Project management assignment evaluating the process in car manufacturing

CAR ENGINE MANUFACTURE PROCESS
Project Management Assignment: Evaluating the
Process in Car Manufacturing
Table of Contents
1. Scope of the Manufacturing Processes ..................................................................................3
1.1. Identify, and document, the parameters and context ......................................................3
1.2 Identify features and functions of plant, facilities, services, labour and skill distribution
used for manufacturing processes..........................................................................................4
1.3 Identify stakeholders to be consulted as part of the evaluation .......................................5
1.4 Confirm work health and safety (WHS) and regulatory requirements, codes of practice,
standards, risk assessment and registration requirements for manufacturing plant...............6
1.5 Investigate sustainability implications of manufacturing processes................................6
1.6 Identify sources of professional and technical assistance................................................7
2 Evaluate manufacturing processes..........................................................................................8
2.1 Identify manufacturing principles and techniques required to evaluate and optimise the
processes ................................................................................................................................8
2.2 Identify appropriate analysis techniques, software and software validation techniques .8
2.3 Evaluate and assess facilities, services, plant and tooling in relation to product
manufacturability and maintainability...................................................................................9
2.4 Evaluate and assess process layout, use of automation and process control using lean
systems and techniques........................................................................................................10
2.5 Evaluate and assess materials, product flow and transfer operations, buffer and
emergency stocks, warehousing, stores and logistics using lean systems and techniques ..12

2
2.6 Evaluate WHS and regulatory compliance and risk management practices of
manufacturing processes and maintenance procedures .......................................................12
2.7 Evaluate processes for sustainability .............................................................................13
2.8 Evaluate process compatibility with maintenance management system .......................14
References................................................................................................................................18

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1. Scope of the Manufacturing Processes
1.1. Identify, and document, the parameters and context
The engine block is essential part of a car manufacturing and assemble process. The
advancement of technology has increase the demand for lightweight, durable, wear resistance
and increase in power and efficiency of the engine (Jadhav, Mantha, & Rane, 2015). The car
manufacturing industry operates closely with the all the organisational and technical
environment required for developing the accurate structure of the manufactured item. The
environment in the manufacturing process is dependent on the interplay between
organisational, psychological and physical ergonomics of both human and technical resource
associated.
The manufacturing procedure and criteria used in the processes associated with chemical,
hazardous substance, safety of the workers, competency development, vibrations and sound.
Further, the engine manufacturing industry follows specific legislative and regulation
compliance for maintaining the safety to the workers as well as to the environment. The
technical design and efficiency of the engine should be specifically made with the aim of
reducing carbon emission from the car.
In this Project Management Assignment it is identified that Lean manufacturing process is
utilised in the engine design and manufacturing in car industry for increasing the work
efficiency and reducing the negative impact on the environment. The manufacturing of the
car engine requires various number of raw materials including aluminium, steel for base and
chassis, rubber for moulded parts used in the engine. Further, technical assessment software
and analysis tools are required to evaluate and manage the yield stress, normal stress, fatigue,
creep and notch toughness on the engine with regular usage.

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1.2 Identify features and functions of plant, facilities, services, labour and skill
distribution used for manufacturing processes
In the car engine manufacturing process, the sand casting process is employed in spite of the
cost effective process obtained with die-casting. The casting process used in the
manufacturing includes high temperature of the molten aluminium for obtaining the coolant
passages and surface finis of the car engine (Prasad, Kumar, & Jeeva, 2016). Further, a
combination of water and silica are used with the sand compacting the high pressure and
vibration of the molten metal during the casting. Therefore, the car manufacturing plant has
specialised element and physical component for handing the high temperature of the molten
metal. In addition to that, physical components like woods are used for compacting and
maintaining the shape of the engine.
Further a worker friendly production line has been utilised in the manufacturing process, for
ensuing the aesthetic design and quality of the engine frame. Press die method is utilised for
analysing the design accuracy of the engine, and welding and assembly jibs robots are used
for precise evaluation of the design constraints (Rafique et al., 2016). The results of the
evaluation process helps in creating technical and physical audits.
The design of the engine is generated with the application of advanced designing and
simulation tools. The technical experts and human resources are allocated based on their
expertise for examining the moulding die components and quality of the finishing. Similarly,
simulated jigs are installed to evaluate the design precision with the help of 3D data of the
engine.

