The development of manufacturing case studies

In manufacturing engineering education, there is a need for problem-solving projects that reflect real issues to supplement or replace drill and practice problems. Authentic activities offer an opportunity to apply new knowledge and skills to manufacturing engineering problems, test theories, and draw conclusions in a safe environment with the help of peers and mentors. Case studies add relevance and real world context to manufacturing engineering education. At Greenfield Coalition, two case studies were developed on the basis of real issues faced by the Focus: HOPE Center for Advanced Technologies (CAT), a tier-one supplier to the automotive industry. The first involves superficial irregularity - determining why some, but not all, batches of aluminum manifold castings discolor during machining. The second study involves dimensional irregularities - stabilizing bore dimensions for a pulley used in the manufacture of diesel engines. Both studies require student teams to brainstorm potential causes, generate solutions and select the best method for elimination of the problems. The final deliverable for each case is a report similar to one that night is presented to management of a given organization. By employing case studies in manufacturing engineering education, students learn to apply skills and techniques to new situations just as they would have to perform on the job.