Assessment Cover Sheet

Assessment Title: Project Plan

Programme Title: Bachelor of Engineering Technology

Course No.: ENB5906

Course Title: Mechanical Project 1

Student Name: Ali Yusuf (201102285)

Hashim Alqasab (201000199)
Hussain Alfarhan (201102238)
Yahya Isa Saif (201001047)

Tutors: Dr Christina Georgantopoulou

Due Date: 30-5-2014 Date submitted: 30-5-2014

By submitting this assessment for marking, either electronically or as hard copy, I confirm the
following:
 This assignment is my own work
 Any information used has been properly referenced.
 I understand that a copy of my work may be used for moderation.

 I have kept a copy of this assignment

Assessor: Date of Marking:

Grade/Mark: /

Comments:
 Contents
Table of Tables: ............................................................................................................................... 2
Time management .......................................................................................................................... 3
Gantt chart ...................................................................................................................................... 3
Critical Path ..................................................................................................................................... 9
Network Diagram .......................................................................................................................... 11
Activity resources: ......................................................................................................................... 14
Human resources plan:.................................................................................................................. 19
Scope: ............................................................................................................................................ 21
Cost management: ........................................................................................................................ 23
 Chassis cost: ...................................................................................................................... 23
 Suspension system costs: ................................................................................................. 23
 Major components costs: ................................................................................................. 24
 The total cost of the vehicle: ............................................................................................ 24
Communication management: ...................................................................................................... 25
Quality management ..................................................................................................................... 26
Human resources (HR) management: ........................................................................................... 27
Risk management: ......................................................................................................................... 28
Procurement management: .......................................................................................................... 29
Appendix:....................................................................................................................................... 31
Semester 5 tasks: ...................................................................................................................... 31
Semester 6 tasks: ...................................................................................................................... 34
Semester 7 tasks: ...................................................................................................................... 35

Table of Tables:
Table 1, Machines.......................................................................................................................... 15
Table 2, Tools................................................................................................................................. 17
Table 3, Safety equipment ............................................................................................................ 18
Table 4, Human resources plan semester 1 .................................................................................. 19
Table 5, Human resources plan semester 2 .................................................................................. 20
Table 5, chassis costs (metalsdepot, 1992-2012) .......................................................................... 23
Table 6, estimated cost for double wishbone suspension (warehouse, 2000-2014) ................... 23
Table 7, Major components costs (metalsdepot, 1992-2012) ...................................................... 24
Table 8, Total car costs (metalsdepot, 1992-2012) ....................................................................... 24
Time management
Time management is defined as the processes of planning for doing tasks over a period
of time. In the car project, the tasks that need to be completed in order to finish the car
within 3 semesters were organized and shown in sequenced way as shown in the Gantt
chart.

Gantt chart

The table below is a Gantt chart for the car project which shows the tasks are going to
be done in each semester with their sub-tasks, going down till three levels of sub-tasks,
were the main title is the semester that the activities will be done at. The first level of
sub tasks is the phase that the project at such as researching, designing, and
manufacturing. The second level is the car component that we are going to work on
such as suspension, chassis, braking system, and engine. The final level is the tasks that
going to be done. The last column is the Work Breakdown Structure which shows the
flow of the steps using a numbering system, were the activities are numbered as
sequence, as well as the sub-headed tasks of each activity, and so on. Hence, beside
each task there will be its number after the title number which it come after it in the
project sequence. The human resources was divided into groups and the members
names will be shown later in the project plan.

