PRODUCTION AND INDUSTRIAL ENGINEERING

SCHEME
Semester II Hrs/Week Sl. No. Course Number Subject L 1 MPIE 201 Advanced Precision Machining Process Flexible Manufacturing Systems Management Information System Supply Chain Management Professional Elective III Professional Elective IV Team Exercise CAD/CAM Laboratory 3 T 2 P 0 Evaluation Scheme (Marks) Sessional Exam ESE (internal) (Theory / Total Sub Practical) TA CT Total 25 25 50 100 150 Credits
T + P L+ 2

MPIE 202

25

25

50

100

150

3.5

3 4 5 6 7 8

MPIE 203 MPIE 204 MPIE 205 MPIE 206 MPIE 207 MPIE 208

3 3 3 3 0 0

1 1 1 1 0 0

0 0 0 0 2 3

25 25 25 25 50 25

25 25 25 25 0 25

50 50 50 50 50 50

100 100 100 100 0 100

150 150 150 150 50 150 1100

3.5 3.5 3.5 3.5 1 1.5 24

18 7 5 400 700 MPIE 205 Professional Elective III 205.1 Principles of Robotics and Applications. 205.2 Sensors for Intelligent, Manufacturing & Condition Monitoring. 205.3 Design for Manufacturing and Assembly. 205.4 Failure Prevention. 205.5 Machine Tool Dynamics. 205.6 Simulation of Manufacturing Systems. MPIE 206 Professional Elective IV 206.1 Neural Network & Fuzzy Logic. 206.2 Lean & Agile Manufacturing. 206.3 Treatment of Metals. 206.4 Product Development & Manufacturing. 206.5 Decision Models. 206.6 Finite Element Method. 206.7 Advanced Operations Research Applications

PRODUCTION and INDUSTRIAL ENGINEERING

COURSE SYLLABI

SECOND SEMESTER
MPIE 201
Prerequisites: Basic understanding of manufacturing processes mechanical and physical properties of materials, and physics. Course objectives: 1. Describe and develop basic theory encountered in the discipline of nontraditional, nano manufacturing processes. 2. Develop the ability to properly assess the capabilities, limitations, and potentials of non-traditional, nano manufacturing processes and their competitive aspects. 3. Describe new developments in processes, materials, and computer integration of both technological and managerial activities in manufacturing organisation. Course description: New, difficult-to-machine materials and increased part complexity have resulted in the creation of new manufacturing processes, known as non-traditional manufacturing processes. This course introduces students to fundamentals of non-traditional manufacturing processes, such as laser cutting and welding, abrasive water jet machining, ultrasonic machining, Electro-discharge machining, chemical and electrochemical machining, hybrid machining (laser beam, plasma arc and water jet assisted machining). Rapid prototyping and manufacturing (RPM) techniques will be included in the program of this course as well. RPM is a new term coined to describe a group of "layer-by-layer" manufacturing processes which are capable of building a free-form part directly from CAD data. The course represents a good balance between theoretical problems and practical considerations related to the non-traditional manufacturing processes. Course outline by topical areas: Module 1 Introduction to non-traditional, nano Manufacturing Processes Module 2 1. Laser Beam Processing - Fundamentals - Materials processing (cutting, drilling, welding, surface modification, micro machining, laser deposition of thin film) - Equipment for Laser Beam Processing

ADVANCED PRECISION MACHINING PROCESS

2. Electron Beam Processing - Fundamentals - Materials Processing (machining, welding, lithography) 3. Ion-Beam Processing - Ion Beam removal, deposition, surface treatment Module 3 1. Electrical Discharge Machining - Operating Principles - EDM micro-hole drilling, grinding - EDM wire cutting 2. Plasma Arc and Laser Beam Assisted Machining Module 4 1. Abrasive Water jet Machining - Operating Principles - Applications 2. Ultrasonic Machining Module 5 Chemical and Electrochemical Machining (principle, types, process parameters, control, MRR, surface finish, application etc. Electro chemical grinding, lapping, honing; process principle & Ra etc, applications EBM, LBM, IBM, AJM, Abrasive water jet machining, LIGA process.

Reference: 1. J.J. Beaman, J.W. Barlow, D.L. Bourell, R.H. Craford, H.L. Marcus and K.P. McAlea, Solid Freeform Fabrication. 2. A New Direction in Manufacturing, Kluwer Academic Publishers, Dordrecht/Boston/London, 1997 3. Kalpakjian, Manufacturing Engineering & Technology, Addison Wesley, 4nd edn. 4. Bhattacharyya A., -"Metal Cutting Theory & Practice", Central Book Publishers. 5. Debitson A.- Hand book of precision engineering. 6. J.A. McGeough, Advanced Methods of Machining, Chapman and Hall, London, New York, 1988. 7. Momber A.W.; Kovacevic R.- Principles of Water Jet Machining, Springer Verlag. 8. Precision Engineering Manufacturing by R.L.Murthy., New age intrnational 9. Metcut research associates - Machinablity Data Center Vol. 3 - Metcut research associates,Cincinnati, USA. 10. G. Chryssolouris, Laser Machining Theory and Practice, Springer Verlag, New York, 1991.

