Short Title:Manufacturing Systems and Innovative Technologies
Full Title:Manufacturing Systems and Innovative Technologies
Module Code:MANU H4000
Credits: 5
NFQ Level:8
Field of Study:Mechanics and metal work
Module Delivered in 3 programme(s)
Module Description:Manufacturing Systems is critical to the optimal delivery of product and services. This module will cover Lean Operations, Six Sigma, Supply Chain Management and Production Planning, as well as an overview of manufacturing technologies and systems (both current and emerging) used in a range of sectors including: Pharmaceutical & Medical devices; Semiconductor & Nanotechnology; Food, packaging & clothing.
Learning Outcomes
On successful completion of this module the learner will be able to:
LO1 Demonstrate an understanding of the fundamentals of Lean Operations and Six Sigma, communicate their key elements, and use some of their tools.
LO2 Discuss the key issues in Supply Chain Management, with an appreciation of the differences that exist in various industries.
LO3 Analyse the merits of different Capacity Management & Production Planning strategies, and develop a Production Plan using a computer spreadsheet.
LO4 Evaluate the technology families utilised by the High Tech manufacturing sectors in Ireland. The evaluation should cover: The effect of technology evolution on the process; materials utilised; costs(fixed and variable); quality; safety and environmental impacts.
LO5 Conduct an piece of individual research based on the literature.
LO6 Disseminate their work to a panel of their peers, and public, using video, oral presentation and poster presentation.
Pre-requisite learning
Co-requisite Modules
No Co-requisite modules listed

Module Content & Assessment

Content (The percentage workload breakdown is inidcative and subject to change) %
Lean Production Techniques
History; aliases; main aim; Lean’s definition of waste; adding value; Sea of Inventory analogy; leadtime and WIP reduction; small batch manufacture; push vs. pull production and kanban; Supplier Relationships and Quality in a Lean environment.
Six Sigma
History. Variation and normal distribution, short-term and long-term sigma. The principles of Six Sigma; The Process Equation; Lean vs. Six Sigma; Roles within Six Sigma programs; the DMAIC model (Define, Measure, Analyse, Improve, Control); some Six Sigma tools including some of the following: Project Charters, Voice of the customer (VOC), SIPOC, CTQ, Cause & Effect Diagrams, 5 Why's, Process mapping.
Supply Chain Management (SCM)
What is a Supply Chain, and SCM; complexity and uncertainty in SCM; why are companies using SCM; The Bullwhip Effect; Information Technology – the SCM enabler – e-business, EDI, RFID, bar-codes, internet, build-to-order; Supply Chain integration; different Supplier relationships.
Capacity Management & Production Planning
Different Capacity Management strategies (Chase demand, Level Production, Excess Capacity etc.) and advantages/disadvantages of each; The hierarchical nature of the production planning process: aggregate planning, master production scheduling (MPS), rough cut capacity planning, final assembly schedule. Developing these in practice using spreadsheets.
Emerging Manufacturing Technologies & Innovation:
Technology development, adoption, evolution and systems analysis. Invention vs innovation: Patents and Patent Analysis. Definition of Innovation, types and theories of innovation, sources of innovation and management of innovation.
Semiconductor & Nanotechnology
Process sequence used to fabricate an integrated circuit/ MOS capacitor. Oxidation: Dry and wet oxidation. Vacuum technology. Metal deposition: Evaporation, magnetron and RF sputtering. Photolithography: Masks, mask alignment. UV, xray and electron beam lithography. Etching: Wet etching and dry etching. Diffusion: Fick's laws. Sheet resistance and four pointprobe. Cleanroom lab based on semiconductor technology.
Pharma & Medical Devices
Unit Operations & Equipment: Batch versus continuous processing, Process Analytical Technology (PAT): Multivariate data acquisition and analysis tools; Modern process analyzers or process analytical chemistry tools; Process and endpoint monitoring and control tools. Formulation & Tablet Production, Active Drug Ingredient and tablet excipients; Production steps for a tablet process: pre-formulation, formulation, milling, blending, drying, granulating, tableting, coating. The role of GMP. Medical Devices: the technologies and systems issues. FDA certification.
Assessment Breakdown%
Course Work100.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Assignment Group Assignment: they must design a simulation game to convince participants of the many benefits of Kanban & Pull Production versus Push Production. They must video the game being run, edit this into a short (c. 5-10 minute) segment which they may show to the class. They must also draw up a document that explains in detail how to run the game/simulation. They will also be marked on how well the group functioned. There will be an element of peer-marking. 1,6 35.00 Week 6
Assignment Various Individual assignments and tests including some/all of the following: test relating to a lab in the college's clean room; test relating to a lab in the college's Pharma lab; in-class tests relating to guest lecturers. 2,4 15.00 Ongoing
Assignment Individual In-Class Assessment: Using a computer-based spreadsheet (such as Excel) the student will create an Aggregate Production Plan and a Master Production Schedule (MPS) and carry out Rough Cut Capacity Planning to develop a feasible plan. 3 10.00 Week 11
Assignment Group Project to find relevant & current academic papers/industry journal articles relating to some area of the course. Individuals summarise specific papers/articles, while the group will make a presentation to the class on the area. They will also create a large poster that explains the issues in layman’s language. This poster will be displayed in the college (along the corridor, or in the library) as well as possibly in South Dublin County Library. The aim of the project is to bring together some of the disparate elements of the course. They will be marked on both the quality of their work, but also on the working of their group. Examples of topics might be: logistical issues in Supply Chain Management in the Electronics Industry; ethical issues in Supply Chain Management in the Pharmaceutical Industry; Innovations in the Packaging Industry; Semiconductor Material Characterisation; Thin Layer Deposition; Photolithography Techniques. 1,2,3,4,5,6 40.00 Sem 2 End
No End of Module Formal Examination