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1.3 Identify stakeholders to be consulted as part of the evaluation
The manufacturing of the car engine process, are associated with both direct and indirect
influence of various stakeholders. The external stakeholder involved in manufacturing
includes:
• Customers: Customers are one of the most essential stakeholders associated with the
engine manufacture process. The requirements, demands, satisfaction of the
customers have vital impact on the engine design and quality;
• Suppliers: The raw materials essential of the manufacturing are outsources from
various countries. Therefore, the availability of the suppliers are essential for the
manufacturing process;
• Policy Maker: the local and international government bodies including Keidanren and
the Japan Automobile Manufacturers Association, often produce various policies and
regulations that needs to be followed during the design and manufacturing. The
environmental laws includes the reduction of the CO2 emission from the car engines
and reduction of the waste chemicals from the manufacturing process (Samant, Mittal,
& Prakash, 2018);
The internal stakeholders involved with the manufacturing process as inferred in this Project
Management Assignment includes:
• Investors: The investors providing financial resource to the manufacturing process are
essential for verifying, reviewing and launching of any new products or process used
in the engine manufacturing.
• Technical Experts: The technical expert associated in the manufacturing process
develops the schematic diagram and engine design for the car. The developed design
are used in the moulding process for manufacturing.

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• Labours: The labours are used during the casting, core design, and assembling of the
main engine mould process;
• Consultant: The consultant are the decision making authorities associated in the
engine manufacturing. The addition, modification or exclusion of any critical design
in the engine are evaluated and reviewed by consultant before including it in
manufacturing.
1.4 Confirm work health and safety (WHS) and regulatory requirements, codes of
practice, standards, risk assessment and registration requirements for manufacturing
plant
The work environment for engine manufacturing is associated with various risks and safety
concern for the workers. The car engine manufacturing process includes various guidance
and regulations that needs to be maintained in the manufacturing environment for ensuring
the safety of the workers. The WHS (Work Health and Safety) ensures the process of safe
and secure equipment used by the labours. The chemical hazards produced as the by-products
of the manufacturing process are treated properly before disposing.
Further, the manufacturing environment as mentioned in this Project Management
Assignment includes and complies with the Work Health and Safety Act 2011 (Qld), along
with regulations mentioned in Workplace Health and Safety Queensland. The utilisation of
the safety acts and regulation in the manufacturing process helps in enabling following of the
safety and best practices used and maintaining save environment to work for the employees.
1.5 Investigate sustainability implications of manufacturing processes
The motor industry has created significant environmental issues and concern in the recent
days. The introduction of the various environmental legislation by Australian government
including “Environmental Resource Efficiency Plans” have affected the process the vehicles

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and its parts are manufactured. Invocative gearbox and enhanced design of the car engine are
developed for reducing the transmission of the CO2 from tailpipe (Ghobakhloo & Azar,
2018). Further, the inclusion of the Auto Oil program in the car design has provided inclusion
of more stringent performance standard for the engine. The manufacturing process is in
continuous monitoring and evaluation for ensuing the effective impact on the environmental
sustainability and compliance with the environmental laws and legislation.
1.6 Identify sources of professional and technical assistance
Source of professional assistance: The manufacturing process requires the development of
the appropriate design for the engine while maintaining the accurate weight, resistance,
durability and power (Karthe et al., 2017). In addition to that, various legislative rules and
regulations are needs to be incorporated in engine design for maintaining the safety of both
environment and the car. Therefore, professional assistance of the laws and policy makers
along with the expertise of the human resource management, process control and industry
specialists are included for smooth operational efficiency.
Source of technical assistance: In terms of technical assistance, the mathematical and
physics experts specialised in drafting. Kinetics, mechanics and mechatronics to be included
in the design. Further, the engineering and technical professionals are utilised for analysing
and incorporating the corrosion resistance, vibration withstanding and elasticity factor of the
engine.