MPIE 202

FLEXIBLE MANUFACTURING SYSTEMS

Module 1 FMS An Overview: Definition of an FMS types and configurations concepts types of flexibility & performance measures. Functions of FMS host computer FMS host and area controller function distribution. Module 2 Development and implementation of an FMS: Planning phases integration system configuration FMS layouts simulation FMS project development steps. Project management equipment development host system development planning hardware & software development. Module 3 Automated material handling and storage: Function types analysis of material handling equipments. Design of conveyor & AVG systems. Automated storage: Storage system performance AS/RS carousel storage system WIP storage interfacing handling storage with manufacturing. Module 4 Concepts of distributed numerical control: DNC system communication between DNC computer & machine control unit hierarchical processing of data in DNC system features of DNC system. Programmable controllers: Control system architecture elements of programmable controllers: language, control system flowchart, comparison of programming methods. Module 5 FMS Relationale: Economic and technological justification for FMS as GT, JIT operation and evaluation personnel and infra structural aspects typical case studies future prospects. Textbooks: 1. Parrish D. J. Flexible Manufacturing. Butter Worth Heinemann Ltd. Oxford, 1993 2. Groover M. P, Automation, Production Systems and Computer Integrated Manufacturing Prentice Hall India (P) Ltd., 1989. 3. Kusiak A Intelligent Manufacturing Systems, Prentice Hall, Englewood Clitts, NJ, 1990. Reference: 1. Considine D. M, & Considine G.D, Standard Handbook of Industrial Automation. Chapman and Hall, London, 1986. 2. Viswanadham N & Narahari Y, Performance Modeling of Automated Manufacturing Systems. Prentice Hall, India (P) Ltd., 1992 3. Ranky P. G, The Design and Operation of FMS, IFS Pub, UK, 1998.

MPIE 203

MANAGEMENT INFORMATION SYSTEMS

Module 1 Introduction: Meaning and definition of Management Information (MIS) System Approach role of MIS to face increased complexity of business and management system view of business MIS organization within the company. Module 2 Conceptual information system design: Defining the problems Setting system objectives Establishing system constraints Determining information needs Determining information sources Developing alternate conceptual design and selecting the most preferred one Documenting the conceptual design preparing the conceptual design report. Module 3 Detailed information system design: Informing and involving the organization Project Management of MIS Detailed Design Identifying dominant and trade-off criteria subsystems definitions sources sketching the details and information flows automation Informing and involving the organization again Inputs, outputs and processing Early system testing organization to operate the system Documentation Revisiting the manager user. Module 4 Evolution of information systems: Basic information Systems Financial information systems Production / Operations systems Marketing information Systems Personal information systems. Information systems and decision making: Decision making and MIS - Programmed and non programmed decision MIS for making programmed decisions decision assisting information systems components of decision support systems. Module 5 Information technology and MIS: Comparison of manual and computer based information systems conversation of manual to computer based systems types of computer based applications in MIS conceptual design of computer integrated security management Information system application of multimedia, internet and intranet technologies in MIS. Textbooks: 1. Murdick R.G., Ross J. E & Claggett. J. R., Information Systems for Modern Management. Prentice Hall of India Private Ltd., India, 3rd edition, 1992. References: 1. Henry C Lucas Jr., The Analysis, Design and Implementation of Information Systems. McGraw Hill Company, New York 4th Edition 1992. 2. Burch J. E., Strater F. R & Grudnikski G., Information Systems: Theory and Practice. John Wiley and Sons, New York, 1987.

MPIE 204

SUPPLY CHAIN MANAGEMENT

Module 1 Introduction to supply chain management: Information systems and Supply chain management, Inventory across the SCM, Supply chain relations. Module 2 Role of information technology in the SCM: Inter organizational information systems, Information requirement determination for supply chain I. T applications for Supply Chain Management. Module 3 Materials flow management across the supply chain: Supply chain Basics Internal supply chain, External supply chain and Inter Organizational supply chain. Supply chain performance measures. Module 4 Re-engineering supply chain logistics: Definition of logistics, SCM and Logistics, International Considerations, Re-engineering challenges and opportunities, Cycle time reduction across the Supply chain, Measurement of performance measures. Module 5 Supply chain relationships: Integrated supply chain model, Total Quality Management and supply chain, developing relationships in the Supply Chain, Resolving conflicts in Supply chain relationships.

References: 1. Hand Field Robert B., Nichols Jr., Ernest L., Introduction to supply chain management. Prentice Hall, New Jersey, 1999. 2. Sunil Chopra, Peter Meindl, Supply Chain Management, Pearson Education, 2001. 3. Roberta S. Russell, Bernard W. Taylor III, Operations Management, PHI, 2003.

MPIE 205 MPIE 205.1

Course Description:

PROFESSIONAL ELECTIVE - III PRINCIPLES OF ROBOTICS AND APPLICATIONS

Physical mechanisms of robotics, issues of modelling, planning, control, and programming. Principles underlying the design and analysis of robotic systems.