Task Name Duration Start Finish WBS Resource Names

Sun Sun
Start 0 days 01
16/02/14 16/02/14
Sun Thu
Semester 5 82 days 02
16/02/14 05/06/14
Sun Thu Group 1, Group 2
Research 15 days 02-01 ,Group 3
16/02/14 06/03/14
Rear and front Sun Tue
13 days 02-01-01
suspension 16/02/14 04/03/14
Look for the types of Sun Thu
5 days 02-01-01-1
suspensions 16/02/14 20/02/14
Selecting suspensions Thu Thu
5 days 02-01-01-2
type for the 20/02/14 27/02/14
Investigating the forces
Thu Tue
and stresses that would be 3 days 02-01-01-3
27/02/14 04/03/14
involved in the suspension
Sun Thu
Chassis 15 days 02-01-02
16/02/14 06/03/14
Sun Thu
The function of chassis 5 days 02-01-02-1
16/02/14 20/02/14
Thu Wed
Research about roll cage 4 days 02-01-02-2
20/02/14 26/02/14
 Look for the chassis Wed Mon
3 days 02-01-02-3
types 26/02/14 03/03/14
Mon Thu
Selecting a chassis type 3 days 02-01-02-4
03/03/14 06/03/14
Thu Wed Group 1,Group 2,
Designing 35 days 02-02 Group 3
06/03/14 23/04/14
Rear and front Thu Wed
35 days 02-02-01
suspension 06/03/14 23/04/14
Obtaining suspension Thu Thu
5 days 02-02-01-1
geometry 06/03/14 13/03/14
Determining a suitable
Thu Thu
factor of safety for 5 days 02-02-01-2
13/03/14 20/03/14
suspension
Calculating the forces
Thu Tue
and stresses on the upper 3 days 02-02-01-3
20/03/14 25/03/14
wishbone
Calculating the forces
Tue Tue
and stresses on the lower 5 days 02-02-01-4
25/03/14 01/04/14
wishbone
Selecting a material for Tue Thu
2 days 02-02-01-5
the wishbones 01/04/14 03/04/14
Calculating the stresses Thu Wed
5 days 02-02-01-6
on the spring 03/04/14 09/04/14
Selecting bolts, rod ends
Thu Wed
(rose joints), sleeves and 10 days 02-02-01-7
10/04/14 23/04/14
bushings
Thu Thu
Chassis 20 days 02-02-02
06/03/14 03/04/14
Taking measurements Thu Thu
5 days 02-02-02-1
from an existing chassis 06/03/14 13/03/14
Drawing the chassis in Thu Thu
10 days 02-02-02-2
solid-works 13/03/14 27/03/14
Applying initial Thu Thu
5 days 02-02-02-3
modifications 27/03/14 03/04/14
Wed Mon Group 1,Group 2,
Analysis 18 days 02-03 Group 3
23/04/14 19/05/14
Rear and front Wed Mon
13 days 02-03-01
suspension 23/04/14 12/05/14
Drawing the model in Wed Tue
4 days 02-03-01-1
Solidworks 23/04/14 29/04/14
Running a Finite Tue Mon
4 days 02-03-01-2
Element Analysis study 29/04/14 05/05/14
 Comparing calculations
Mon Mon
to the finite element analysis 5 days 02-03-01-3
05/05/14 12/05/14
results
Wed Mon
Chassis 18 days 02-03-02
23/04/14 19/05/14
Calculating the acting Wed Wed
5 days 02-03-02-1
forces 23/04/14 30/04/14