IT Tallaght reserves the right to alter the nature and timings of assessment


Module Workload

Workload: Full Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Theory, explanation, discussion, examples, instruction on CA to be carried out 4.00 Every Week 4.00
Independent Learning Time Reviewing lectures, viewing sources on moodle, doing CA, studying for exams 4.00 Every Week 4.00
Total Weekly Learner Workload 8.00
Total Weekly Contact Hours 4.00
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Theory, explanation, discussion, examples, instruction on CA to be carried out. 4.00 Every Week 4.00
Independent Learning Time Reviewing lectures, viewing sources on moodle, doing CA, studying for exams 4.00 Every Week 4.00
Total Weekly Learner Workload 8.00
Total Weekly Contact Hours 4.00

Module Resources

Recommended Book Resources
  • Stan Lee and Graham Robinson, Process development [ISBN: 978-0198558248]
  • edited by W. Hoyle 1999, Pilot plants and scale-up of chemical processes II, Royal Society of Chemistry Cambridge [ISBN: 978-0854047192]
  • Roberta S. Russell, Bernard W. Taylor, 2010, Operations Management, 7 Ed., Wiley [ISBN: 9780470525906]
  • Michael L. George... [et al.] 2004, The lean Six Sigma pocket toolbook, 1 Ed., McGraw Hill [ISBN: 978-0071441193]
  • John Mangan, Chandra Lalwani, Tim Butcher, Roya Javadpour, 2011, Global Logistics and Supply Chain Management, 2 Ed., Wiley [ISBN: 9781119998846]
This module does not have any article/paper resources
This module does not have any other resources

Module Delivered in

Programme Code Programme Semester Delivery
TA_EMECH_B B.Eng (Honours) in Mechanical Engineering [1 year Add-On] 8 Mandatory
TA_EAMEC_B B.Eng(Hons) in Mechanical Engineering [Ab Initio] 8 Mandatory
TA_EAAUT_B Bachelor of Engineering (Honours) in Mechanical Engineering (Automation) (1 yr Add on) 8 Mandatory