Advanced Manufacturing 2 (Grade 12)

by Bret Richards

This is a Capstone level high school course that will build on skills developed in the concentrator level courses completed as prerequisites. The course focuses on CNC and advanced machining functions found in today's machining and forming processes. Successful students will earn a capstone certificate in proficient operation of manual mills, lathes, and fabrication equipment as well as in-depth capabilities in CNC operation and setup. NIMS certifications can be made available based on students' demonstrated aptitudes.

Program Information
Course Certification Elements
Course Standards
California Math Common Core Standards (93)
Next Generation Science Standards (4)
California's 2013 CTE Standards (13)
Course Competencies / Outcomes

These competencies and outcomes apply at multiple levels throughout the units listed in the outline.

  • Plan production or operational procedures or sequences of operations, applying knowledge of physical properties of workpiece materials.
  • Program computers or electronic instruments, such as numerically controlled machine tools.
  • Read work orders, lueprints, data, manuals, or other materials to determine specifications, inspection and testing procedures, adjustment methods or other instructions to determine product specifications or materials requirements.
  • Confer with engineering, supervisory, or manufacturing personnel to exchange technical information.
  • Evaluate machining procedures and recommend changes or modifications for improved efficiency or adaptability.
  • Recommend necessary corrective actions, based on inspection results.
  • Design and construct patterns, templates, or other work aids.
  • Layout guidelines or markings on materials or workpieces using patterns or other references.
  • Align and secure holding fixtures, cutting tools, attachments, accessories, or materials onto machines.
  • Enter commands or load control media, such as tapes, cards, or disks, into machine controllers to retrieve programmed instructions.
  • Implement changes to machine programs and enter new specifications, using computers.
  • Verify alignment of workpieces on machines, using measuring instruments, such as rules, gauges, or calipers.
  • Verify that workpiece reference lines are parallel to the axis of table rotation, using dial indicators mounted in spindles.
  • Adjust machine controls and change tool settings to keep dimensions within specified tolerances.
  • Apply protective or decorative finishes to workpieces or products.
  • Check to ensure that workpieces are properly lubricated and cooled during machine operation.
  • Clean, treat, buff, or polish finished items, using grinders, brushes, chisels, and cleaning solutions and polishing materials.
  • Run machines through cycles, stopping to adjust tool positions and machine controls to ensure specified timing, clearances, and tolerances.
  • Fold or shape materials before or after cutting them.
  • Grind out burrs or sharp edges, using portable grinders, speed lathes, or polishing jacks.
  • Listen to machines during operation to detect sounds such as those made by dull cutting tools or excessive vibration and adjust machines to compensate for problems.
  • Load materials and products into machines and equipment using hand tools and moving devices.
  • Make minor adjustments to equipment, such as turning setscrews to calibrate instruments to required tolerances.
  • Modify cutting programs to account for problems encountered during operation and save modified programs.
  • Monitor machine operation/control panel displays and compare readings to specifications to detect malfunctions.
  • Align parts or workpieces to ensure proper assembly.
  • Assemble metal or plastic parts or products.
  • Attach decorative or functional accessories to products.
  • Clean machines, tooling, or parts, using solvents or solutions and rags.
  • Clean work area.
  • Clean workpieces or finished products.
  • Move products, materials, or equipment between work areas or storage areas..
  • Compute dimensions, tolerances, and angles of workpieces or machines, according to specifications and knowledge of metal properties and shop mathematics.
  • Record and analyze test data, making computations as necessary, to determine test results.
  • Check arriving materials to ensure that they match purchase orders, submitting discrepancy reports as necessary.
  • Collect or select samples for testing or for use as models.
  • Compare colors, shapes, textures, or grades of products or materials with color charts, templates, or samples to verify conformance to standards.
  • Discard or reject products, materials, or equipment not meeting specifications.
  • Examine completed workpieces for defects, such as chipped edges or marred surfaces and sort defective pieces according to types of flaws.
  • Grade, classify, or sort products according to sizes, weights, colors, or other specifications.
  • Perform quality checks in process on products and parts.
  • Position products, components, or parts for testing.
  • Weigh materials, products, containers, or samples to verify packaging weights or ingredient quantities.
  • Weigh or measure materials or products to ensure conformance to specifications.
  • Write test or inspection reports describing results, recommendations, or needed repairs.
  • Add chemicals, solutions, or ingredients to machines or equipment as required by the manufacturing process.
  • Adjust, clean, or repair products or processing equipment to correct defects found during inspections.
  • Change worn cutting tools, using wrenches.
  • Clean and maintain machinery, equipment, and work areas to ensure proper functioning and safe working conditions.
  • Clean, maintain, calibrate, or repair measuring instruments or test equipment, such as dial indicators, fixed gauges, or height gauges.
  • Diagnose machine tool malfunctions to determine need for adjustments or repairs.
  • Dismantle machines or equipment, using hand tools or power tools to examine parts for defects and replace defective parts where needed.
  • Refill, change, and monitor the level of fluids, such as oil and coolant, in machines.
  • Remove and replace housings, feed tubes, tool holders, or other accessories to replace worn or broken parts, such as springs or bushings.