Doing finite element Wed Wed

5 days 02-03-02-2
analysis study 30/04/14 07/05/14

Confirming if the chassis

Wed Mon
will perform as required and 3 days 02-03-02-3
07/05/14 12/05/14
meets the specifications
Doing final modifications Mon Mon
5 days 02-03-02-4
to the chassis 12/05/14 19/05/14
Mon Thu Group 1,Group 2,
Manufacturing 14 days 02-04 Group 3
19/05/14 05/06/14
Mon Thu
Chassis and Suspensions 14 days 02-04-12
19/05/14 05/06/14
Mon Tue Group 1,Group 2,
Safety induction 1 day 02-04-12-1 Group 3
19/05/14 20/05/14
Practice on welding,
grinding, notching, drilling, Tue Sun Group 1,Group 2,
3 days 02-04-12-2 Group 3
using the various equipment 20/05/14 25/05/14
in the workshop
Cut the members into
Sun Tue
the desired dimensions using 2 days 02-04-12-3 Group 1
25/05/14 27/05/14
the electrical saw
Drilling the locations Tue Wed
1 day 02-04-12-4 Group 1
where bolts will be used 27/05/14 28/05/14
Threading and Tapping Thu Sun
1 day 02-04-12-5 Group 1
the bolts holes 29/05/14 01/06/14
bend the required
members into the desired Wed Thu
1 day 02-04-12-6 Group 2
shape using the bending 28/05/14 29/05/14
machine
Apply welding where it Sun Sun
1 day 02-04-12-7 Group 2, Group 3
is required 01/06/14 01/06/14
Connect the suspension Mon Mon
1 day 02-04-12-8 Group 2
into the chassis 02/06/14 02/06/14
Fining the welding
Tue Tue
places with files and 1 day 02-04-12-9 Group 3
03/06/14 03/06/14
sandpaper
Wed Wed
Apply primer painting 1 day 02-04-12-10 Group 3
04/06/14 04/06/14
 Paint the suspensions
and the chassis with wear Thu Thu Group 1, Group 2,
1 day 02-04-12-11 Group 3
and corrosion resisting 05/06/14 05/06/14
coating
Sun Tue
Semester 6 80 days 03
14/09/14 30/12/14
Sun Thu Group 1,Group 2,
Research 30 days 03-01 Group 3
14/09/14 23/10/14
Sun Thu
Braking systems 30 days 03-01-01
14/09/14 23/10/14
Types of braking Sun Thu
10 days 03-01-01-1
systems 14/09/14 25/09/14
How braking systems Thu Thu
10 days 03-01-01-2
work 25/09/14 09/10/14
Selecting a type of Thu Thu
10 days 03-01-01-3
braking system 09/10/14 23/10/14
Sun Thu
Cooling systems 30 days 03-01-02
14/09/14 23/10/14
Sun Thu
Types of cooling systems 10 days 03-01-02-1
14/09/14 25/09/14
How cooling systems Thu Thu
10 days 03-01-02-2
work 25/09/14 09/10/14
Selecting a type of Thu Thu
10 days 03-01-02-3
cooling system 09/10/14 23/10/14
Sun Thu
Exhaust systems 30 days 03-01-03
14/09/14 23/10/14
Types of exhaust Sun Thu
10 days 03-01-03-1
systems 14/09/14 25/09/14
How exhaust systems Thu Thu
10 days 03-01-03-2
work 25/09/14 09/10/14
Selecting a type of
exhaust system based on the Thu Thu
10 days 03-01-03-3
required performance criteria 09/10/14 23/10/14
for racing cars
Thu Wed Group 1,Group 2,
Designing 30 days 03-02 Group 3
23/10/14 03/12/14
Thu Wed
Braking systems 10 days 03-02-01
23/10/14 05/11/14
Calculating the required
Thu Wed
braking torque for the front 10 days 03-02-01-1
23/10/14 05/11/14
and rear brakes
Thu Wed
Cooling systems 30 days 03-02-02
23/10/14 03/12/14
 Calculating the required
Thu Wed
flow rate in the cooling 15 days 03-02-02-1
23/10/14 12/11/14
system
Calculating the required
cross sectional area and the Wed Wed
15 days 03-02-02-2
length of the pipes that will 12/11/14 03/12/14
be used in the cooling system
Thu Wed
Exhaust systems 10 days 03-02-03
23/10/14 05/11/14
Calculating the required
Thu Wed
length and cross sectional 10 days 03-02-03-1
23/10/14 05/11/14
area of the exhaust pipes
Purchasing a cooling
Thu Wed
system and braking systems 10 days 03-02-04
23/10/14 05/11/14
based on requirements
Wed Wed Group 1,Group 2,
Manufacturing 15 days 03-03 Group 3
03/12/14 24/12/14
Wed Thu
Safety Induction 1 day 03-03-01
03/12/14 04/12/14
Practice on welding,
Thu Wed
cutting, drilling, grinding, 4 days 03-03-02
04/12/14 10/12/14
notching, etc…
Manufacturing of the Wed Wed
5 days 03-03-03
exhaust system 10/12/14 17/12/14
Testing the exhaust
system in order to see if the Wed Wed
5 days 03-03-04
required specifications are 17/12/14 24/12/14
being met
Wed Tue Group 1,Group 2,
Installing 5 days 03-04 Group 3
24/12/14 30/12/14
Installing the braking and Wed Sun
3 days 03-04-01
cooling system 24/12/14 28/12/14
Testing if the braking and
cooling system in order to Mon Tue
2 days 03-04-02
check if they meet the 29/12/14 30/12/14
desired specifications
Sun Tue
Semester 7 80 days 04
15/02/15 02/06/15
Sun Wed Group 1,Group 2,
Research 45 days 04-01 Group 3
15/02/15 15/04/15
Types of engines and how Sun Thu
10 days 04-01-01
they work 15/02/15 26/02/15
Selection of type of Thu Thu
5 days 04-01-02
engine 26/02/15 05/03/15
 Thu Thu
Gears systems 5 days 04-01-03
05/03/15 12/03/15
Thu Thu
Selecting a gear system 5 days 04-01-04
12/03/15 19/03/15
Power transmission parts Thu Thu
5 days 04-01-05
and their purpose 19/03/15 26/03/15
Selecting transmission Thu Thu
5 days 04-01-06
parts 26/03/15 02/04/15
The purpose of flywheels,
Thu Wed
clutches, belt drives and how 5 days 04-01-07
02/04/15 08/04/15
they work
Types of bearings, their Thu Wed
5 days 04-01-08
purpose and how they work 09/04/15 15/04/15
Wed Wed Group 1,Group 2,
Designing 15 days 04-02 Group 3
15/04/15 06/05/15
Calculating the required
dimensions of pistons,
connector rod, piston pin and Wed Wed
5 days 04-02-01
crankshaft based on the 15/04/15 22/04/15
forces and stresses that will
be involved
Determining a suitable
Wed Wed
factor of safety for each 5 days 04-02-02
22/04/15 29/04/15
component
Selecting a suitable Wed Wed
5 days 04-02-03
material for each component 29/04/15 06/05/15
Wed Tue Group 1,Group 2,
Analysis 20 days 04-03 Group 3
06/05/15 02/06/15
Drawing the designed
Wed Wed
parts (pistons, connector rod, 5 days 04-03-01
06/05/15 13/05/15
piston pin and crank shaft)
Doing Finite Element
Wed Wed
Analysis for the designed 5 days 04-03-02
13/05/15 20/05/15
parts
Doing Modifications to Wed Wed
5 days 04-03-03
the parts if required 20/05/15 27/05/15
Checking if the designed
Wed Tue
parts meet the requirements 5 days 04-03-04
27/05/15 02/06/15
and specifications
Tue Tue
Finish 0 days 05
02/06/15 02/06/15
Critical Path
The critical path was done for the whole project using MS project, the figure below
demonstrates the critical path for semester five. Were each task is connected to the step that
has to follow it. For example each semester have to end to start doing the next semester
activities.
Network Diagram
Network diagram was created through using MS project; the figure below demonstrates a whole view of
the network diagram for the three semesters. The first semester of the project is shown in the following
figures that are demonstrating a zoomed view of the drawn rectangles on the diagram.
(To see the rest of the network diagram you can refer to the MS project file.)

