12P506 INSTRUMENTATION AND CONTROL SYSTEMS 3003

INTRODUCTION:
Basic principles of measurement Measurement systems, generalized configuration and
functional descriptions of measuring instruments examples. Dynamic performance
characteristics sources of error, Classification and elimination of error.(4)

MEASUREMENT SYSTEMS:
Resistive sensors, Potentiometer and strain gauges, Inductive sensors: Self inductance type,
mutual inductance type, LVDT. Capacitive sensors, piezoelectric sensors, Temperature
measurement: thermocouples, thermistors, radiation pyrometry, Fibre optics in temperature
measurement, pressure and flow measurement. (10)

SIGNAL CONDITIONING:
Amplification, Filtering Level conversion, Linearisation, Buffering, sample and hold circuit.
Quantization, multiplexer / demultiplexer, analog to digital converters, digital to analog
converters. (4)

INTRODUCTION TO CONTROL SYSTEMS:

Open-loop and closed-loop systems, Components of feedback control systems:
Potentiometers, synchros, servo motor, tachometers, sequential controllers. Transfer function:
Block diagram reduction, Signal flow graphs, Masons gain formula. (6)

MATHEMATICAL MODELS OF PHYSICAL SYSTEMS:

Mechanical translational and rotational systems, Fluid and Thermal systems, D.C. generator
and motor; Transportation Lag Systems. (8)

TRANSIENT RESPONSE:
Typical inputs, Time domain specifications, First and second order systems, steady state
errors. Stability: Concept of stability, necessary and sufficient conditions of stability, Routh
Hurwitz Criterion. (7)

FREQUENCY RESPONSE:
Definition, equivalence between transient response and frequency response; Bode plots,
Nyquist stability criterion: Development of the criterion; Gain and phase margins. (6)

TEXT BOOKS:
1. Ernest O Doebelin, Measurement Systems: Applications and Design, Tata McGraw Hill,
New Delhi, 2006.
2. Ogata K, Modern Control Engineering, Pearson Education, New Delhi, 2004.

REFERENCES:
1. Gopal M, Control Systems - Principles and Design, Tata McGraw Hill Company Limited,
New Delhi, 2005.
2. Rangam C S, Sarma G R and Mani V S V, Instrumentation - Devices and Systems", Tata
McGraw Hill Publishing Company Limited, New Delhi, 2005.
3. Nagrath I J and Gopal M, Control System Engineering, Wiley and Sons, New Delhi, 2004.
4. Benjamin C Kuo, Automatic Control Systems, John Wiley & Sons, Singapore, 2003.
12P602 DESIGN FOR MANUFACTURE AND ASSEMBLY 3 1 0 3.5

DFM APPROACH, SELECTION AND SUBSTITUTION OF MATERIALS:

DFM approach, DFM guidelines, standardisation, group technology, value engineering,
comparison of materials on cost basis, design for assembly, DFA index, Poka - Yoke principle;
6 concepts. (3+1)
TOLERANCE ANALYSIS:
Cumulative effect of tolerances, sure fit law, normal law and truncated normal law, obtainable
tolerances in axial dimensions for various machining operations, Process capability, process
capability metrics, Cp, Cpk, cost aspects, feature tolerances, surface finish, review of
relationship between attainable tolerance grades and different machining process. (6+2)
GEOMETRIC DIMENSIONING AND TOLERANCING:
Introduction to GD&T, ASME Y 14.5 standard. Examples for application of geometric
tolerances. 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, zero true position tolerance, functional gauges,
paper layout gauging, compound assembly, examples. (10+3)
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 translational and rotational accuracy, geometric analysis and applications.
(4+1) FORM DESIGN OF CASTINGS AND WELDMENTS: Redesign of castings based on
parting line considerations, minimising core requirements, redesigning cast members using
weldments, use of welding symbols, design of weldments. (4+1)
TOLERANCE CHARTING TECHNIQUE: Operation sequence for typical shaft type of
components, preparation of process drawings for different operations, tolerance worksheets
and centrality analysis, examples. (6+3)
DESIGN FOR MACHINING: Design features to facilitate machining, datum features -
functional and manufacturing, component design-machining considerations, redesign for
manufacture, Practical examples on references for machining. (6+2)
TEXT BOOKS:
1. Paul J Drake, Dimensioning and Tolerancing Handbook, McGraw Hill Publications, New
York, 1999.
2. Harry Peck, Designing for Manufacture, Pitman Publications, London, 1983.
REFERENCES:
1. Creveling C M, Tolerance Design - A Hand Book for Developing Optimal Specifications,
Addison Wesley Longman Inc., New York, 1997.
2. Poka-Yoke Improving Product Quality by Preventing Defects, Productivity Press, New
York, 1992. 3. Spotts M F, Dimensioning and Tolerance for Quantity Production, Prentice
Hall Inc., New Jersey, 1983. 4. James G Bralla, Hand Book of Product Design for
Manufacturing, McGraw Hill Publications, New York, 1983.
5. Oliver R Wade, Tolerance Control in Design and Manufacturing, Industrial Press Inc., New
York, 1967.
12P603 PRODUCTION AND OPERATIONS MANAGEMENT
3003
DEMAND MANAGEMENT: Demand forecasting: Types, techniques of forecasting, forecast
errors, forecast control. (3)

