btech prod 2011
TRANSCRIPT
SHRI GURU GOBIND SINGHJI INSTITUTE OF ENGINEERING
TECHNOLOGY VISHNUPURI, NANDED – 431 606
B. Tech (PRODUCTION) w.e.f. 2008-09
Sr
No
Course
Code Course Name Credits
Theory
(Hrs/Week)
Tutorial
(Hrs/Week)
Practical/Sessional
(Hrs/Week)
Semester VII
1 PR411 Production
Management –I 4 3 -- 2
2 PR412 Quality and Reliability
Engineering 4 3 -- 2
3 PR413 Design and Automation 4 3 -- 2
4
PR414 Micro-Nano.
Fabrication
Techniques.
4 3 -- 2
5 PR415 Elective-III 5 3 1 2
6 PR416 Project-I 2 -- -- 2
7 PR417 In plant Training 2 -- -- 2
25 15 01 14
Semester VIII
8 PR421 Production
Management-II 4 3 -- 2
9 PR422 Total Quality
Management 4 3 -- 2
10
PR423 Productivity
Improvement
Techniques
4 3 -- 2
11 PR424 Costing and Estimation 4 3 -- 2
12 PR425 Elective-IV 5 3 1 2
13 PR426 Project-II 4 -- -- 6
Total 25 15 01 16
Sr
No
Course
Code
Elective – III Sr No Course
Code
Elective – IV
1 PR415 A Plant Engineering 1 PR425 A Finite Element Analysis
2 PR415 B Modern Management
Techniques
2 PR425 B Product Design Engg.
3 PR415 C Automotive Mechanics 3 PR425 C Management Information System
4 PR415 D Entrepreneurship
Development
4 PR425 D Plastic and Powder Metallurgy
Processes
Chairman, DUGPC and
Head, Production Engineering Department
2
PRODUCTION MANAGEMENT – I (PR 411)
Operations Strategy
Competitive priorities. Strategic decisions in operations. Strategy deployment
Forecasting
Casual and Time series models, Simple and weighted moving average, Exponential smoothing,
Trend and Seasonality.
Layout
Designing process layouts, product layouts, and service layouts. Line balancing.
Capacity Planning
Defining and measuring capacity. Determinants of effective capacity. Capacity planning
decisions. Tools for capacity planning.
Inventory Management
Inventory Costs, Functions, Inventory control systems, How much to order – EOQ, EPQ, FOI,
Quantity discounts.
Project Management
CPM, PERT, Time scale diagrams, Resource leveling and smoothing, Crashing.
Term Work
Minimum Six assignments based on the above syllabus.
Practical Examination
It shall consist of oral based on the term work and the above syllabus.
References Operations Management – Krajewski and Ritzman
Operations Management – Russell and Taylor
Production planning and Inventory Control – Narsimnhan, Maleavey, and Billington.
Operations Management – Stevenson
Production and operation management – Adam and Ebert
Production and operation management – Martinich
3
QUALITY AND RELIABILITY ENGINEERING (PR412)
Introduction : (2 hrs)
Quality - The changing business condition. Significance and meaning of quality, quality function,
various definitions of quality viz. Juran, P. Crosby ASQC, ISO 9000, Taguchi, etc. and their
comparison, brief discussion on quality of design, quality of manufacturing and quality
assurance.
Basic Probability Concepts : (4 hrs)
The histogram, Box-and-whisker plot, numerical indices for summarizing data (mean, median,
standard deviation, etc) probability distribution (Normal, Exponential, poisson, Binomial )
concept, nature and applicability.
Statistical Tools For Analyzing Data: (4 hrs)
Scope of data analysis, statistical inference, sampling variation and sampling distribution,
statistical estimation: confidence limits, importance of confidence limits in planning test
programs, sample size determination for given accuracy. Hypothesis testing and drawing
conclusion, determination of sample size required for testing of hypothesis. Simple numerical
based on above.
