Management Challenge Project - 2023 entry

Engineering design is a complex activity, which combines using technical knowledge, and combining it with more creative knowledge and skills. In this module, which will be completed over two terms, you will apply the core knowledge gained throughout your degree so far, as well as develop your previous knowledge of the stage gate innovation process through a creative real-world Project Based Learning (PBL) collaborative technical design project. You will learn to produce and use engineering drawings, and apply this along with your previous knowledge of sketching and CAD to appreciate how engineering drawing can be used as a method of unambiguous communication.

The PBL driving question is ‘How can we design products to optimise performance, cost and manufacturing?’

This module will introduce you to the more technical aspects of design and manufacture such as component selection, fit and tolerance, design for manufacture and assembly and CAD/CAM (Computer Aided Design/Computer Aided Manufacturing). This module will enhance your 3D modelling skills from Multidisciplinary Challenge Project 1 (ENG1105) and equip you with the challenge of optimising designs in terms of performance, cost and manufacturing through an awareness of automated manufacturing techniques such as Computer Numerical Control (CNC) and Additive Layer Manufacturing (ALM). This knowledge will be combined with the technical content that you have learnt in core modules to complete a group design project focused on the design and manufacturing process of a product. The specific product brief will be set by an industry engineer who will effectively be your client for the design project, and who will assess your final design and prototypes as part of a poster and group presentation during a design fair at the end of the module.

This will provide you with an awareness of how engineering design fits within a business. As part of the group design project, you will be encouraged to use the wide range of workshop facilities to make proofs of concept, scale models, or specific component prototypes (using manual or automated machine tools) to improve your understanding of your design, and how to optimise your final design.

• Managing projects successfully from an original business idea into a final manufactured product 
• Active team working and improving communication skills
• Developing professional engineering reports and presentations 
• Engagement with members of businesses and industries 
• Analysing market needs for engineering products 

ILO #1: Demonstrate knowledge and understanding of engineering design and the hone your ability to undertake technical research in terms of current and future developments and technologies

ILO #2: Understand concepts within your discipline, outside your discipline and outside engineering, evaluate them using critical thinking and apply them effectively in engineering projects

ILO #3: Demonstrate understanding of the knowledge gained in theoretical modules and the ability to apply it to analyse key engineering processes

ILO #4: Evaluate business, customer and user needs and through the formulation of a detailed product design specification and apply engineering techniques taking account of a range of commercial and industrial constraints

ILO #5: Plan and manage the Stage Gate Innovation Process, including cost drivers, and evaluate outcomes

ILO #6: Quantify the effect incomplete information on the designs and apply theory, prototyping and computational methods to solve engineering problems and mitigate deficiencies

ILO #7: Identify, classify and design components using a product design specification, analytical methods and modelling techniques ILO #8: Develop advanced 3D modelling skills and apply them to generate conceptual designs, test prototypes and detail engineering design drawings

ILO #9: Demonstrate knowledge and experience of prototyping tools such as laser cutting, card modelling and 3D Printing and appreciate the challenges of interfacing CAD designs with CAM techniques

ILO #10 Apply advanced problem-solving skills, technical knowledge and understanding to establish rigorous and creative solutions that are fit for purpose for all aspects of the problem including production, operation, maintenance and disposal

ILO #11: Understand the role of engineers to lead sustainable product development and apply quantitative techniques if necessary, to justify the change required

ILO #12: Understand the assessment and management of risk in terms of H&S, environmental and commercial risk.

ILO #13: Knowledge of characteristics of particular equipment, processes, or products, materials and component

ILO #14: Work in teams to analyse problems, find and optimise solutions, and communicate the entire process to audience

ILO #15: Enhance critical thinking, communication, report writing, and organisational skills

The module is designed to establish the foundation for advanced engineering design projects. The purpose of this module is to:

- Establish the principles of the design processes as part of engineering practice working with industry collaborators to ensure relevance and authenticity of the PBL project and assessment to professional engineering.

- Develop 21st century skills in creativity, collaboration, communication, critical thinking, problem solving, leadership and technology literacy.

- Build on project research/study skills, conceptual and detail design using 3D modelling and prototyping and report/technical writing.

- Develop new skills in engineering part and assembly drawings.

- Steering projects through the Stage Gate Innovation Process and creating posters and working prototypes for your final PBL ‘Public Product’.

This module will be delivered over two terms. The first term will focus on 3D modelling and engineering drawing, the delivery of specific design content and the assessment the preliminary

stages of the group design project. The second term will focus on the support and assessment of the detailed design phase of the group project. Specific design content will include revision of the stage gate innovation process, an introduction to orthographic projections, the principles of part and assembly drawings and 3D modelling. The basis for mechanical component selection will include the quantitative analysis of threads, bearings, gears. The fundamentals of fit and tolerance will also be introduced in relation to manufacturing techniques and CAM, to provide students with an awareness of how fit, tolerance, manufacturing, and materials selection all affect the cost and performance of designed parts and assemblies.

1: Project introduction:

2: Project Launch – product design inspiration:

3: Project management tools and  techniques:

4: 3D modelling and engineering drawing lectures and tutorials:

Reassessment will be by coursework in the failed or deferred element only. For deferred candidates, the module mark will be uncapped. For referred candidates, the module mark will be capped at 40%.

Reading list for this module: