Metals-Manufacturing 3: Mass Production and Documentation Portfolio
Course Page
View the course Handouts.
INSTRUCTOR: MR. MUNTZ
INDUSTRIAL TECHNOLOGY DEPARTMENT
dmuntz@lghs.net
408-354-2730 x220
TEXTBOOK: MODERN METAL WORKING, JOHN R. WALKER
COURSE INFO
Course Content:
The primary purpose of this class is to provide a learning experience in some underlying principles of production technology. This class will consist of one major project to be completed in coordination with all members of the class.
To complete the class successfully this class will require outside of class time in the lab. Past classes have needed to come in during Winter and Spring breaks. The amount of outside of class time needed will depend on the complexity of the project chosen by the class.
Topics to be covered in Metals-Manufacturing 3 are:
- Plan, develop and complete a unit that would exemplify Production Technology in industry. The conceptual product idea should come from the students in the class followed by designing, developing fixtures when necessary, fabricating, machining, welding all assemblies together, and finishing the product. This is to stimulate all aspects of industrial practices. Within the manufacturing of this product, equipment from the CAM lab might be integrated. A document will be created containing:
- All drawings, flow charts, manufacturing procedure, daily logs, and job descriptions.
- Poster, Video, Power Point, Binder Required
- Become familiar with the principles of Computer Numerical Control (CNC) and Computer Assisted Manufacturing (CAM). This would include:
- A short history of CNC and CAM.
- Explaining the Cartesian or Rectangular Coordinates.
- Programming Direct Machine Input (DMI) devices.
INSTRUCTOR INFO
My Philosophy: The Instructor is here to teach and the student is here to learn.
The purpose of this class is to develop critical thinking and manipulative skills while exploring industrial processes. The main themes of this course are the practical arts of: Following Directions, Personal Organization, Time Management, and Responsibility. My personal goals as an instructor are to maintain a safe learning environment for all students, while producing productive young members of society. The best way to ensure success in this class is to be kind, courteous, observant, and thoughtful.
Office Hours
The instructor is available for tutoring or other assistance in the lab during tutorial, Monday through Friday, unless otherwise posted. Lecture material missed during an absence from school should be made up during this time.
REQUIRED MATERIALS
Materials Required:
- Safety Glasses (may be purchased from the instructor or brought from home)
- Respirators for Arc Welding -recommended. (type N95 particulate or equivalent "good for metal fumes, welding, brazing, flame cutting and other operations involving heating of metals")
- 6 ea #2 wooden Pencils
- Shop Apron-recommended not required. (new ones available from the instructor for $6.00)
- Three Ring Binder which the student should have from Metals Manufacturing 1
- Lockers, Lock and Textbook are provided.
Three Ring Binder for notes: 1"-1 ½" size rings, hard cover.
This class requires a three ring binder that may be stored in the students' in-class locker. This binder is to be present in class every day, and will be checked by the instructor every six weeks. This binder should be maintained from Metals Manufacturing 1 and should contain all notes and handouts from that class as well as from Metals Manufacturing 2.
Required Class Lab Fee: $10.00
This fee covers the cost of consumable materials specific to the course. The cost for all materials used to learn skills required for the course are covered by this fee. Any projects the student makes and takes home must be paid for individually. Any additional projects students complete using school-provided materials must be paid for on an individual basis. Students will be instructed in how to make a bill of materials for each project before it is completed so they may predict the cost ahead of time. Students unable to pay the Lab fee are instructed to see the instructor to make individual arrangements.
Lockers
Lockers are provided for each student. They may keep their binder, safety glasses and pencils in their locker. It is recommended that students also keep a pair of shoes on hand if they plan to wear sandals to school. No open toed shoes are allowed in the lab while any of the tools are being used. If a student is wearing sandals whey will not be allowed to enter the lab and will be unable to work on their project that class day. Locks for lockers are provided by the instructor, if lost, locks cost $5.00 to replace.NOTE: Damage to tools or shop equipment due to misuse or carelessness will be the responsibility of the student to replace or compensate. Cost of repair will be provided if necessary.
POLICIES AND RULES
Class Rules:
- No Hats
- No Electrical Devices
- No Sunglasses
- No Swearing
- No Food Drink or Gum
- Show Respect for all
- Be Prepared
- Do Your Best
- The Instructor dismisses students at the end of class, not the bell.