Part B

0
Part C
Part A
0
Part A
 Part B

0
Part C
Activity resources:

Several machines are available in building 30 and building 34 at the Bahrain Polytechnic
Campus; the following table shows a list of these components with an illustrating figures:

N.O Machines: Figure:

Bending machine ( Box and Pan folding

1
machine):

2 Milling machine:

3 Lathe machines:

4 Angle grinder:

5 Bench drill:

Welding machine (TIG welding and MIG

6
welding machines):

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7 Polishing machines:

8 Cut off saw:

9 Tube bender:

10 Notching machine:

Table 1, Machines

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 The following table shows some of the tools that are available in building 30 and building
34 at the Bahrain Polytechnic Campus:

N.O Tools: Figure:

1 files and sand paper :

2 Hammers:

3 Hacksaws:

4 Vice:

5 Vice clamp:

6 Measuring tools

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7 Welding fixture:

8 Drill bits:

9 Spanners:

10 Screwdrivers:

11 Primer:

12 Paint and brush:

Table 2, Tools

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 The following table shows safety equipment:

N.O Safety equipment: Figure:

1 Gloves:

2 Welding helmet:

3 Safety Shoes:

4 Coverall

5 Safety glasses:

Table 3, Safety equipment

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 Human resources plan:

Names Semester 1 Activities Duration From To

Cutting
1. Yahya
Drilling
2. Abdulrahman
Threading
3. Ahmed Alsayed
Group 1

Manufacturing Taping Sunday Thursday

4. Fatema
the front Notching 2 weeks 19/5/20 5/6/201
5. Omar
suspension Welding 14 4
6. Husain AlFarhan‎
Surface
7. Raed
finishing
Painting
Cutting
1. Ahmed Alkuwaiti‎ Drilling
2. Husain Abbas ‎ Threading
Sayed mujtaba ‎
Group 2

3. Manufacturing Taping Sunday Thursday

4. Yusuf Engineer‎ the rear Notching 2 weeks 19/5/20 5/6/201
5. Ahmed Fekri‎ Suspension Welding 14 4
6. Hasan Khalaf‎ Surface
7. Ahmed Khan finishing
Painting
Cutting
1. Ebrahim
Bending
2. Hasan Mohamed ‎
Doing Notching
Sakina ‎
Group 3

3. Sunday Thursday
modifications to Welding
4. Ali Yusuf‎ 2 weeks 19/5/20 5/6/201
an existing Surface
5. Sara Yusuf 14 4
chassis finishing
6. Hashem
Painting
7. Amr
Table 4, Human resources plan semester 1

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 Names Semester 2 Activities Duration From To
Cutting
1. Yahya
Drilling
2. Abdulrahman
Threading
3. Ahmed Alsayed Wednes Wednes
Group 1

Manufacturing Taping
4. Fatema day day
the exhaust Notching 15 days
5. Omar 3/12/20 24/12/2
system Welding
6. Husain AlFarhan‎ 14 014
Surface
7. Raed
finishing
Painting
1. Ahmed Alkuwaiti‎
Cutting
2. Husain Abbas ‎
Tightening bolts Wednes Wednes
Sayed mujtaba ‎
Group 2

3.
Installing the using torque day day
4. Yusuf Engineer‎ 15 days
braking system wrench 3/12/20 24/12/2
5. Ahmed Fekri‎
Testing the 14 014
6. Hasan Khalaf‎
braking system
7. Ahmed Khan
Cutting
1. Ebrahim Tightening bolts
2. Hasan Mohamed ‎ using torque
Wednes Wednes
Sakina ‎
Group 3

3. wrench
Installing the day day
4. Ali Yusuf‎ Filling the 15 days
cooling system 3/12/20 24/12/2
5. Sara Yusuf radiator with a
14 014
6. Hashem fluid (water).
7. Amr Testing the
cooling system.
Table 5, Human resources plan semester 2

Note: there is no manufacturing in the third semester. The groups will work simultaneously.

