Advanced Manufacturing Course

Lesson 1 • Safety and Regulatory Compliance

Addresses hazard identification, personal protective equipment, and workplace safety regulations. Establishes non-negotiable compliance baseline for all lab activities.

Lesson 2 • Tolerances, Standards, and Specifications

Explains dimensional tolerancing, geometric dimensioning, and international standards. Connects specification literacy to downstream quality outcomes.

Lesson 3 • Process Classification and Selection

Introduces subtractive, additive, forming, and joining process families. Equips learners to match process type to part requirements.

Lesson 4 • Materials Science Essentials

Covers metals, polymers, ceramics, and composites relevant to advanced processes. Links material properties to process selection decisions.

Lesson 1 • CNC Machine Architecture

Examines axes configurations, drive systems, and controller types. Grounds programming decisions in machine mechanical behaviour.

Lesson 2 • Multi-Axis Machining Strategies

Introduces 4- and 5-axis simultaneous machining for complex geometries. Extends 3-axis skills to aerospace and medical part profiles.

Lesson 3 • Speeds, Feeds, and Depth of Cut

Applies cutting parameter theory to real machining scenarios. Reduces scrap and tool breakage through data-driven parameter setting.

Lesson 4 • Cutting Tool Technology

Covers tool geometry, coatings, and wear mechanisms for common materials. Supports optimal tool selection and replacement scheduling.

Lesson 1 • Post-Processing and Finishing

Details heat treatment, HIP, machining, and surface finishing for AM parts. Ensures dimensional and mechanical compliance with end-use specifications.

Lesson 2 • Design for Additive Manufacturing

Teaches topology optimisation, support minimisation, and lattice design. Translates design freedom into weight reduction and functional integration.

Lesson 3 • Additive Process Families

Compares FDM, SLA, SLS, DMLS, and binder jetting across resolution, material, and cost axes. Enables informed process selection for given applications.

Lesson 4 • AM Quality and Qualification

Applies NDT, CT scanning, and statistical process control to AM production. Establishes qualification pathways for regulated industries.

Lesson 1 • Joining Quality and Inspection

Applies destructive and non-destructive testing to weld and bond evaluation. Connects inspection results to process parameter correction.

Lesson 2 • Solid-State Joining Methods

Covers friction stir welding, diffusion bonding, and ultrasonic welding. Enables joining of dissimilar and heat-sensitive materials.

Lesson 3 • Sheet Metal Forming Operations

Examines stamping, deep drawing, hydroforming, and incremental forming. Connects forming limits to material ductility and tooling design.

Lesson 4 • Fusion Welding Technologies

Teaches GMAW, GTAW, laser, and electron beam welding for advanced alloys. Addresses heat-affected zone control and distortion mitigation.

Lesson 1 • Advanced Inspection Technologies

Introduces structured light scanning, laser trackers, and inline vision systems. Extends inspection capability to large and complex assemblies.

Lesson 2 • Measurement System Analysis

Covers gauge R&R, bias, linearity, and stability studies. Validates measurement systems before production data collection.

Lesson 3 • Coordinate Measuring Machines

Teaches CMM programming, probe qualification, and GD&T evaluation. Enables automated dimensional inspection of complex geometries.

Lesson 4 • Statistical Process Control

Applies control charts, process capability indices, and run rules to manufacturing data. Distinguishes common-cause from special-cause variation.

Lesson 1 • Discrete Event Simulation

Models production lines, queues, and resource utilisation using simulation software. Validates improvement scenarios before physical implementation.

Lesson 2 • Total Productive Maintenance

Implements OEE measurement, autonomous maintenance, and planned maintenance pillars. Maximises equipment availability and performance.

Lesson 3 • Six Sigma DMAIC Methodology

Applies Define, Measure, Analyse, Improve, Control phases to chronic defect problems. Delivers statistically validated process improvements.

Lesson 4 • Value Stream Mapping and Analysis

Teaches current-state mapping, waste identification, and future-state design. Provides the visual framework for systemic improvement initiatives.

Lesson 1 • Manufacturing Data Analytics

Applies descriptive, diagnostic, and predictive analytics to production datasets. Converts raw machine data into actionable process insights.

Lesson 2 • Predictive Maintenance Systems

Designs vibration, thermal, and oil analysis-based maintenance programmes. Reduces unplanned downtime through condition-based intervention.

Lesson 3 • IIoT Architecture and Connectivity

Covers sensors, edge computing, protocols, and cloud integration for factory floors. Establishes the data infrastructure for smart manufacturing.

Lesson 4 • Autonomous and Collaborative Robotics

Covers cobot programming, AMR integration, and human-robot collaboration safety. Deploys flexible automation in mixed human-machine environments.

Lesson 1 • Change Management for Manufacturing

Applies structured change models to technology adoption and process transformation. Sustains gains by addressing human and organisational resistance.

Lesson 2 • Make vs. Buy and Sourcing Strategy

Applies total cost of ownership, core competency, and risk frameworks to sourcing decisions. Optimises vertical integration for competitive advantage.

Lesson 3 • Factory Layout and Capacity Planning

Designs cellular, functional, and flow-line layouts using systematic layout planning. Aligns physical capacity to demand forecasts and product mix.

Lesson 4 • Business Case and ROI Development

Constructs financial models for capital equipment, automation, and process improvement projects. Secures executive approval through rigorous justification.