Topics
Module 1 Introduction: Definition, configurations, work envelopes, specifications, and other basic parameters of robots. Module 2 Kinematics Principles: Position and orientation, co-ordinate systems, Relative Frames, Homogeneous Co-ordinates, Direct and inverse Kinematics, Differential motions and the Jaconians. Module 3 Introduction to Dynamics. Types of Motions: Slew, joint-interpolated, Straight line interpolated motions. Planning of manipulator Trajectories and control. Drives Basic Electrical, Hydraulic, and pneumatic drives basics and relative merits. Module 4 Components: Harmonic reduction Units, servo valves, and grippers. Module 5 Sensors: Basic types including vision, Force torque wrist sensors. Programming various methods levels typical languages like VAL. Industrial Applications. Robot cell formation. Case studies. Textbooks: 1. Richard D.Klafter, Thomas A.Chmielwski, Michael Negin, Robotics Engineering, An Integrated approach, Prentice Hall of Indi. 1989 2. Fu.K.S.Gomalez, R.C, LeeC.S.G., Robotics: Control, Sension, Vision and Intelligence, McGraw Hill, 1980. 3. Mikell.P.Grooveretal, Industrial Robots Technology, Programming and application, McGraw Hill, 1980. Reference: 1. Shiman.Y.nof.Handbook of Industrail Robotics, John Wiley & sons, 1985 2. Deh.S.R.,Robotics Technology and Flexible Automation, Tata McGraw Hill, 1994. 3. Craig, J.J., Robotics: Mechanics and Control, Addison Wesley, 1989.

4. Groover, M.P., Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Prentice Hall, 1996. 5. Craig, J., Adaptive Control of Mechanical Manipulators, Addison Wesley, 1988. 6. Snyder, W.E., Industrial Robots: Computer Interfacing and Control, PrenticeHall, 1985. 7. Song, S.M., and Waldron, K.J., Machines That Walk, MIT Press, 1988 8. IEEE Journal of Robotics and Automation 9. International Journal of Robotics Research 10. IEEE Transactions on Man, System, and Cybernetics

MPIE 205.2 SENSORS FOR INTELLIGENT MANUFACTURING AND CONDITION MONITORING

Module 1 Introduction role of sensors in manufacturing automation operation principles of different sensors electrical, optical, acoustic, pneumatic, magnetic, Electro optical and vision sensors. Module 2 Condition monitoring of manufacturing systems principles sensors for monitoring force, vibration and noise, selection of sensors and monitoring techniques. Module 3 Acoustic emission principles and applications concepts of pattern recognition. Sensors for CNC machine tools linear and angular position and velocity sensors. Module 4 Automatic identification techniques for shop floor control bar code scanners, radio frequency systems optical character and machine vision sensors. Module 5 Smart / intelligent sensors integrated sensors. Adaptive control of machine tools. Reference: 1. Sensors: Hand Book by Sabrie Soloman ; McGraw Hill 2. Thermal Sensors: Vo. IV, Sensors: A Comprehensive Survey by Jorg Scholz (Editor), John wiley & Sons 3. Mechanical Sensors: Vo. VII, Sensors: A Comprehensive Survey by H.H. Bau (Editor), John wiley & Sons 4. Sensor Technology & Devices by Ljubisa Ristia (Editor), Artech House Publishers.

MPIE 205.3

DESIGN FOR MANUFACTURE AND ASSEMBLY

EFFECT OF MATERIALS AND MANUFACTURING PROCESS ON DESIGN : Major phase of design. Effect of material properties on design. Effect of manufacturing process on design. The material selection process cost per unit property, weight properties and limits on properties methods. TOLERANCE ANALYSIS: Process capability, mean variance, skewness, kurtosis, process capability metrics Cp., Cpk cost aspects, feature tolerances, geometric tolerances, surface finish, review of relationship between attainable tolerance grades and different machining process, cumulative effect tolerances, sure fit, law normal law and truncated normal law. SELECTIVE ASSEMBLY: Interchangeable and selective assembly, deciding the number of groups Model-I group tolerances of mating parts equal; Model II: total and group tolerances of shaft, control of axial play introducing secondary machining operations, laminated shims, examples. DATUM SYSTEMS: Degrees of freedom, grouped datum systems different types, two and three mutually perpendicular grouped datum planes, grouped datum system with spigot and recess, pin and hole, grouped datum system with spigot and recess pair and tongue slot pair computation of transitional and rotational accuracy, geometric analysis and applications. TRUE POSITION THEORY: Comparison between co-ordinate and convention method of feature location, tolerancing and true position tolerancing, virtual size concept, floating and fixed fasteners, projected tolerance zone, assembly with gasket, zero true position tolerance, functional gauges, paper layout gauging, compound assembly, examples. FORM DESIGN OF CASTINGS AND WELDMENTS: Redesign of casting based on parting line considerations, minimising core requirements, redesigning cast members using weldments, use of welding symbols. TOLERANCE CHARTING TECHNIQUE: Operation sequence for typical shaft type of components, preparation of process drawings for different operations, tolerance worksheets and centrality analysis, examples, design features to facilitate machining, datum features functional and manufacturing, component design machining considerations, redesign for manufacture, examples. CASE STUDIES: Redesign to suit manufacture of typical assemblies, tolerances design of typical drive system, example, design of experiment, value analysis and design rules to minimize cost of a product. Computer aided DFMA, poke yoka principles.