PLANT DESIGN: Long range capacity planning - decision tree analysis, Plant location factors,
location evaluation methods ; Plant layout types, characteristics, Introduction to layout
design techniques SLP,CRAFT; Introduction to Material handling. (7)

AGGREGATE PLANNING AND MASTER PRODUCTION SCHEDULING: Approaches to

aggregate planning: graphical, empirical and optimization; Development of master production
schedule. Introduction to MRP-I and MRP-II. (6)

INVENTORY MODELS: Classification of fixed order quantity models, deterministic demand

models - types, inventory models with probabilistic demand, price breaks, quantity discount,
safety stocks, selective inventory control techniques - Vendor managed inventories. (7)
SEQUENCING AND SCHEDULING: Scheduling process - Priority dispatching rules, n jobs
one machine, mean flow time, tardiness; Order sequencing - Johnsons algorithm n jobs 2
machines,, extended Johnsons algorithm, 2 jobs through M machines, Assignment problems -
Hungarian algorithm. (6)

WORK SYSTEMS ENGINEERING: Evolution of industrial engineering fields and functions;

industrial productivity types, work systems engineering - recording tools and techniques,
motion study, PMTS, Therbligs, work measurement, rating systems work sampling. (6)

LEAN MANUFACTURING: Value stream mapping - The as-is diagram-the future state map -
line balancing. (3)
MAINTENANCE MANAGEMENT: Repair programs, Preventive maintenance programs, Bath-
tub curve, TPM, OEE. (4)
PROJECT MANAGEMENT: PERT/CPM principles - applications; time - cost trade off
crashing. (3)

TEXT BOOKS:
1. Gaither N and Frazier G, Operations Management, CENGAGE Learning, New Delhi,
2009.
2. Jay Heizer and Barry Render, Production and Operations Management, Prentice Hall,
New Delhi, 2008.

REFERENCES:
1. Chary S N, Production and Operations Management, TMH, New Delhi, 2009.
2. Gupta P K and Hira D S, Operations Research, S Chand & Company, New Delhi, 2008.
3. Paneerselvam R, Production and Operations Management, Prentice Hall of India Private
Limited, New Delhi, 2007.
4. Askin R G and Goldberg J B, Design and Analysis of Lean Production Systems, John
Wiley and Sons Inc., New Delhi, 2003.
5. Elwood S Buffa, Modern Production / Operations Management, John Wiley & Sons Inc,
New York, 1991.
12P604 JIGS, FIXTURES AND DIE DESIGN 3024

