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EMS5RIE | Risk Engineering | Engineering

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You and your team have been tasked to evaluate the risks associated with moving from a traditional subtractive manufacturing method of making lightweight aluminum components for satellite frame structures, to an advanced manufacturing method that that 3D prints bionic inspired shapes with a special AISi7Mg designed to take advantage of additive and digital manufacturing techniques.

Firstly, draw on your engineering background to gain an overview of the current manufacturing methods and their respective production times. Obviously, this information may not be readily available, therefore, you may be required to make some assumptions – but use your engineering judgments to make sure these are justified.

Then, select an appropriate advanced manufacturing method for your products. When we refer to advanced manufacturing, this may additive, subtractive or another method that can be integrated into an industry 4.0 framework. It could also be a future manufacturing method that is yet to be commercialised. Remember, this subject is about risk engineering, and this report does not require a full technical evaluation.

The next stage will be to implement a risk management process based on the ISO31000 and the content of this course. Some things to think about would include:

• Risks and opportunities

• Hazards

• Safe design principles

• The risk management process

  o Risk identification

  o Risk analysis

  o Risk evaluation

  o Risk treatment

  o Risk monitoring and review

• Techniques and tools used for planning and probabilistic analysis

  o CPM

  o PERT

  o Monte Carlo

• Summary

  o Conclusions and lessons learnt

  o Recommendations

  o Future research

 Go through the step-by-step process with your team, brainstorm what the different risks for your company and project are, where they are coming from, are they internal or external, what category, etc. Set-up a risk matrix and score the various risks.

With regard to the techniques and tools you will use for planning and probabilistic analysis you may wish to compare different methods. For instance, one could compare the use of PERT calculations to a Monte Carlo simulation?

You will need to include at least one network diagram – preferably two. One could be either specific to an assembly process (such as print part → machine part → assemble part etc.). The other could be related to your manufacturing company as a whole, i.e., buy raw materials

→ manufacture part → package and store → ship part/component to customer etc. In each case there are risks involved and they can be assigned times, or costs or both.

How can digital manufacturing be of use when implementing and monitoring risks? Could you think of a feedback loop for data along the path?

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