Course Work Based Learning Activities

Students will be involved with industry partners through Industry chat-based software programs, field trips to manufacturing facilities, industry skills application, making a product for an actual company, responding to a posting and interviewing with a business partner for a position they may be looking to fill, and internships.

Course Materials

Title: Introduction to Manufacturing Processes Publisher: Wiley ISBN : 978-1-118-21488-6

Title: Machining Fundamentals Publisher: Goodheart-Wilcox, ISBN: 978-1-61960-209-0

In addition any industry-based training material and media will be incorporated based on individual module needs and application.

Course Units (180 hour course)

Unit 1 Student retention assessment

Unit Length (Hours):
1 hour

Unit Description:
This unit uses an assessment questionnaire for students to complete based on retained knowledge of the past practices learned in prerequisite courses. 

Unit Competencies/ Outcomes:
Students will gain an understanding of their level of retained knowledge to be used within the application of advanced practices instructed in this course.

The instructor will gain knowledge of student retention for implementation of scaffolding and lesson differentiation  as a measurement for students success.

Unit Assessment:
Online or handout questionnaire encompassing required knowledge of shop rules, safety, code of conduct, proper tool selection, proper equipment selection, perform required calculations to efficiently run product, and project planning elements. 

Unit 2 Shop and Equipment Safety

Unit Length (Hours):
4 hours

Unit Description:
Reintroduction to safety requirements for safe equipment operation, shop code of conduct, and personal protective equipment. 

Unit Competencies/ Outcomes:
Demonstrate safe work habits in shop, understand repercussions for violation of rules, up to date knowledge of course procedures, up to date understanding of equipment hazards, knowledge of mitigation and procedures to reduce hazards to minimal level.

Unit Assessment:
General Safety test
Equipment specific safety tests

Unit 3, G-Code Review

Unit Length (Hours):
5 hours

Unit Description:
Review of G-CODE used in programming of CNC equipment. 

Unit Competencies/ Outcomes :
Demonstrate retained knowledge of Word Address Programming function within the G-CODE environment, Demonstrate manual programming capabilities for a machined part of moderate difficulty.

Unit Assessment :
Functional program that passes simulation and runs a complete product that meets all dimensional requirements for components of the project identified.

Unit 4 Project Planning Fundamentals

Unit Length (Hours):
5 hours

Unit Description:
Introduction of Project Planning requirements of Project Schedule, Bill of Materials (BOM), Equipment List, Operation and Routing documentation and Product Documentation Package (PDP).

Unit Competencies/ Outcomes:
Demonstrated capabilities to complete a Project Schedule, Equipment List, Operation and Routing documentation and compile a PDP including a BOM for the project identified.  

Unit Assessment:
Completed Project Plan for project identified

Unit 5, Introduction to Product Procurement

Unit Length (Hours):
10 hours

Unit Description:
Introduction to Procurement Package activities required with in the manufacturing process including Request for Proposal/Quote (RFQ), Bid and Proposal documentation, Purchase Order (PO), Terms and Conditions (T's & C's) documentation and PDP.

Unit Competencies/ Outcomes:
Demonstrated capabilities to complete a RFQ, Bid and Proposal documentation review, Supplier selection, Issue of PO accompanied by T's & C's and PDP,  and received product verification (Incoming Inspection) with documentation for components used in the project identified.

Unit Assessment:
Completed Procurement Package for project .

Unit 6, Non-Conforming Material Report

Unit Length (Hours):
2 hours

Unit Description:
Introduction to defective product documentation in the form of a Non-Conforming Material Report (NCR), the reasons for controlling defective product and the basis of a Non-Conforming Material Review Board (MRB) for disposition of defective product.  

Unit Competencies/ Outcomes:
Demonstrated capabilities to complete a NCR document and control defective product to prevent its use.
Explain a NCR to a MRB for disposition of defective product.

Unit Assessment:
Complete NCR document, quarantine defective product, and complete the MRB process.

Unit 7, Component Raw Material

Unit Length (Hours):
3 hours

Unit Description:
Students will develop a raw material cut sheet, cut raw material to size, and perform component verification (product inspection) with documentation.

Unit Competencies/ Outcomes:
Demonstrated capabilities to complete a raw material cut sheet, material cutting and component verification with documentation for components used in the project identified.