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2 Evaluate manufacturing processes
2.1 Identify manufacturing principles and techniques required to evaluate and optimise
the processes
The manufacturing of the car engine are developed based on the casting process for
developing the main block. The manufacturing process requires controlled environment for
the safety of the workers and ensuring the quality of the engine compliance with design.
Further the reliability and quality of the engine design is developed based in the application
of various principles that are followed throughout the manufacturing process. For the
optimisation of the manufacturing process, various principles are utilised including optimised
production, zero defects, zero wastage for scaling up the performance metric (Dandin, &
Mench, 2015). Further, for ensuing the required quality and decreasing defects in the engine,
the permeability of the sand grains are monitored and maintained for reducing the porosity
and providing a good surface finish. Further it is identified in this Project Management
Assignment that the evaluation and testing process are optimised by the inclusion of
automated system for precise size and design of the engine. In addition to that, during the
entire manufacturing cycle and process, proper monitoring and control of the equipment are
done for ensuring the effectives and reducing the possibility of flaws.
2.2 Identify appropriate analysis techniques, software and software validation
techniques
The casting process used during the engine manufacturing often creates small indentation and
glitches in the finishing surface of the aluminium body. The lack of proper evaluation and
verification of the engine before assembling in the car would result in poor performance.
Therefore, in order to ensure the required quality and design of the engine, various simulation
and advanced quality assurance tools are utilised. Jigs are installed for installation of 3D data
creation in the manufacturing process. The 3D simulation process helps in determining the

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quality and productivity of the engine with heat simulation. In addition to that, for analysing
the reliability and design optimisation of the produced engine, CAE (Computer Aided
Software), CFD (Computational Fluid Dynamics) tools are used for time efficient and
accurate design analysis (Alhuraish, Robledo & Kobi, 2016). This ensures that the
manufactured engine have met the requirements and specification of ISO 13485 and ISO
9000 (Murugesan, Rajenthirakumar & Chandrasekar 2016).
2.3 Evaluate and assess facilities, services, plant and tooling in relation to product
manufacturability and maintainability
Product manufacturability: Product manufacturability of the car engine is identified based in
the impact of various factors that influence the manufacturing process as illustrated in the
below section:
Cost: The manufacturing proves for the engine are planned to be cost effective with the use
of light weight and durable materials. In addition to that, reusability of the sand and wood for
inserting pressure reduced the overall cost.
Quality Control: Various advanced technical software application are utilised including
failure effects analysis (FEA) for ensuing the best quality provided to the market (Rafique et
al., 2016).
Efficiency: The efficiency of the manufactured engine are ensured with the advanced design
and simulation process for gaining enhanced resistance, durability, strength, wear resistance
and low carbon emission.
Resource Requirement: The engine manufacturing process requires lightweight materials
including aluminium, sand and wood for casting process. Other raw materials includes
vinyl’s, silicon and plastics (Schnellbach, & Reinhart 2015). Other resources includes
specialised equipment for controlling high temperature and pressure required for

10
manufacturing. In addition to that, specialised technical personnel and software application
are essential for ensuing the quality and efficiency of the developed engine.
Price: The required cost for manufactured engine ranges between AUD $5000 to AUD
$3000 (Kumar, Sharma & Agarwal, 2015).
Product maintainability: The maintainability of the car engine is developed based on the
remedial maintenance and preventive maintenance. Based on the historical data obtained,
preventive maintenance requires the replacement of spark plugs after every 30 thousand km
of usage for reducing the chances of failure (Samant, Mittal, & Prakash, 2018). Further,
changes of the oil filter in regular time interval would help in cleaning the metal sludge inside
the engine and ensure optimised performance of the engine. The remedial maintenance
requires the replacement of the engine in case of any failure or issues identified.
2.4 Evaluate and assess process layout, use of automation and process control using lean
systems and techniques
Process layout: Reducing waste in the manufacturing process are implemented with the
development of effective plan while eliminating or reducing the possibilities of errors.
Waiting, overproductions, over processing defects are reduced with implementation of
transparent layout of operations (Nallusamy, & Saravanan, 2016). The below process layout
have been provided for the engine management used in the industry. The transparency in the
process layout has assisted the workers in the manufacturing industry to reduce the waiting time
for raw materials to reach the production area while ensuing the verification of each engine
before distribution in the market.