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Scope:

In Bahrain, there is gap between what students study at universities and what they actually
need in the industry. Furthermore, graduates in Bahrain don’t have the necessary employability
and practical skills.
In Scope: Out of Scope:

 Designing, analysing and

manufacturing:
1. A chassis
2. Front suspension
3. Rear suspension
4. Exhaust system

 Selecting and installing:

1. Cooling system
2. Braking system
 Manufacturing of the engine.
 Analyzing:  Manufacturing of transmission parts.
1. Transmission parts  Design and manufacture the wheels.
2. Pistons  Design and manufacture the electrical
3. Piston pin devices.
4. Connector rod
5. Crank shaft

 Doing tests after the manufacturing in

order to see if the required
specifications are being met.
 Assembling the vehicle components.
 Installing electrical systems.
 Painting the car.

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 Project Constraints:
 Time: the project must be finished within 3 semesters.
 Factor of Safety: the components of the car must be designed with a minimum factor of
safety of 2
 Tolerance: the components of the car must be manufactured within the specified
tolerance which is plus or minus 1 mm.
 Stress: the stress in the components should not exceed the maximum allowable stress.
 Weight: the weight of the car should not exceed 1000 kg
 Centre of gravity: the height of the center of gravity should not be greater than 0.5m in
order to maximize the stability of the car.
 Safety: the engine and fuel tank should be kept away from the passengers, and the car
should contain roll bar, safety belts, air bag and a well-designed crumble zone.

Assumptions:
 The specified time (which is 3 semesters) is enough to complete the whole project.
 All the necessary equipment and tools are available in the workshop and in a good
condition.
 The material that is in the workshop is enough to manufacture the components of the
car.
 The Bahrain Polytechnic will pay for this project.
 The training period that is specified for the students is enough, and the students will not
require further training.
 The students will be able to do the manufacturing processes (such as welding, cutting
drilling, machining etc…) efficiently and with high quality.
 The number of students will be sufficient to complete the manufacturing stage within
the specified duration.
 The components that will be ordered (such as springs, rose ends, universal joints) will be
delivered in time and before the manufacturing stage.

Deliverables:
 A Chassis
 Front and rear suspension
 Braking system
 Steering system
 Cooling system
 Exhaust system
 Investigating, analyzing and selecting a type of engine, gearbox and transmission parts

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 Cost management:

The project is constrained by a budget which is 3000 BHD. In this part of the report, the
cost of the project will be estimated.
 Chassis cost:

The table shows the estimated cost of the chassis:

Dimensions (mm) Price
Required Tubes
Product type (metalsdepot Total price
Length Width thickness length Quantity
, 1992-2012)
1 X 1 X 14 GA (.083 wall) A513 Steel 8.1 BHD per (9*8.1)
25 25 2 33.1 m 9
Structural Square Tube 3.7 m 72.9 BHD
3/4 X 3/4 X 14 GA (.083 wall) A513 6.3 BHD per (5*6.3)
20 20 2 14 m 5
Steel Structural Square Tube 3.7 m 31.5 BHD
2 OD x .065 wall x 1.87 ID 1020 21.3 BHD per
Diameter 50 mm 1.7 2.8 m 1 21.1 BHD
DOM Structural Round Steel Tube 3m
1-1/2 OD x .095 wall x 1.310 ID 1020 24.1 BHD per
Diameter 38 mm 2.8 2.3 m 1 24.1 BHD
DOM Structural Round Steel Tube 3m
Total 149.6 BHD
Table 6, chassis costs (metalsdepot, 1992-2012)

For the material availability; there are diverse types (different sizes) of circular and square
tubes are available in the workshop in building 30; all of these tubes are manufactured from
mild steel tubes (mild steel 1018). For our project we are planning to use two types of square
tubes (25 mm square tubes with a thickness of 2mm, and 20 mm square tubes with a thickness
of 2mm) for the members and side members; for the roll cage we are going to use two types of
circular tubes (50 mm diameter tubes with a thickness of 2mm and 38 mm diameter tubes with
a thickness of 2.5mm). A good quantity of these tubes is available in the workshop.

 Suspension system costs:

The table below shows the estimated costs for of the double wishbone suspension system
parts:
Part name Quantity required Price (BHD)
Coil over 1 52
Control arm rubber bushings 4 6*4 = 24
Ball joint 2 13*2 = 26
Nuts and bolts 4 1.5 * 4= 6
Steering Knuckle 1 33
Total 159 BHD
Total cost for 4 suspension systems 636 BHD
Table 7, estimated cost for double wishbone suspension (warehouse, 2000-2014)

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  Major components costs:

The table below shows the estimated costs for the major components of vehicle:
Part name Quantity required Price (BHD)
Engine 1 450
transmission 1 250
wheels 4 4*50 = 200
Braking system 4 80*4 = 320
Electric components 1 300
Seats 2 15*2 = 30
Battery 1 25
radiator 1 40
Steering system 1 80
exhaust system 1 120
Total 1815 BHD
Table 8, Major components costs (metalsdepot, 1992-2012)

 The total cost of the vehicle:

Part name Price (BHD)

Chassis 149.6
Suspension system 636
Major components 1815
Total 2600 BHD
Table 9, Total car costs (metalsdepot, 1992-2012)

Note: these prices are subjected to change.