Required Footwear
No open toed shoes allowed in the Lab at any time. If the student is not wearing appropriate footwear he/she will not be allowed to enter the lab. This is important to remember, because the student may miss important demonstrations or work time in the lab.
Grading Policy
See separate grade sheet.
Repeat work
All lab work can be redone until quality is achieved is acceptable to student and teacher.
LAB SAFETY
Lab safety and Safety Test
In this course safety is of the utmost concern. For each tool the instructor will provide appropriate instruction and demonstrations to ensure safety of all who use it. A safety test must be passed each semester before students may use any tools in the lab. This test is a Pass/Fail exam. Safety is extremely important, and many of the tools and machines used in this class are potentially harmful if used carelessly or ignorantly. It is for this reason; a passing score on a Safety test must be 100%.
ATTENDANCE AND LATENESS
Lateness
All students must be in their seat with their notebook, and pencil ready, before the bell starts ringing.
Absences
Students are responsible for material and assignments missed. The student will be allowed the same number of days to make up work missed as the length of the absence.
Late Work
Late work and repeats are only accepted during the first six weeks of the school year. The work must be turned in within five days of the original due date or as per agreement with the instructor.
CITIZENSHIP AND CLASS PARTICIPATION
Citizenship: You earn 210 points every semester, 70 points every six weeks.+10 points for no infractions
-5 points for a tardy
-5 points for an absence
-5 points for leaving the lab/classroom
-5 points for any minor safety violation
-20 points for any major safety violation
This is a hands-on, activity based class. Students must be responsible for their own assignment completion. To complete all projects within the time allotted students must be on task every day they are in the lab. Your presence in class daily is vital to your success in the course. Lateness, and absences, will adversely affect your citizenship points.
Failure to take notes or be respectful during lecture/demo portion of class may result in a loss of citizenship points. This is considered failure to participate fully in the class.
AVAILIABLE SUPPORT/REASONABLE ACCOMODATIONS
Open Lab Time
The lab is available for use on school days after school until 5:00 PM unless otherwise posted. Open Lab Time is supervised work time for students to work on their class projects. If you require additional personal instruction on a course topic please come in during tutorial.
Personalized Tutoring and Special Accommodations
See Office Hours above.
ASSIGNMENTS DUE IN METALS MANUFACTURING 3
A written Document (binder) containing the work done by the team the entire year. The binder must include:
- Drawings
- Daily log
- Flow chart
- Bill of Materials
- Jigs and Fixtures
- Development Sketches
A presentation ten to fifteen minutes long, given to the class using multimedia (pictures, video, power point etc.). This will happen the last week of class. The audience could possibly be people from local industry, advisors, and an administrator.
TESTS
Final Exam Semester One
There will be no written portion of the final. The Practical portion consists of the following: The instructor will choose an item to be produced. Each team will be given a drawing and a two hour final class period to plan and produce the item. Grades will be assigned based on completion, quality and accuracy.
Final Exam Semester Two
See "presentation" above.
COURSE CONTENT FOR METALS-MANUFACTURING 3
The primary purpose of the Manufacturing 3 class is a learning experience in some underlying principles of production technology.
The secondary purpose is to finish the course with a product representing the culmination of the effort.
It is important to choose the item to be produced expeditiously. This may mean sacrificing some individuals' project preferences in favor of getting into production with the majority's acceptance.
Some of the underlying mechanics of the course should proceed as follows:
- Unless the class unanimously agrees and is willing to prepay a 75% assessment, the accepted project idea should not exceed $100.00.
- A design group of students will emerge from the class composed of not more than three students. The group will be composed of:
- The person who proposed the project initially
- A qualified CAD drafting student or an import from the drafting program
- The eventual project group leader
- These people will design, develop, and complete a working drawing and present it to the entire class before commencing production. The design group may call for meet and confer sessions with the entire class. (Anytime four students or more in the class-at-large demand a meeting then that meeting will be conducted within two class days)
- There will be a project coordinator and a quality control coordinator. Both of these people can work within the class on production jobs if the instructor is satisfied that their primary jobs are operating satisfactorily.
- A CAD drawing and a flowchart of operations will be developed before production starts.
- The production coordinator and quality control person should be mindful of the other members in the class and their need to experience different jobs. Therefore, occasional rotation of students through the jobs occurring at a given time should be expected unless agreement is reached to the contrary.
HANDOUTS
All handouts are in .pdf format.
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