Module Name: Motorsport Product Innovation

Module Code: 6055MAA

Assignment Title: Bill of Materials & design Freeze

Assignment Task

You will be required to complete a manufacturing flow chart, Manufacturing Bill of Materials

This document is intended for Coventry University Group students for their own use in completing their assessed work for this module. It must not be passed to third parties or posted on any website. and answer some cost explanation questions for your specific project area.

The format of the BOM and flow chart must also align to the standard format provided and should tie into a master BOM collating the cost information for the entire vehicle.

The master file will be provided via AULA.

Please note, the boundaries between systems should be decided within your sub -teams with NO areas of the vehicle being neglected and no duplicates of parts, identical or otherwise .

1.    Flow chart for sub-assemblies

2.    BOM for the parts which shows deadlines for the 2024 build (spreadsheet of all parts)

3.    Questions to be answered:

a.    How have you designed to reduce cost of your part, and where have you chosen performance over cost and why (max 250 words)

b.    Explain choice between inhouse and external supplied parts (max 150 words)

c.    What are the overheads of the part not seen in the assembly flowchart (max 200 words)

d.   Create a table of these overheads with estimated hours of work needed for each overhead.

Mark Distribution

Flowchart (30%)

•    Use of template

•    Detail in the flowchart

Manufacturing/BoM Spreadsheet (40%)

•    Completeness of information

•    Inclusion of fixings and standard parts

•    Part naming

•    Sensible process choices

•    Sensible timings

Response to questions (30%)

•    Logical explanation/justification of statements

•    Concise explanation

For technical report submissions:

•    Report Layout (10%)

•    Introduction and definition of objectives (10%)

•    Manufacturing or simulation Detail (35%)

•    Evaluation of results in relation to objectives (20%)

•    Conclusions and further work (15%)

•    Referencing (10%)

Design Freeze

Aim

As part of your group projects, you have either been assigned to design, evaluate and manufacture a specific component or sub-assembly. Some of you have been designing parts from scratch and   others have been looking at the installation of electrical systems or simulation/analysis.

If you have designed an electrical system, please refer to Section 1.

If you have been designing a mechanical part or subsystem refer to Section 2.

If you have been doing a Simulation or Benchmarking project, please refer to Section 3. If you have designed a Cooling system, please refer to Section 4.

If you have designed an Aerodynamics part, please refer to Section 5.

1. Electrical systems

Produce a complete wiring diagram, this does not mean a wiring schematic, which complies with BS 7845:1996,  BS 3939  and BS EN 60617.

This must include all pin-in and pin-out labelling, wire gauge, wire lengths, use of correct symbols for each component.

2. Mechanical parts

Produce a comprehensive Technical Engineering drawing for apart you are designing, if you are designing more than one part, please liaise with your supervisor to choose an appropriate part.

This technical drawing must comply with BS 8888:2013;  there is also a link on the 306MAA Moodle page for more information on engineering drawings and standards.

Your drawings must include, but not limited to:

•          Dimensions

•          Geometrical tolerances

•           Datum’s

•           Material

3. Simulation/benchmarking projects

Produce a technical report on your findings to date and how your findings are critical to the vehicle’s performance. You need to state your inputs into your analysis and justify the values you have used. If you are using software as part of your work, you must present an overview of how  the software works from the inputs to the outputs.

4. Cooling

At current you have designed for manufacture very low quantities (one) . As part of the remit for Formula Student cost report you must give consideration for an annual production of 1000 units   per year (S4.7.1) . You must consider production methods suitable to manufacture the required number of parts (ducting and heat exchanger) and justify your choice. You must reflect the cost of the entire build of the cooling system (heat exchanger, pump, air ducting and piping) . This might   include mould making, mould preparation, body forming, trimming, painting, fitting, etc.

You will submit a small technical report (c.1000 words) comparing the cost of manufacture of the RP parts verses alternative methods of production. If your designs require modification include    technical drawings.

5. Aerodynamics

You are designing the bodywork and/or assessing downforce generating devices for the 2022 FSAE vehicle. As part of the remit for Formula Student cost report you must give consideration for an annual production of 1000 units per year (S4.7.1) . You must reflect the cost of the entire build of the body, floor or wings; accordingly, this will include mould making, mould preparation, body forming, trimming, painting, fitting, etc.

You must also present a full set of instructions for the manufacture of the moulds and bodywork   for both the way of manufacture for your chosen design and also for a more cost-effective way for the hypothetical 1000 units per year.

You will submit a small technical report (c.1000 words)

For Electrical and Mechanical systems:

•    Compliance to relevant British Standards (25%)

•    Completeness of schematic/drawing (50%)

•    Manufacturing considerations (25%)

Submission Instructions:

The  submission format for this coursework is a typed technical report to be submitted online through Aula. The  technical  report  needs to cover all the tasks described above and  to include supporting  diagrams and clear referencing where  needed throughout.

The report should be submitted as a Microsoft Word document with the following requirements:

Report size: The report should be typewritten and the total length of the main report should not exceed 1000 words. You may wish to include some additional pages of appendices. Word count does NOT include title page, contents page, references pages or appendices.  Tables and figure captions   are also exempt from the word count.

Page layout: The  margin shouldn’t be “Moderate” or lower i.e. Top and Bottom of 2.54 and Left and Right 1.91.

Font size: The acceptable font size is minimum of  10 and maximum of 12.

Subdivision - numbered sections: Divide your report into clearly defined and numbered sections. Subsections should be numbered 1.1 (then 1.1.1, 1.1.2, ...), 1.2, etc. Use this numbering also for internal cross-referencing: do not just refer to 'the text' . Any subsection may be given a brief  heading. Each heading should appear on its own separate line. It is suggested (but not mandatory) to follow this structure:

Recommended report structure:

• Flowcart using format provided on AULA page.

• Spreadsheet using excel format provided on AULA page.

• Word document with questions asked and answers.

• Drawings/schematics on given drawing templates.

• Reports in word Documents as detailed above.

All figures (including graphs), tables and equations should have a number and a caption: Thus all figures and tables should be referred to from the body of the report.

Marking and Feedback

How will my assignment be marked?

Your assignment will be marked  by the module team.

How will I receive my grades and feedback?

Provisional marks will be released once internally moderated.

Feedback will be provided by the module team alongside grades release.

This document is intended for Coventry University Group students for their own use in completing their assessed work for this module. It must not be passed to third parties or posted on any website.

Marks and feedback will be provided via Aula and present on your Handin assignment either commented within the text or within the comments section

Your provisional marks and feedback should be available within 2 weeks / 10 working days

What will I be marked against?

Details of the marking criteria for this task can be found at the bottom of this assignment brief .

Assessed Module Learning Outcomes

The Learning Outcomes for this module align to the marking criteria which can be found at the end of this brief. Ensure you understand the marking criteria to ensure successful achievement of the assessment task. The following module learning outcomes are assessed in this task:

1.    Analyse and define a problem and identify constraints including; environmental and

sustainability limitations; health and safety; risk assessment issues; fitness for purpose; production; operation; maintenance and disposal.

2.    Analyse and manage cost drivers; applying knowledge of management techniques which maybe used to achieve engineering objectives within that context.

3.    Apply and integrate knowledge and understanding of other engineering disciplines to support study of their own engineering discipline; demonstrating the application of a  systems approach to engineering problems.

4.    Evaluate and apply appropriate codes of practice and industry standards and be able to work with technical uncertainty.

5.    Apply themselves professionally, communicating effectively through presentation of written and verbal methods by demonstrating autonomous and group working to develop, monitor and update a plan to reflect a changing operating environment.