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Communication management:

 Meetings:
1. Short meetings with the students in each day during the manufacturing stage. The
meetings should remind the students about the importance of safety. In the meetings,
the roles and duties of each student will be distributed in order to make sure that
everyone is involved in the manufacturing.
2. Tutors should meet with the higher management in order to inform them with the
project progress, obstacles, and what needs to be changed in order to improve the
project.

 Emails:
1. Ability to remind the students with the due dates of assignments.
2. Ability to send important notifications to students.
3. Tutors can answer students’ concerns.
4. Students can send their assignments to their tutors’ emails in case there is a problem
with moodle.

 Phone Calls and SMS:

1. Students can quickly communicate with their tutors in case of emergency.

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Quality management

To achieve the main objective of the project (manufacture a racing car) we applied a
quality management system. This quality system ensures that the products are satisfying the
customer requirements (target quality), the products are consistent where the variation is
reduced (as much as possible), doing things right the first time, every time and on time freedom
from defects (Failure) and also, continuous improvements. This system consists of three
elements which they are quality planning, quality control and quality assurance. These
elements are included in the Gantt chart in detail; the following figures show a summary of
each element:

Quality planning:
A full plan for the manufacturing the racing car (from A to Z) is created;
this plan includes researching and designing methods with duration.
This plan shows the manufacturing steps, period and the project
requirements (budget, activity resources and human resources).
Furthermore, this plan covers the cost and procurement management,
and communications management.

Quality control:
Before manufacturing each component of the car; the students
(employees) will take a practice course in welding, grinding, notching,
drilling and how to deal with the various equipment that are available
in the workshop (building 30 and 34). At the end of this course the
employees will be competent, and they can do the practical works with
the required quality.

Quality assurance:
To insure that the manufactured components are satisfying the
required quality for the project; each component will be double
checked, and a corrective actions will take place if the manufactured
component is out of the requirements.

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Human resources (HR) management:
The Gantt chart classifies the human resources into three categories; the first category
is the group members, the second is tutors and the third is the project sponsors:
Group members (students):
The responsibilities of group members:
 Researching about each component that will be manufactured;
this includes theoretical concepts and forces calculations.
 Designing and modifying the components based on the research
outcomes.
 Analysing the design through drawing a 3d models in solid-works
and using finite element analysis feature.
 Develop human resources plan.
 Manufacturing the project car components based on the plan.

Tutors:
The responsibilities of tutors:
 Check and monitor the progress of group members in each stage
(researching, designing and manufacturing stages).
 Give the group members comments about the work that done,
and assist them to make sure that the progression is on the right
track.
 Answer some of the group member’s questions, and give them
the gaudiness about any helpful internet sources or books.
 Providing and testing the project activity resources, and support
the group members with project requirements (like, materials).

Project sponsors (Bahrain polytechnic management):

The responsibilities of sponsors:
 Allocate a budget for the project (3000BD).
 Approve the project.

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Risk management:

Project Risks: Mitigation Strategy

 Checking if the material available in the
workshop is enough or not. If it is not
enough, ordering material from local or
international suppliers. This should be
The material in the workshop is not enough.
done before the beginning of the
semester in order to make sure that
they will be delivered when they are
needed.
 Inspecting the equipment and tools
Malfunction of equipment or tools.
regularly, repairing or buying a new one
 Repairing the computers by the IT
Malfunction of the computers in the department or replacing the computers
workshop. by a new one before the designing and
analyzing stage
 Giving sufficient training to the students
Not achieving the required quality due to
and giving instructions on double
bad welding or machining etc…, or not
checking the measurements before
achieving the required tolerances.
machining.
 The designs should first be approved by
the tutors before the manufacturing.
Failure to some of the components of the
 The calculations should be checked by
car due to wrong designs.
the tutors in order to confirm that they
are correct.
 Comparing the price of different
suppliers when purchasing materials or
The specified budget is not enough components in order to see the best
price.
 Doing Cost management.

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Procurement management:

Procurement management is when the company or the project unit acquires goods or
objects from an outside source. Usually, this tends to work when the purchase goods from
sources that manufacture the objects needed, meaning that they are not manufactured from
the same company’s self. Also, procurement management occurs if outside services or help is
needed. Of course, the quantity and the quality of the product must meet the procured time
and cost at the best possible.