Text Books: 1. Harry Peck, Designing for Manufacture, Pitman Publications, 1983. 2. Matousek, Engineering Design A systematic Approach Blackie & Son Ltd., London 1974. Reference: 1. Spotts, M.F., dimensioning and tolerance for Quantity Production, Prentice Hall Inc., 1983 2. Oliver R.Wade, Tolerance Control in Design and Manufacturing, Industrial Press Inc., New York, 1967 3. James G.Bralla, Hand Book of Product Design and Manufacturing, McGraw Hill Pubilications, 1983. 4. Trucks, H.E., Design for Economic Production, Society of Manufacturing Engineers, Michigan, 2nd Edition, 1987. 5. Poka Yoke, Improving Product Quality by Preventing Defects, Productivity Press, 1992 6. Creveling, C.M., Tolerance Design A Hand Book for Developing Optimal Specifications, Addison Wesley Longman, Inc, 1997 7. Pahl, G. and Beitz W. Engineering Design Systematic Approach, Springer Verlag Pub., 1996. 8. Mahmoud M.Farag, Material Selection for Engineering Design, Prentice Hall, 1997.

MPIE 205.4

FAILURE PREVENTION

Modes of mechanical failure, strength and deformation of metals, theories of failure, fatigue and fracture, life prediction, statistics, fretting, wear, and corrosion. Goals: The course is designed to introduce the students to the wide variety of failure modes of mechanical systems. They will investigate current models to predict structuralfailure, and they will use the available methodologies to design structures to prevent these failures. Topics: 1. Introduction to Mechanical Failure 2. Deformation Response of Metals 3. Fracture Mechanics 4. High-Cycle Fatigue 5. Cumulative Damage and Life Prediction 6. Low-Cycle Fatigue 7. Neuber Analysis 9. Fatigue Crack Growth 10. Statistics in Fatigue Analysis

11. Weibull Analysis 12. Fretting, Wear and Corrosion Course Outcomes: 1. Students will be able to identify a wide variety of failure modes of mechanical systems. 2. Students will be able to design mechanical structures to prevent failures from deformation, brittle fracture, fatigue, and corrosion. 3. Students will be able to analyze data using appropriate statistical tools. 4. Students will be able to generate a computer code to predict the fatigue life of a structure. Text Book: 1. Ewalds H. L. & Wanhill R.J.H., Fracture Mechanics, Edward Arnold Edition Reference: 1. Broek D., Elementary Engineering Fracture Mechanics, Sijthoff & Noordhoff International Publishers 2. Kare Hellan, Introduction to Fracture Mechanics, McGraw Hill Book Company 3. Prashant Kumar, Elements of Fracture Mechanics, Wheeler Publishing 4. ISBN; 81 7371 259 X Fracture Mechanics for Modern Engineering design by Simha, K.R.Y. University Press

MPIE 205.5

MACHINE TOOL DYNAMICS

Machine tools as a closed loop. Machine tool frames-static deflection models. Thermal distortion. Dynamic behaviour, longitudinal, laternal and torsional vibrations. Dynamics of cutting forces. Tool chatter. Slide ways, hydrodynamic bearing, air and gas bearings. Instability Hydraulic servomechanisms. Vibration dampers Practical design considerations Measurement of dynamic forces and vibrations Reference: 1. Theory of Machines 2. Theory of Machines 3. Mechanical Vibrations, V edition -

Thomas Bevan P.L. Ballaney G.K. Groover

4. Theory of Vibrations with applications, III Edn 5. Mechanical Vibrations 6. 7. 8. 9. Fundamentals of Vibrations A text book of sound Engineering Noise Control Noise & Vibration Control

W.T. Thomson S. Graham Kelly, Schaums outlines Leonard Meirovitch, MacGraw L.P. Sharma & H.C. Saxena D.A. Bies & C.H. Hausen. Leo N. Beraneck

MPIE 205.6

SIMULATION OF MANUFACTURING SYSTEMS

Module 1 Principle of computer modelling and simulation: Monte Carlo simulation. Nature of computer modelling and simulation. Limitations of simulation, areas of application. Module 2 System and environment: Components of a system discrete and continuous systems. Models of a system a variety of modelling approaches. Random number generation: Techniques for generating random numbers Midsquare method The midproduct method Constant multiplier technique Additive congruential method Linear congruential method Test for random numbers The Kolmogorov Smirnov test the Chi-square test. Module 3 Random variable generation: Inverse transform technique exponential distribution uniform distribution Weibull distribution Emprical continuous distribution generating approximate normal variants Erlang distribution. Module 4 Emprical discrete distribution: Discrete uniform distribution poisson distribution geometric distribution acceptance rejection technique for Possion distribution gamma distribution. Module 5 Design and evaluation of simulation experiments: Variance reduction techniques antithetic variables verification and validation of simulation models. Discrete event simulation: Concepts in discrete-event simulation, manual simulation using event scheduling, single channel queue two server queue, simulation of inventory problem. Textbooks: 1. Jerry Banks & John S. Carson II, Discrete Event System Simulation Prentice Hall Inc., 1984. 2. Gordon G, System Simulation, Prentice Hall Ltd. 1991.