TOOL DESIGN: Tool design objectives, Tool design in manufacturing, Planning the design,
Challenges to the tool designer, Production devices, Inspection devices. (2)
PRINCIPLES OF LOCATING AND CLAMPING ELEMENTS: Principles of location, Planes of
movement, Locating from a flat surface, Locating from a internal diameter, Locating from a
external diameter, Locating from external profile, Ejectors, Spring stop buttons, Principles of
clamping, Types of clamps, Chucks and vices, Non mechanical clamping. Power work holding,
Materials used in jigs and fixtures. (5)
DESIGN OF JIGS: Drill bush Types of bushings, Types of jigs - plate, latch, channel, box,
post, angle plate, angular post, turnover, pot, Trunnion type indexing jig, Pump jig ,Rack and
pinion operated jig, Air operated jig, Design and development of jig for given component. (6)
DESIGN OF FIXTURES: Types of fixtures - Milling, Lathe, Boring, Broaching and Grinding
fixtures, Welding fixtures, Assembly and Inspection fixtures, Modular fixtures, Design and
development of fixture for given component. (6)
POWER PRESSES: Press working terminologies, Press operations, Types of presses,
Computation of press capacity, Strip layout, Material utilization, Shearing action, Clearances,
Center of pressure. (5)
DESIGN OF PRESS WORKING TOOLS: Design and development of progressive and
compound dies for blanking and piercing operations. Die block-die shoe, Bolster plate, Punch
plate, Punch holder, Guide pins and bushes, Strippers, Knockouts, Stops, Pilots, Selection of
standard die sets, Sheet Metal Forming, Drawing, Fine blanking and bending dies. (11)
DESIGN OF PLASTIC INJECTION MOULDS: Injection moulding machine, Injection moulding
- terminologies, Mould making, General mould construction, Factors influencing quality of
moulding, Feed system - runners, gates, Ejectors, Mould cooling, Split, Side core, Moulding
internal cuts, Runner less mould. Three plate injection mould. (10)
PRACTICAL:
1. Selection of the component (1)
2. Conceptual design of jig/fixture/die (5)
3. Selection of support, locating and clamping elements. (2)
4. Detail design of jig/fixture/die (4)
5. Jig/fixture/die - prototype fabrication and testing. (10)
6. Design and development of injection moulding die using reverse engineering. (8)
TEXT BOOKS:
1. Edward G Hoffman, Jigs and Fixture Design, Thomson Delmar Learning, Singapore,
2005.
2. Pye R G W, Injection Mould Design, East West Press, 2000.
REFERENCES:
1. Joshi P H, Jigs and Fixtures, Tata McGraw Hill Publishing Company Limited, New Delhi,
2010.
2. Joshi P H, Press Tools - Design and Construction, S Chand, New Delhi, 2010.
3. Cyrll Donaldson, George H Lecain and Goold V C, Tool Design, Tata McGraw Hill, New
Delhi, 2009.
4. Prabodh C Bolur, A Guide to Injection Moulding of Plastics, Allied Publishers Limited,
2000.
5. William E Boyes, Hand book of Jig and Fixture Design, SME, 1989.
12P007 PRODUCT DEVELOPMENT STRATEGIES 300
3
PRODUCT ANALYSIS: Product design in pre and post economic liberalization, Product
Classification, product life cycle, cost, quality and servicing, concurrent engineering. (5)

DIGITAL AND PHYSICAL PROTOTYPES: Prototype development, digital prototyping,

physical prototyping, rapid prototyping, dimensional analysis and similitude, assembly and
testing. (4)

IT ENABLED PRODUCT LIFE CYCLE MANAGEMENT: Internet, concept of CPC, PDM/PLM,

Need for PLM, Importance of PLM. (4)

PRODUCT CONCEPT: Concept Generation, Concept Selection, Product Architecture,

architecture types, product modularity, types of modularity. (6)

INDUSTRIAL DESIGN: Definition, ergonomics, anthropometric data, visual effects of line and
form, color, aesthetic concepts, style, styling and design studios, CAD. (6)

ENGINEERING APPROACHES: Taguchi methods, QFD, FMEA, Fault tree analysis, Design
for six sigma, DFMA, design for safety, reliability and environment, axiomatic design. (10)

INTELLECTUAL PROPERTY RIGHTS: Introduction to IPR. Patent Searches and Application,

Patent Ownership and Transfer, Patent Infringement, New Developments and International
Patent Law. (3)

REVERSE ENGINEERING: Scanning methods, cloud points, NURBS surfaces, reengineering,

tear down approach, bench marking. (4)

MANAGING DESIGN PROJECTS: Tasks, selecting team members, Collaborators and

consultants, Design for environment issues. (3)
Total L: 45
TEXT BOOKS:
1. Karl T Ulrich and Steven D Eppinger, Product Design and Development, Tata McGraw Hill,
New Delhi, 2004.
2. Kevin Otto and Kristin Wood, Product Design, Pearson, New Delhi, 2001.

REFERENCES:
1. Michael Grieves, Product Life Cycle Management, Tata McGraw Hill, New Delhi, 2006.
2. Chitale A K and Gupta R C, Product Design and Manufacturing, Prentice Hall of India, New
Delhi, 2005.
3. Mayall W H, Industrial Design for Engineers, London Iliffe Books, London, 19