The procurement management of the car project will involve the following:

1. Check if the required component is available or not (in building 30); if not do step 2,3,4
and 5.
2. Researching for new and different suppliers in order to find the most suitable supplier in
terms of cost, quality and delivery time.

3. Budget management: making sure that the budget will not exceeded. This can be done
by doing cost management. The parts that are not very important will be purchased
from the cheapest suppliers in order to save money for other important parts that
cannot be found with cheap prices such as the engine.

4. Negotiating the prices with the suppliers in order to get reduced prices.

5. Following up with the suppliers concerning the delivery time in order to ensure that all
the components or tools will be available when they are needed.

Components available at building 30

An old car purchased by Bahrain polytechnic.
Several types, sizes of the tubing sections purchased by Bahrain polytechnic.

The following table demonstrates the procurement was followed for each component in the car
project.

 The engine and transmission are acquired

Engine + Transmission from an old car that is available at
building 30.
 The chassis is manufactured and welded in
the workshop, but the metallic tubes are
acquired from the available stock of tubing
Chassis sections at building 30.
 Welding is needed to weld the tubes
together in order to produce a chassis, and
the welding machines are procured from

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 an outsource company.
 The front and rear suspension has a similar
procurement state as the chassis, where
Front and Rear Suspension the metallic tubes are also obtained from
the available stock of tubing sections at
building 30.
 Since braking requires many difficult
strategies to manufacture, there is no
Braking
other way than obtaining the braking
system from an outside local source.
 Bearings, rose joints, bolts, bushings,
universal joints, electrical systems: will be
Major car components: obtained from an outside local source.
 Radiator and seats are acquired from an
old car that is available at building 30.

Having a procurement management helps the company in many ways. First, it helps in
specifying the project needs, and it allows us to obtain wanted components that we are unable
to manufacture due to deficiency of tools and time and cost. Obtaining them from an out
source, could save time and money also since we are purchasing them for specialized sources
that concentrated their time and management on manufacturing those components.

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 Appendix:

Semester 5 tasks:

1. Rear Suspension
 Research : 4 week
 Types of suspension: 4 days (Sunday-Wednesday)
 selecting a type of suspension for the rear suspension: 3 days (Thursday-
Monday)
 Investigating the forces and stresses that would be involved (Tuesday-Thursday).

 Designing: 6 weeks
 Obtaining suspension geometry based on best roll centre and camber
compensation for the rear suspension. 1 week (Sunday-Thursday)
 Determining a suitable factor of safety . 1 day (Sunday)
 Calculating the forces and stresses on the upper wishbone. 1 week (Monday-
Monday)
 Calculating the forces and stress on the lower wishbone. 1 week (Tuesday-
Tuesday.
 Selecting a material for the wishbones 2 day (Wednesday-Thursday).
 Calculating the stresses on the spring 1 week (Sunday-Thursday).
 Designing and selecting bolts, rod ends (rose joints), sleeves and bushings for the
rear suspension 2 week (Sunday-Thursday).

 Analysing (1 week)
 Drawing the model in solid works: 2 days (Sunday-Monday).
 Running a Finite Element Analysis study: 1 day +one extra day as a margin in
order to solve any unexpected problem with the simulation (Tuesday-
Wednesday) .
 Confirming the hand calculations results by comparing them with the finite
element analysis results : 1 day (Thursday)
 Modifications (1 week)
 identify the weak areas in the design: 1 day (Sunday)
 Modify the design in order to keep the maximum stress below the allowable
stress with maintain a suitable factor of safety: 3 days ( Monday-Wednesday)
 Confirming if the design will perform as required and meets the specifications: 1
day (Thursday).

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  Manufacturing (4 weeks)
 Practice on welding, grinding, notching, drilling, using the various equipment in
the workshop (building 30) 1 week (Sunday-Thursday).
 Manufacturing the front and rear suspension, and the chassis. 3 weeks (Sunday-
Thursday).

Note: in the manufacturing specified duration, the chassis, front and rear suspensions will be
manufactured C.
2. Front Suspension:
 Research : 4 week
 Types of suspension: 4 days (Sunday-Wednesday)
 selecting a type of suspension for the front suspension: 3 days (Thursday-
Monday)
 Investigating the forces and stresses that would be involved (Tuesday-
Thursday).