Reference: 1. Narsingh Deo, System Simulation with Digital Computer Prentice Hall, 1979 2. Francis Neelamkovil, Computer Simulation and Modeling, John Wiley & Sons, 1987. 3. Ruth M. Davis & Robert M.OKeefe, Simulation Modeling with Pascal, Prentice Hall Inc., 1989.

MPIE 206 MPIE.206.1

PROFESSIONAL ELECTIVE IV NEURAL NETWORKS AND FUZZY SYSTEMS

Course Description: Discussion of neural networks, architectures, algorithms and applications, including Hebbian, Hoffield, Competitive Learning, ART and Back propagation neural nets. INTRODUCTION TO NEURAL NETWORKS: Difference between Biological and Artificial Neural Networks Typical Architecture, Common Activation function, McCulloch Pits Neuron, Simple Neural Nets for Pattern Classification, Linear Seperability Hebb Net, Perceptron, Adaline, Madaline Architecture, Algorithm, and Simple applications. PATTERN ASSOCIATION: Training Algorithms for pattern association Hebb rule and Delta rule, Heteroassociative, Autoassociative and lterative Autoassociative Net, Bidirectional Associative Net, Bidirectional Addociative Memory Architecture, Algorithm, and Simple applications. NEURAL NETWORKS BASED ON COMPETITION: Fixed Weight Competitive Nets Maxnet, Mexican Hat and Hamming Net, Kohenen Self organizing Maps, Learning Vector Quantization, Counterpropagtion Architecture, Algorithm, and Simple applications. ADAPTIVE RESONANCE AND BACKPROPAGATION NEURAL NETWORKS: ART1 and ART2 Basic Operation and Algorithm, Standard Backpropagation Architecture Derivation of learning rules, Multi layer Neural Nets as Universal Apporximators, Boltzman Machine Learning and Neocognitron - Architecture, Algorithm, and Simple applications. CLASSICAL AND FUZZY SETS AND RELATIONS: Properties and operations on Classical and Fuzzy sets, Crisp and Fuzzy relations Cardinality, Properties and operations, Composition, Tolerance and Equivalence relations, Value Assignments Cosine Amplitude, Max-min Method, Simple problems.

MEMBERSHIP FUNCTIONS: Features of membership function, standard forms and boundaries, fuzzification, membership value assignment, fuzzy to crisp conversions, lambda cuts of fuzzy sets and relations. DeFuzzification methods. FUZZY ARITHMETIC: Extension principle Fuzzy numbers, Fuzzy vectors, Classical predicate logic, fuzzy logic approximate reasoning, fuzzy tautologies, fuzzy rule based system-natural language, linguistic hedges, graphical techniques of inference. FUZZY APPLICATIONS: Neonlinear simulations, fuzzy associated memories, fuzzy decision making Evaluation ordering, multiobjective decision making, fuzzy classification cluster analysis, cluster validity, c-Means clustering, fuzzy pattern recognition, fuzzy control applications in industry, fuzzy logic controllers. Reference: 1. Neural Computing Theory & Practice - Philip D. Wasserman. 2. Simon Haykins, "Neural Network a - Comprehensive Foundation", Macmillan College, Proc, Con, Inc 3. Zurada J.M., "Introduction to Artificial Neural Systems, Jaico publishers 4. Driankov D., Hellendoorn H. & Reinfrank M., "An Introduction to Fuzzy Control", Norosa Publishing House 5. Thimothy J. Ross, "Fuzzy Logic with Engineering Applications", McGraw Hill 6. Bart Kosko. "Neural Network and Fuzzy Systems", Prentice Hall, Inc., Englewood Cliffs 7. David E. Goldberg, "Genetic Algorithms in Search Optimisation and Machine Learning", Addison Wesley 8. Suran Goonatilake & Sukhdev Khebbal (Eds.), "Intelligent Hybrid Systems", John Wiley & Sons 9. Adaptive Pattern Recognition & Neural Networks - Pay Y.H. 10. An Introduction to neural computing - Chapman & Hall 11. Artificial Neural Networks - Robert J. Schalkoff, McGraw Hill 12. Artificial Neural Networks - B.Yegnanarayana, PHI 13. Architectures, Algorithms and Application, Laurene Fausett, Prentice-Hall, 1994. 14. Simon Haykin,Neural Networks: A Comprehensive Foundation, MacMillan Publishing, 1994. 15. Bart Kosko, Neural Network and Fuzzy Systems: A Dynamic System Approach to Machine Intelligence, Prentice-Hall, 1992 16. David E. Rumelhart and James L. McClleland, Parallel Distributed Processing Vol. I Foundations, MIT Press, 1986. 17. James L. McClleland and David E. Rumelhart, Explorations in Parallel 18. Charles Koelbel, et. al., Fundamental of Neural Networks: Distributed Processing: A Handbook of Models, Programs and Exercises, MIT Press, 1986. 19. LiMin Fu, Neural Networks in Computer Science, McGraw-Hill, 1994.