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Figure: Process layout for engine manufacture
(Source: Zhang, 2015)
Use of Automaton: Robotic Process Automation have been integrated in the manufacturing
process fir increasing the efficiency and productivity. The simulation software used in the
manufacturing process helps in ensuring the design precision of the process. The introduction
of the automation process in the manufacturing helps in increasing the efficiency of the work.
The use of simulation software provided 3D analysis and heat simulation of the engine for
identifying any possible errors (Prasad, Kumar, & Jeeva, 2016).
Process Control: In the manufacturing of the car engine, the producers and management
includes the application if LPA (layered process audits) for integrating regular monitoring
and control of the process. The inclusion of LAPs in the manufacturing process, enables the
management to conduct audit in generic multiples for embracing continuous development
and progress (Jadhav, Mantha, & Rane, 2015). Further, Value stream mapping is used for
managing and controlling the flow of information and raw materials.

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2.5 Evaluate and assess materials, product flow and transfer operations, buffer and
emergency stocks, warehousing, stores and logistics using lean systems and techniques
Materials: The elimination of the waste materials, defect products are the essential needs of
the lean manufacturing process used. (Amrouche, et al., 2016) During the manufacturing of
the engine, the application of the automated software and machineries have eliminated the
possibilities of the defects.
Product flow: The flow of manufacturing for the car engine includes the software design of
the engine, simulation of the schematic work, steel casting process, and quality analysis of
the developed engine structure (Mahendran, Kumar & Jeyapaul, 2016). The prominent
identification of the manufacturing process have reduced unnecessary transfer of the
materials. In addition to that, the visual presentation of each step and information has boosted
the problem solving processes while increasing the work efficiency.
Transfer operations: The transfer of the raw materials along with the engine during the
manufacturing has been limited with the proper identification of the process flow and
defining the manufactuing environment for optimised results.
Warehousing, store, and logistics: The completion of the successful manufacture of the
engine requires the painting and storage job for the engines. Automated simulation process
identified the appropriate condition for paint and automated robots are used for simulated
movement and effective painting (Ellis 2016). Further, proper inspections are carried out with
3D simulation tools for identification of effects or manufactuing errors.
2.6 Evaluate WHS and regulatory compliance and risk management practices of
manufacturing processes and maintenance procedures
With the increase in environmental concern, the Government of Australia have highlighted
and introduced various policies and rules that needs to be integrated within the automobile

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manufactuing process for car engine. The increased number of regulations and policies have
created multiple challenges for the manufactured and engineers. The failure in manufacturing
process often results in significant financial loss, injury to the workers and even death.
Application of security standard ISO 26262 have become more essential and unavoidable for
ensuing the product development and safety of the work environment (Alves Filho, Nogueira,
& Bento 2015). Furthermore, various studies have showed that the technical development in
the field of automobile industry have been emerging that improved the product alignment,
verification, quality assurance and integration of various safety regulation in much effective
manner. In addition to that, the regular risks management and assessment in the manufactuing
process assist the manufacturing team to be updated with the possible risks.
2.7 Evaluate processes for sustainability
The right balance between the work efficiency, social responsibility, environmental care and
economic progress recognises the manufacturing process for the automobile engine
production. Therefore, in engine manufacturing process, the sustainability steps have been
included in LCA (life cycle analysis), reducing carbon footprints, and testing of the
automobile volatile organic compounds (Ferguson & Kirkpatrick, 2015). Through the
application of the LCA the management gets detailed information regarding the distribution,
production, outsourcing raw materials, proper disposal of the waste materials. Further, this
includes the alignment of various governmental policies and environmental laws for reducing
the carbon footprints and emission from the engine.

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2.8 Evaluate process compatibility with maintenance management system
Figure: process for maintenance system
(Source: Iyengar, & Bharathi, 2018)
The manufactuing process includes various integrated system and procedure including engine
design, steel casting, quality assurance, and other. It is essential for the management to align
the process with the sustainability procedure used in the manufactuing for ensuing the
availability and reliability of the process lifecycle.
2.9 Evaluate labour requirements and skills distribution
The skills required in the automobile industry are broadly categorized based on the job roles
and responsibilities. In car engine manufacturing, it is essential to list and rank the different