 Designing: 6 weeks
 Obtaining suspension geometry based on best roll centre and camber
compensation for the front suspension. 1 week (Sunday-Thursday)
 Determining a suitable factor of safety for the front suspension . 1 day (Sunday)
 Calculating the forces and stresses on the upper wishbone. 1 week (Monday-
Monday)
 Calculating the forces and stress on the lower wishbone. 1 week (Tuesday-
Tuesday.
 Selecting a material for the wishbones 2 day (Wednesday-Thursday).
 Calculating the stresses on the spring 1 week (Sunday-Thursday).
 Designing and selecting bolts, rod ends (rose joints), sleeves and bushings 2
week (Sunday-Thursday).
 Analysing (1 week)
 Drawing the model in solid works: 2 days (Sunday-Monday).
 Running a Finite Element Analysis study: 1 day +one extra day as a margin in
order to solve any unexpected problem with the simulation (Tuesday -
Wednesday).
 Confirming the hand calculations results by comparing them with the finite
element analysis results : 1 day (Thursday)
 Modifications (1 week)
 identify the weak areas in the design: 1 day (Sunday)
 Modify the design in order to keep the maximum stress below the allowable
stress with maintain a suitable factor of safety: 3 days ( Monday-Wednesday)

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  Confirming if the design will perform as required and meets the specifications: 1
day (Thursday).

 Manufacturing (4 weeks)
 Practice on welding, grinding, notching, drilling, using the various equipment in
the workshop (building 30) 1 week (Sunday-Thursday).
 Manufacturing the front and rear suspension, and the chassis. 3 weeks (Sunday-
Thursday).

Note: in the manufacturing specified duration, the chassis, front and rear suspensions will be
manufactured simultaneously.

3. Chassis:
 Research
 Research about the function of chassis 1 week (Sunday-Thursday).
 Research about roll cage: 1 week (Sunday-Thursday).
 Research about chassis types 1 week (Sunday-Thursday).
 Selecting a type of chassis 1 week (Sunday-Thursday).

 Analysing:

 Taking measurements from an existing chassis 1 week (Sunday-Thursday).

 Drawing the chassis in solid-works 2 weeks (Sunday-Thursday).
 Doing modifications to the chassis: 2 weeks (Sunday-Thursday).
 Calculating the forces that will act on the chassis 1 week (Sunday-Thursday).
 Doing finite element analysis study 1 week (Sunday-Thursday).
 Confirming if the chassis will perform as required and meets the specifications.

 Manufacturing (4 weeks)

 Practice on welding, grinding, notching, drilling, using the various equipment in

the workshop (building 30) 1 week (Sunday-Thursday).
 Manufacturing the front and rear suspension, and the chassis. 3 weeks (Sunday-
Thursday).

Note: in the manufacturing specified duration, the chassis, front and rear suspensions will be
manufactured simultaneously.
Note: These dates are subjected to change. Some of the durations may seem longer
than required but in reality these tasks will be done simultaneously with other tasks.

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Semester 6 tasks:

Research: 6 weeks
 Types of braking systems. 2weeks
 How braking systems work. 2 weeks
 Selecting a type of braking system. 2 weeks
 Types of cooling systems. 2 weeks
 How cooling systems work. 2 weeks
 Selecting a type of cooling system 2 weeks
 Types of exhaust systems. 2 weeks
 How exhaust systems work. 2 weeks
 Selecting a type of exhaust system based on the required performance criteria for racing
cars. 2 weeks

 Designing (6 weeks)
 Calculating the required braking torque for the front and rear brakes. 2 week
 Calculating the required flow rate in the cooling system. 1 week
 Calculating the required cross sectional area and the length of the pipes that will be
used in the cooling system. 1 week
 Calculating the required length and cross sectional area of the exhaust pipes. 1 week
 Purchasing a cooling system and braking systems based on requirements 1 week.

 Manufacturing: 3 weeks
 Safety Induction 1 day (Sunday).
 Practice on welding, cutting, drilling, grinding, notching, etc… 4 days (Monday-
Thursday).
 Manufacturing of the exhaust system. 1 week
 Testing the exhaust system in order to see if the required specifications are
being met. 1 week

 Installing : 1 week
Installing the braking and cooling system.
Testing if the braking and cooling system in order to check if they meet the desired
specifications.

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Semester 7 tasks:

 Research: 9 weeks
 Types of engines and how they work. 2 week
 Selection of type of engine. 1 week
 Gears systems. 1 week
 Selecting a gear system. 1 week
 Power transmission parts and their purpose. 1 week
 Selecting transmission parts. 1 week
 The purpose of flywheels, clutches, belt drives and how they work. 1 week
 Types of bearings, their purpose and how they work. 1 week

 Designing: 3 weeks
 Calculating the required dimensions of pistons, connector rod, piston pin and
crankshaft based on the forces and stresses that will be involved. 1 week
 Determining a suitable factor of safety for each component. 1 week
 Selecting a suitable material for each component. 1 week

 Analysing: 4 weeks
 Drawing the designed parts (pistons, connector rod, piston pin and crank shaft). 1 week
 Doing Finite Element Analysis for the designed parts. 1 week
 Doing Modifications to the parts if required. 1 week
 Checking if the designed parts meet the requirements and specifications. 1 week

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