MPIE 206.2

LEAN AND AGILE MANUFACTURING

INTRODUCTION TO LEAN MANUFACTURING: Meaning of lean prerequisites of becoming lean in manufacturing systems ford Production System (FPS) phases of change education and training new measurable in FPS managing change in a large corporation. LEAN MANUFACTURING PRACTICES: System model of lean manufacturing lean supplier to system sub model core production system sun model Interaction between production worker influence and production strategies performance impacts of the lean manufacturing system, - relationship between lean manufacturing practices and performance measures. IMPLEMENTING LEAN MANUFACTURIENG: Lean manufacturing program defining lean manufacturing principles lean flow two paths of implementing lean manufacturing pitfalls in implementing lean manufacturing. SUCCESFUL IMPLEMENTATION OF LEAN MANUFACTURING: Meaning and definition of agility forces pulling towards agility three consequences of converging physical products, information and services empowerment enterprise integration concurrent operations. NTRODUCTION TO AGILE MANUFACTURING: Meaning and definition of agility forces pulling towards agility three consequences of converging physical products, information and services empowerment enterprise integration concurrent operations. CUSTOMIZING AGILE BUSINESS STRATEGIES: Model for agile relationships products, services and enrichment of each customer enrichment chain moving from one time product to providing customer enrichment steps in customising the agile business strategies analysis of company overall opportunity analysis comparison with current products initial plan of market presence refining the plan analysing the barriers to change planning the internal realignment of the company role of strategic planning departments. BARRIERS TO ASSIMILATING AGILITY: Generally accepted accounting principles activity based costing time based costing fully utilised balanced line fallacy budgeting procedures dysfunctional organisation and information systems betrayal of trust not sharing information external barriers. INTRASTRUCTURE AND ENABLING SYSTEMS FOR AGILITY: Infrastructure for agility enterprise elements customer dialogue and support communication and information co-operation and teeming continuous improvement and change enterprises wide concurrency environmental enhancement flexible and rapidly responding operations people support supplier support enabling subsystems continuous education and training customer interactive systems lean organisation and methods modular re configurable process components performance metrics and evaluation waste management and elimination.

Text Books: 1. Liker, J.K. (ed.), 1997, Becoming Lean, Productivity Press, Oregan. 2. Goldman, S.L., Nagal, R.N. and Preiss, K. 1995, Agile competitors and Virtual organizations, Van Nostrand Reinhold, New York. Reference: 1. Montgomery, J.C. and Levine, L.O., 1995. The transition to agile manufacturing Staying flexible for competitive advantage, ASQC Quality Press, Wisconsin.

MPIE 206.3

TREATMENT OF MATERIALS

Functional characteristics of engineering surfaces Material treatments Significance of material treatments on function Material treatment techniques Case hardening Phosphating Aluminising Plating Ion treatment Metal spraying Micro alloy materials characteristics and their functional behaviour Case study Reference: 1. Stan Grainger, Editor; Engineering Coating Design and applications 2. Chapman.B. Glow Discharge Process, John Wiley. 3. G. Dearnaley - Ion Implantaion North Holland Publishing Co. amsterdam. 4. Bunshah, R.f.; et.al. Deposition Technologies for films and Coatings. Park Ridge, NJ. Noyes Publications, 1982. 5. Ballard W.E. Mtal Spraying and the Flame Deposition of Ceramics and Plastics. 6. Rabinowicz, Friction and Wear of Materials, John Wiley and Sons.

MPIE 206.4 PRODUCT DEVELOPMENT AND MANUFACTURE

PRODUCT ANALYSIS: Consumer Industrial products, demand and quality of production, life cycle, cost, quality and service aspects. Component classification makes or buys decision. Group technology, introduction to concurrent engineering. LATEST TRENDS IN PRODCUT DEVELOPMENT: Internet, collaborative product commerce, and concept, functionality and implementation software for CPC, use of software for CPC Use of software in CPC. ENGINEERING MATERIALS: Use of standard sections and components, review of different materials and its properties like Machinablity, hardenability, weldability, formability, use of standard assembly (sub modular assembly). ASSEMBLY AND FINISHING TECHNIQUES: Types of fasteners, types of joints. Assembling methods site assembly (shipbuilding), group assembly and line assembly. MANUFACTURING OF PRISMATIC COMPONENTS: Methods of loading, holding, sequence of operations, inspection of gear box body, headstock, gear pump body, application in milling machines, special purpose machines, transfer lines and machining centres. MANUFACTURING OF COMPONENTS BY FORMING Need for forming process, die casting, injection moulding, extrusion and cold heading with examples of components. Manufacturing of sheet metal components. Selection of press, selection of material for blanking and piercing dies, manufacturing of components like circlip, cups, control panel and cabinets. PRODUCTION OF HEAVY COMPONENTS: Casting (pit moulding) and fabrication of components like machine tool parts pressure vessels, scooter frame and press frames. Text Books: 1. Product design and manufacture. A.K.Chitale, R.C.Gupta Prentice Hall India, 1997 2. Design and manufacture An integrated approach. Rod Black Macmillan Publishing Company, 1996. Reference: 1. Automation, Production system and Computer Integrated Manufacturing, Michael, P.Groover Prentice Hall, 1980. 2. Purchasing and Materials Management Donald, W.Dobler, Lamer Lee Jr and David N burt, 1989.