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level or degree of skills pertaining to each personnel. Engine manufacturing is a vast process
encompassing a huge part of mechanical engineering integrated with automobile engineering.
Therefore, it requires certain IT and mathematical skills, technical skills as well as cognitive
and communicate skills. Now, it is important to identify which skill is useful in what context.
Therefore, these different types of skills are required to successfully perform and execute the
complete process of car engine manufacturing (Singh, Rastogi & Sharma, 2013). Apart from
that, the time and timing requirements are to be assessed in order to identify the necessary
project requirements related to material block casting, tooling and finally manufacturing the
engine block. Another factor to decide when categorizing the labour skills is the component
considerations. It is closely associated with maintenance skills and therefore, it is important
that the project manager of the particular car engine-manufacturing project clearly define the
roles and responsibilities depending on the degree of skills expertise and availability of
labour resources.
2.10 Evaluate process information flows for control and process improvement
The overall process of manufacturing the engine block involves information flow across the
different activity or process segments. The schedule planning, resource allocation and skills
distribution information are shared with the concerned entities involved with the project in
order to execute the individual process segments and activities / tasks in a successful manner.
Protection upkeep requires the substitution of parts that are yet working however are relied
upon to bomb soon. It is additionally attempted where corruption of a segment jeopardizes
parts somewhere else in the item (Koren, 2010). The primary apparatus required for sand
throwing is the shape; the form is created by a blend of sand, earth, and water. The example
is the primary instrument required to shape the form, it is typically machined by wood or
aluminium, which can be effectively machined (Jiang, Zhang & Sutherland, 2012). With the
end goal to meet the above utilitarian necessities the material utilized for assembling the item

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ought to contain numerous properties (Kalpakjian, Vijai Sekar & Schmid, 2014). The
material ought to contain high quality, modulus of flexibility, wear opposition, capacity to
withstand vibrations, and erosion obstruction. High quality is for the most part worried in
diesel motors due to their high pressure proportions contrasted and petroleum motors.
3 Report results
3.1 Review results of evaluation and assessment with stakeholders
The engine manufacturer company needs to establish proper stakeholder engagement plan in
order to review the results of evaluation and assessment in a successful manner so that the
product meets the requirements. For this purpose, surveys and networking events are carried
out in order to get feedbacks from all the stakeholders directly or indirectly associated with
the project. Information of all the issues is shared across the concerned authoritative
department for reviewing. Outside evaluation results, partner corporations and opinions from
the participants are thoroughly reviewed within a specific span of time. It also closely relates
to the corporate social responsibility of the organization. The communities, investors,
shareholders and customer feedbacks need to be reviewed in order to reach to a meaningful
conclusion and achievement.
3.2 Provide recommendations for improvements, where appropriate
It is important to establish a supportive and stable regulatory environment to be able to drive
productivity and growth simultaneously. New labour laws should be thoroughly monitored
and suitable laws are required to be incorporated in the regulatory structure of the automobile
manufacturing companies. In addition to that, it is recommended to make efforts for
simplification of the existing regulations and laws in order to ensure ease of compliance.
Another important aspect for process improvement in the automobile manufacturing industry
is to have a strong and efficient resource management program (Callister & Rethwisch,

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2011). The organization needs to ensure that the manufacturing process has adequate
transparency. In will in turn reduce the resource management costs as well as logistics costs
in an indirect manner. Moreover, it is recommended to concentrate more on developing a
skilled and talented labour pool, which will essentially drive growth and productivity.
3.3 Provide reports and documentation, such as layouts, programs and flow charts
Throughout the process, the engineers need to document all the steps involved in each
process so that the issues and problems can be effectively identified and appropriate measures
can be undertaken. It is essential to develop an initial high-level flow chart to understand the
nature of the process and dependencies between the interrelated tasks or activities.
Furthermore, it helps in performing performance analysis and maintenance and monitoring in
the post-production phases (Unger & Eppinger, 2011). It also sets the pre-requisites or
requirements related to the different aspects of industrial practices in the organizational
culture as well as in the automobile manufacturing sector. Moreover, the overall
manufacturing process will follow a predefined sequential phases, which in turn involves
particular layouts of the individual processes in each stage. It is inferred in this Project
Management Assignment that the responsibility of the project manager to design a clear
activity flow chart and diagram as a guideline or framework for executing the overall
manufacturing project.

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Amrouche, F., Erickson, P. A., Varnhagen, S., & Park, J. W. (2016). An experimental study
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