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Manufacturing and Production Engineering Explained: Processes, Systems, Automation and Quality Control is an open-access, accreditation-aligned curriculum module developed under the PREP4UNI.ONLINE OER Initiative for undergraduate engineering candidates, manufacturing specialists, and STEM educators. Structured in accordance with the Washington Accord, EUR-ACE, and IEA Global Engineering Competency frameworks, this module bridges fundamental material removal mechanics with modern smart factory automation and production operations optimization.

The technical scope covers Merchant orthogonal cutting mechanics, chip compression ratios, shear plane angles, and specific cutting energy. Tool life kinetics are formulated using the extended Taylor equation, examining optimal cutting speeds alongside CNC G-code milling interpolation. Operations research coverage includes Economic Order Quantity (EOQ) inventory models, line balancing, Statistical Process Control (Cp and Cpk indices), and injection molding clamp force calculations. Industrial case studies examine chatter in Inconel blisk milling, thermal drift in automotive engine boring, die casting gas porosity, composite drilling delamination, and DMLS titanium micro-porosity. The resource integrates systems engineering trade-off matrices, seven industrial case studies, and six multi-step quantitative worked examples with explicit engineering interpretations.

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