MPIE 206.5
Goals:

DECISION MODELS

Focus on quantitative and qualitative decision models and techniques for technical and managerial problems. Emphasis on application and interpretation of results. The goal of this course is to provide the student with an understanding of how various business situations can be modelled effectively as mathematical models using optimisation and stochastic modelling techniques. We will learn, through examples and cases, how such techniques provide framework for decision making when information from several sources need to be integrated and we will understand the benefits of an aggregate approach over linear decision process. We will learn how to incorporate multiple decision criterion and uncertainty in the decision process. We will learn modelling techniques that are suitable for taking decisions with partial information, and situations that are naturally modelled as a network of queues using simulation. The skills learned in the course should enhance students ability to think methodically while making important decisions. This course should be of primary interest to people aspiring to a career in general management or leading the engineering function in an enterprise. It should be of interest to people who may manage and participate in the decision process in operations and other business functions such as marketing, finance, accounting and human resources.

Topic outline
Module 1 Decision trees, Influence diagrams Module 2 Weighting methods. Value of information. Module 3 Analytical hierarchy process. Bayes theorem. Module 4 Monte Carlo simulation. Utility theory. Module 5 Risk analysis. Group decision-making.

Reference: 1. Management Science and Decision Technology; Jeffrey D. Camm and James R. Evans South-Western Thomson Leaning, 2000, ISBN # 0-324-00715-9 2. Data, Models, and Decisions: The fundamentals of Management Science, by Dimitris Bertsimas and Robert M. Freund, South-Western Thomson Learning, 2000 Additional Topics: Statistical Sampling, More advanced coverage of regression models, non-linear and discrete optimisation. Comments: Material at slightly more advanced level, more advanced examples 3. Quantitative Methods for Business, 8th Ed, by Anderson, Sweeney and Williams, South-western Thomson Learning Additional Topics: Markov Decision Process Comments: Material at more introductory level, but nicely organised. 4. Introductory Management Science, by Eppen, Gould, Schmidt, Moore and Weatherford, Prentice Hall, 1998 Additional Topics: Extensive discussion on basic spreadsheet modelling, and linear programming modelling in Excel, LP graphical analysis, Non-linear optimisation. Comments: Lots of very nice illstructured cases. Interesting discussion on proper consideration of sunk and variable costs 5. Applied Management Science, by Lawrence and Pasternack, John-Wiley, 1998 Additional Topics: Most topics are covered in the books mentioned above. Comments: The discussion in this book is very readable. The cases are more structured and may be viewed as large well-defined problems. 6. Practical Management Science, by Winston and Albright, Duxbury, 2001 Additional Topics: Decision-Making under Uncertainty Comments: The book is spread sheet based and tied very closely to @Risk and spread sheet solvers. Lots of very nice examples, and cases, particularly those on financial topics. 7. Managerial Spreadsheet Modelling and Analysis, by Hesse, 1997 Additional Topics: More extensive discussion on Routing Models, Integer Programming Models Comments: A well-organised book with readable examples and cases. 8. AMPL A Modelling Language for Mathematical Programming, by Fourer, Gay and Kernighan, The Scientific Press, 1993 Comments: This book serves as a reference for a very popular modelling language: AMPL. Other similar languages are GAMS and the modelling language that comes with LINDO. One can write AMPL models and submit them over www to a server at the optimisation technology centre, and get solutions to the model on line. Highly recommend this if you want to learn the use of mathematical modeling beyond the use within spreadsheets. 9. Simulation with Arena, by Kelton, Sadowski and Sadowski. McGraw Hill 1997. Comments: Arena is one of the most popular user-friendly simulation software, which has been used extensive to model queuing system. This book has a good introduction to discrete event simulation. The book is shipped with an academic version of Arena software.

MPIE 206.6

FINITE ELEMENT ANALYSIS

Introduction to FEM: Engineering design analysis meaning and purpose-steady state, propagation and transient problems-basic concepts of FEM applicability of FEM to structural analysis, heat transfer and fluid flow problems-advantages and limitations of FEM, commercial finite element packages organization advantages & limitations. Static analysis: General procedure of FEM skeletal and continuum structures Discretization of domain-basic types of elements concept of stiffness analysis Direct approach Formal approach using Shape Functions Reyleigh Ritz methodformulation of elements stiffness matrices truss, beam, triangular, quadrilateral and brick elements Isoparametric elements Axisymmetric elements. Dynamic analysis: equations of motion for dynamic problems consistent and lumped mass matrices formulation of element mass matrices tree vibration and forced vibration problem formulation. Solution methods for finite element equations: Handling of simultaneous equations Gaussian elimination method Choleski method solving of eigen value problems Jacobi & subspace iteration methods direct integration and mode superposition method Interpolation techniques. Heat transfer and fluid flow analysis: basic equations of heat transfer & fluid flow problems Galerkin method finite element formulation one dimensional heat and fluid flow problems. Mechanism analysis: Introduction to analysis of mechanisms creation of kinematics models imposement of constraints and forces inertial data static and dynamic analysis of kinematics system analysis of output data animation displacement, velocity and acceleration functions.

