language
social skills/etiquette.
(c) The ability to communicate/convey
Communication information/ideas/reports cogently
skills and professionally in appropriate
language.
(d) Digital skills The ability to use information/digital Use a range of digital applications to support
technologies to support studies. study/work as well as to seek and process data related
(e) Numeracy The quantitative skills that require to work or study.
skills learners to acquire increasingly Demonstrate skills to use and interpret routine and
higher levels of numerical abilities complex numerical and graphical/visual data.
which may include understanding of
basic mathematics, symbols relating
to statistical techniques and etc.
(f) Leadership, Refers to an individual’s ability to Perform work with significant degree of personal
Autonomy and build relationships and work with responsibility and autonomy under broad guidance
Responsibility teams made up of peers or in and direction on well-defined and non-routine
managerial capacities with varying study/work activities performed in a variety of
Diploma in Mechanical Engineering
College of Engineering

degrees of autonomy. contexts.

Lead and manage diverse teams to manage issues at
work.
4 (a) Personal Life skills that learners are expected
skills to use daily, which may include Identify self-improvement initiatives and possibilities
demonstrating confidence, self- for further education.
control; social skills and proper Develop realistic career and professional goals.
etiquette, and commitment to Explore and engage in activities relating to
professionalism. entrepreneurship.
(b) The skills that require relevant Show interest in and participate at professional and
Entrepreneurial knowledge, ability, talent and civic activities leading to local and region wide
skills expertise in key areas of an communities building.
enterprise.
5 Ethics and The awareness/ understanding and Demonstrate ability to understand and comply with,
Professionalism respect of ethical, social and cultural organizational and professional ethics in work
differences and issues, as well as environment.
professional skills and responsibilities Demonstrate ability to apply sustainable practices in
(integrity and professional conduct). the context of local and global work and social
environment.