Unit Assessment:
Complete raw material cut sheet, components cutting, and inspection with documentation.


Unit 8, Lathe operation for project components

Unit Length (Hours):
5 hours

Unit Description:
Students will demonstrate manual lathe skills by producing a variety of components with product verification and documentation used in the project identified.

Unit Competencies/ Outcomes:
Demonstrated capabilities to operate the manual lathe safely and effectively to produce a variety of products and perform product verification with documentation. Demonstrated capability for the work performed to select proper tooling , calculate required Spindle Speed based on tooling selected and calculate Feed Rates based on tooling selected.

Unit Assessment:
Completed manual lathe components with product verification documentation.


Unit 9, Mill operation for project components

Unit Length (Hours):
8 hours

Unit Description:
Students will demonstrate manual mill skills by producing a variety of components with product verification and documentation used in the project identified.

Unit Competencies/ Outcomes:
Demonstrated capabilities to operate the manual mill safely and effectively to produce a variety of products and perform product verification with documentation. Demonstrated capability for the work performed to select proper tooling and calculate spindle speed based on tooling selected.

Unit Assessment:
Completed manual mill components with product verification documentation.


Unit 10, CNC Programming

Unit Length (Hours):
7 hours

Unit Description:
Students will demonstrate manual G-Code programming skills, capability to do a program outline, and run a program simulation to machine a variety of components used in the project identified.

Unit Competencies/ Outcomes:
Demonstrated capabilities to manually program using G-Code to produce a variety of products and machining processes. Demonstrated capability to run a program simulation, identify programming errors, make corrections and produce a functional and efficient program. Demonstrated capability for the work performed to; Select proper tooling Calculate Spindle Speed based on tooling selected and material Calculate feed rates based on tooling selected, material, and functions being performed.

Unit Assessment:
Completed manually created programs for specified components with document program outlines.


Unit 11, CNC Operation

Unit Length (Hours):
10 hours

Unit Description:
Students will demonstrate CNC set up, program load and verification, tool offset, work offset, and programmed operation of the CNC equipment programs were previously completed for.

Unit Competencies/ Outcomes:
Demonstrated capability to operate the CNC equipment.
Demonstrated capability to perform accurate machine set ups for components to be run.
Demonstrated capability to accurately load and set tool length and/or diameters for tool selected in the programs for components to be run.
Demonstrated capability to accurately complete work offset requirement for components to be run.
Demonstrated capability to perform product verification with documentation.

Unit Assessment:
Completed CNC programmed components with product verification documentation.

Unit 12, Assembly Instructions

Unit Length (Hours):
5 hours

Unit Description:
Students will be introduced to creating assembly instructions for the components of the identified project. Elements of the assembly instructions will include: step-by-step sub-assembly/assembly information, in process verification steps, warnings, tooling requirements, incidental components/consumables, and process documentation/verification data sheet. Concepts will be covered in complete, hand written format and an electronic document format.  Revision control and revision verification process will also be covered

Unit Competencies/ Outcomes:
Demonstrated capabilities to complete a hard copy format and an electronic format documentation for effective and correct assembly of the project components

Unit Assessment:
Completed assembly instructions for the project identified with product verification documentation.

Unit 13, Assembly

Unit Length (Hours):
10 hours

Unit Description:
Students will demonstrate skills required to assemble the components of the project identified with assembly process and verification documentation.  

Unit Competencies/ Outcomes:
Demonstrated capabilities to complete an assembly based on drawing package and assembly instruction.

Unit Assessment:
Completed assembly with process and verification documentation.

Unit 14, Test Specification

Unit Length (Hours):
3 hours

Unit Description:
Students will be introduced to creating a test specification for assembly of the identified project. Elements of the test specification will include: step-by-step testings information, acceptance and failure requirements, retesting requirements in case of failure, warnings, tooling requirements, incidental components/consumables and a data collection sheet for documentation of results, failures and retests.   Revision control and revision verification processes will also be covered.

Unit Competencies/ Outcomes:
Demonstrated capabilities to create an effective and safe testing specification for correct testing of the project assembly.

Unit Assessment:
Completed assembly instructions for the project identified with product verification documentation.

Unit 15, Test

Unit Length (Hours):
7 hours

Unit Description:
Students will demonstrate skills to assemble the project identified.  Once assembly is complete the students will perform a series of tests to verify functionality of the engine.

Unit Competencies/ Outcomes:
Demonstrated capability to complete testing requirements per a test specification with results documentation.
Demonstrated capability to trouble-shoot an assembly that fails a test step, correct errors, and retest as required

Unit Assessment:
Completed test specification and assembly with all acceptance requirements met.

