Manufacturing process engineering
How an AFS order flows from drawing to delivery with its control points, the limits and thickness bands that bound a flashing process, worked limits, yield, flow and bend-development methods, and how to verify and diagnose a defect.
4 lessons · about 50 min · 13 diagrams · 0 videos
Version 1.0.0
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Lesson 1 · 13 min · 12 slides · 9 questions
Manufacturing process engineering: principles and terminology
What a process engineer changes and what stays fixed, how an AFS order moves from drawing to delivery, where the process stops a mistake early, the words that mean two things in flow and capacity, and the machine-safety rules to check before changing a process.
You will be able to: Describe AFS’s order-to-delivery process as a flow with control points, define the vocabulary of flow and capacity (processing time, flow time, takt, work in process, throughput, bottleneck), and state the safety boundary that applies before any process change.
Not startedStart →Lesson 2 · 11 min · 11 slides · 8 questions
Manufacturing process engineering: materials, standards and design constraints
AFS’s geometry and thickness limits, what shop review means, why a gauge is a name and thickness is the number, how thickness varies by gauge, and how a bend is developed from mold-line legs.
You will be able to: Identify the limits that bound a flashing process (geometry, material, thickness variation, bend development) and say whose each limit is: AFS’s, a manufacturer’s or a standard’s.
Not startedStart →Lesson 3 · 13 min · 12 slides · 9 questions
Manufacturing process engineering: methods and worked application
A repeatable method template, then worked limits, sheet-yield, run-length, bottleneck and bend-development examples using AFS’s own limits, template geometry and register thicknesses, with textbook flow figures marked as such.
You will be able to: Apply four documented methods to a realistic job: a limits check, a sheet-yield calculation, a bottleneck and work-in-process calculation, and a bend-development uncertainty budget, recording assumptions, units and inspection points.
Not startedStart →Lesson 4 · 13 min · 12 slides · 9 questions
Manufacturing process engineering: defects, verification and case study
Preventing versus detecting defects, how to read control charts and capability indices, why the instrument comes first, a five-step root-cause method, and a case study and checklist built only from sourced or AFS-register material.
You will be able to: Choose a verification method (first-article check, control chart, capability index), read it correctly, and run a five-step root-cause analysis on a plausible defect, documenting the evidence.
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Practical task
Study one real flashing profile as a process engineer: write a one-page process map with its control points, run a limits check and a yield calculation with every input sourced, and design (but do not claim results for) a first-article measurement plan with a control chart.
Hand in
- A process map of one job from drawing to delivery, with the three control points marked and each step labelled as AFS’s or the customer’s
- A limits check and a strips-per-sheet calculation for the chosen profile, written with inputs and their sources, assumptions, arithmetic with units, result and check
- A measurement plan for one leg: subgroup size, how often, the instrument and its calibration trail, and the blank X-bar and R chart with the NIST constants for your subgroup size
- A one-page root cause worksheet for a made-up drift in that leg, listing hypotheses and the evidence that would confirm or reject each, declaring no cause
Rubric
| Criterion | Meets the standard when |
|---|---|
| Process map | Shows the order from drawing to delivery with the limits check, the verified approval and the one-button-per-state queue marked, and does not claim a measured step time. |
| Limits and yield | Adds the legs to a girth, compares each limit to its source, computes strips per sheet as 48 divided by the blank width rounded down, and says the legs are template defaults. |
| Whose number | Labels every value as an AFS register value, a published value, a derived value or a textbook value, and never presents a manufacturer or textbook number as an AFS measurement. |
| Measurement plan | Uses a subgroup size with its NIST constants, charts for stability before any Cpk, and names the instrument and how it is traced to a reference. |
| Root cause | Follows the five steps, writes each cause as a hypothesis with a test, and states no cause as fact without data. |
| Safety | States that any change touching the machine is checked against 29 CFR 1910.212, 1910.147 and AFS’s own written procedure first. |