MPIE 206. 7
Goals:

ADVANCED OPERATIONS RESEARCH APPLICATIONS

The course is designed to develop an understanding of operation research with Particular attention to linear programming, network analysis, dynamic programming, and Integer programming. Topics: Module 1 Linear Programming a. Problem formulation b. Graphical solution c. Interpretations

d. Simplex method e. Duality theory f. Sensitivity analysis Module 2 Network Analysis a. Shortest route problem b. Minimal spanning tree problem c. Maximum flow problem Module 3 Integer Programming a. Graphical method b. The branch and bound technique c. Gomarys cutting plane method d. Transportation problem Module 4 Goal Programming a. Goal programming formulation b. Goal programming algorithms a. Weighting Method b. Preemptive Method Module 5 Dynamic Programming a. Prototype example b. Characteristic of Dynamic Programming c. Deterministic Dynamic Programming Course Outcomes: 1. Students will have a working knowledge of operation research techniques such as linear programming, Integer Programming, Goal Programming and Dynamic Programming. 2. Students will have the ability to analyse and perform sensitivity analysis on different Optimum solutions generated. 3. Students will have the ability to tackle real life optimisation problems. Reference Books: 1. Hamda & Taha, Operations Research - 7th edn; Pearson 2. Ravindran, Phillips, Solberg: Operations Research Principles and Practice, Willey & Sons 1987. 3. Ronald L.Rardin, Optimisation in Operation Research, Pearson Education 4. Verma A.P., Operation Research, S.K.Katharia & Sons 5. Winston W. L.: Operations Research: Applications and Algorithms (3rd ed.), PWS-Kent Pub, (1994).

6. Gnedenko B., Kovalenko I.: Introduction to Queuing Theory, Birkhauser, 1987. 7. Kon-Popovska M.: Mre`no planirawe, analiza na tro{oci, analiza na resursi, Matemati~ka {kola, 1979.)

MPIE 207

A TEAM EXERCISES

The student will take part in a primarily design-based group/team exercise, giving him experience in managing a long-term project. The student will be encouraged to work within his team in competition with the other teams, planning and carrying out the work within a set time frame

MPIE 208

CAD/CAM

LABORATORY

Review: Study of chip formation in turning process; Study of operation of tool & cutter grinder, Twist drill grinder, centreless grinder; Determination of cutting forces in turning; Inspection of parts using toolmakers microscope, roughness and form tester; Studies on PLC programming. Condition monitoring in machining processes using acoustic emission. Determination of cutting forces in drilling and broaching; Experiments in cylindrical grinding process. Objective: At the end of this laboratory course you must be able to Create and Edit solid models and working drawings Perform Static and Dynamic analysis using FEM Program and Simulate CNC machine tool operations Program an industrial robot for simple material handling tasks Demonstrate the capabilities of a CMM for quality control 1. Exercises on solid modeling Introduction to computer graphics - viewing transformations, curves and surfaces generation, curve fitting and curve fairing techniques - 2D, wire frame, 3D shading familiarity with Boolean operations - sweep, revolve, loft, extrude, filleting, chamfer, splines etc. - windowing, view point, clipping, scaling and rotation transformations using commercial solid modeling packages 2. Exercises on finite element analysis Introduction to FEM - 1D, 2D and 3D elements - shape functions - preprocessing - boundary conditions, structured and free mesh generation - analysis - linear and non linear analysis - static and dynamic analysis - post processing - display, animation, extraction of nodal data - exercises on heat conduction and elasticity may be given using commercial FEM packages

3. Assembly and mechanism design Assembling of various parts and tolerance analysis - synthesis and design of mechanisms - animations - exercises on various mechanisms like four bar linkages and its variations - cam and follower - two and four stroke engines 4. Computer aided manufacturing Part programming fundamentals - manual part programming and computer aided part programming - hands on training in computer controlled turning and milling operations - familiarity with windows based software packages - tool path generation and simulation - exercises on CNC lathe and machining centre /milling machines 5. Programming of industrial robots Introduction to robotics - structure, workspace analysis and various components actuators - sensors - encoders - end effectors - applications - hands on training on industrial robots - manual and programmed path planning 6. Computer aided inspection and quality control Introduction to CMM - classification - structure - components - familiarity with measurement software packages and its modules - demonstration of the capability of coordinate measuring machine using a sample component e.g. - engine block - concepts of reverse engineering and rapid prototyping technology Reference: 1. Rogers D.F. & Adams J.A., "Mathematical Elements for Computer Graphics", McGraw Hill, 2nd Edition. 2. Rogers David F., "Procedural Elements for Computer Graphics", McGraw Hill 3. Cook, Robert Davis et al., "Concepts and Applications of Finite Element Analysis", John Wiley & Sons. 4. Koren Yoram, "Computer Control of Manufacturing Systems", McGraw Hill. 5. Kundra Rao & Tewari, "Numerical Control and Computer Aided Manufacturing", Tata McGraw Hill. 2. Ramamurthy V., "Computer Aided Mechanical Design", Tata McGraw Hill 3. Fu K.S., Gonzalez R.C. & Lee C.S.G., "Robotics: Control, Sensing, Vision and Intelligence", McGraw Hill. 4. Koren Yoram, "Robotics for Engineers", McGraw Hill. 5. John A. Bosch, "Coordinate Measuring Machines and Systems", Marcel Decker Inc. 6. Learning Computer Numerical Control, By Michael Janke, Delmar Publishers Inc.