Unit 16, Engine run off

Unit Length (Hours):
5 hours

Unit Description:
Students will be randomly paired to show their engine performance capabilities in a bracketed run-off competition.  Students' engines will compete in a minimum air pressure functional demonstration, a maximum air pressure speed demonstration, and a running for a specified duration demonstration.  Winners of each bracket will then proceed to the next level where they will demonstrate capability to run at the lowest air pressure possible,  top speed capable of being achieved and a longevity competition at specified air pressure.

Unit Competencies/ Outcomes:
Demonstrated personal traits in integrity, sportsmanship and fairness.

Unit Assessment:
Competition and the placement in overall standings.  Students receive points for participation and extra credit for competitions won.

Unit 17, Production work

Unit Length (Hours):
10 hours

Unit Description:
Students will be introduced to a production-based work environment that includes: master scheduling, manpower distribution, capacity management, and statistical indicators that determine effectiveness of the production system.

Unit Competencies/ Outcomes:
Demonstrated capability to create a master schedule, manage manpower distribution, and measure capacity effectiveness.
Demonstrated capability to collect, evaluate and provide improvement recommendations based on evaluation 

Unit Assessment:
Completed master schedule, managed manpower distribution, and capacity management documentation. 
Completed statistical data packet with data collection and evaluation.
Completed report of evaluation performed and improvement recommendations.

Unit 18, Production project

Unit Length (Hours):
10 hours

Unit Description:
Students will receive a production-based product package that requires development of a master schedule and capacity management activities prior starting a product project that requires multiple types of equipment  in a specific order.  Students will be required to produce multiple units within the project that will be verified to Product Documentation Package.

Unit Competencies/ Outcomes:
Demonstrated capability to create a master schedule and maintain required capacity management data for future evaluation.
Demonstrated capability to produce product in a production environment that meets quality requirements.

Unit Assessment:
Completed scheduling and capacity documentation.  Completed product meeting all quality requirements.

Unit 19, Statistical Process Control (SPC)

Unit Length (Hours):
5 hours

Unit Description:
Students will be introduced to the Statistical Process Control processes used to reduce defects and inspection requirements.  SPC process elements covered will be Pre-Control Charts, X-Bar and R Charts and the steps need to collect the statistical data.  Evaluation techniques for statistical data will be practiced.

Unit Competencies/ Outcomes:
Demonstrated capability to collect statistical data, evaluate data and make process corrections as required in the Pre-Control and X-Bar and R Chart processes.

Unit Assessment:
Completed SPS project documentation 

Unit 20, Production project including SPC

Unit Length (Hours):
15 hours

Unit Description:
Students will receive a production-based product package that will produce multiple units with SPC processes applied during the production of product.  The statistical data will be used to demonstrate process control that will eliminate the requirement for post production verification and compliance with the PDP quality requirements.

Unit Competencies/ Outcomes:
Demonstrated capability to produce product in a production environment that meets quality requirements.
Demonstrated capability to maintain SPC process documentation to reduce defects and post production product verification.

Unit Assessment:
Completed product meeting all quality requirements. Completed SPC documentation package.  

Unit 21, Complete production process

Unit Length (Hours):
15 hours

Unit Description:
Students will produce multiple components for a specified assembly. The components will then be assembled and tested in accordance with assembly instructions and test specifications.

Unit Competencies/ Outcomes:
Demonstrated capability to produce components, perform assembly process, and testing with all quality and testing requirements met.

Unit Assessment:
Completed assemblies and process documentation.

Unit 22, CAM programming

Unit Length (Hours):
10 hours

Unit Description:
Students will be introduced to a CAM software tool for programming product to a CAD model.  Students will produce a CNC program based on the CAD model supplied using the CAM tool, and run program simulation.

Unit Competencies/ Outcomes:
Demonstrated capability to use CAM software effectively.
Demonstrated capability to develop a CAM produced functional program.

Unit Assessment:
Completed CAM developed program. 

Unit 23, CAM programming production product

Unit Length (Hours):
25 hours

Unit Description:
Students will produce a CAM program for a product and run  production.  Some SPC processes and post production verification processes will be included in the project.

Unit Competencies/ Outcomes:
Demonstrated capability to use CAM software effectively.
Demonstrated capability to develop a CAM produced functional program.
Demonstrated capability to maintain SPC process documentation to reduce defects and post production product verification.

Unit Assessment:
Completed CAM program and product with SPC and product verification documentation

Course Summative Assessment

Overall summative assessments within the course include written and online knowledge retention testing.  The completion of project-based activities is used as both formative activities and summative assessment.  Skills introduced in one unit are built upon and those skills built upon are summative as units progress.