Control Charts: (8 hrs)
Control Chart Point of View, System of Chance Causes, Patterns of Variations SPAN- PLAN
Method, Interpretation of Lack of Statistical Control, Interpretation of Patterns of Variation on X
& R Charts, Shewart’s Normal Bowl, Estimation of Control Limits For X, R Charts. Control
Charts For Variables, Control Chart Points of View, X & R, 6 Charts, Control Charts For
Attributes: p, c, np, u-Charts.
Process Capability Analysis: (4hrs)
Objectives Of Analysis, Estimation Of Process Capability, Process Capability Indices, Viz: Cp,
Cpk, Cpm, And Their Interpretation.
Scientific Sampling : (10 Hrs)
Concept and importance of sampling, economics of inspection, symbols and terms used in
relation to sampling plans.
Lot-by-lot acceptance using single sampling plan, OC curves, sampling risk, AQL, LTPD,
alpha and beta risk, construction of OC curve for given sampling plan, estimating alpha and beta
risks for a given plan. Effect of lot size, sample size, acceptance number, producer's and
customer's risk. Indexing of acceptance sampling plans by using a single point on OC curve.
Average outgoing and the AOQL. Double sampling plans, analysis of double sampling plans,
minimizing average total inspection.
Use of ANSI/ASQC Z 1.4 standards for attribute sampling plans switching procedure for
normal and tightened inspections. Calculation of average sample numbers in double sampling
plans. Use of Dodge - Romig sampling plans. Construction of OC curves. Estimation of average
inspection, sampling risks, etc. for single and double sampling plans selected for the standard
plan.
Reliability Engineering : (8 hrs.)
Introduction, Bathtub curve, causes of failure, concepts/definitions of reliability availability,
maintainability.
4
Computation of component reliability: failure rate, hazard rate, MTBF, MTTF etc. Reliability of
series and parallel systems, redundancy, product/component design analysis using FMECA and
fault tree analysis
TERM WORK :
1. One assignment on test on hypothesis.
2. Two assignments / case studies on each of the control charts.
3. Two assignments on special control charts.
4. One assignment on process capability study.
5. Construction of OC curve for sampling plan selected from the standard.
6. Estimation of quality indices, average inspection and other such parameters for double
sampling.
7. One assignment on reliability.
PRACTICAL EXAMINATION :
It shall consist of oral based on the above syllabus and term work.
REFERENCE :
1. Quality Planning and Analysis - J.M. Juran, Frank M. Gryna - Tata McGraw Hill.
2. Statistical Quality Control - E.L.Grant, R.S. Leavenworth. - Tata McGraw Hill.
3. Assurance Science - Walter A Shewart.
4. Quality Control - Besterfield. - Prentice Hall, New Jercy.
5. Introduction to Reliability in Design - Charles O. Smith - McGraw Hill Ltd.
6. Mechanical Reliability – L.S.Srinath.
7. Quality Control & Reliability Analysis, - Dr.Brijendra Singh
5
DESIGN AUTOMATION (PR 413)
1. Introduction to Design Automation: System customization, Design automation, Scope,
Need and necessity, Typical facilities for system customization, Open source CAD and
commercial CAD CAE CAM systems.
2. Overview of Tools for Automation of various CAD CAM Software: Macro, Scripts and
Application Programming Interfaces (API) (General purpose and System dependent API)
in various CAD CAM software like AutoCAD, Autodesk Inventor Professional, UG/NX,
Solid Works, CATIA, Pro-Engineer, ANSYS, Hypermesh, etc
3. General Purpose APIs – Introduction to Visual BASIC (VB) and VB for Applications
(VBA); Objects; AutoCAD VBA environment; VBA application in AutoCAD;
Introduction to OOP and AutoCAD Object Oriented Database; AutoCAD Object Model,
Class modules and Objects, VB and VBA;
4. Graphical User Interface (GUI) Design: Menu design; Dialog box design using Dialog
Control Language (DCL) in AutoCAD, User Interface (UI) Styler Application in
UG/NX;
5. Spreadsheet and database applications for Design Automation: Wizards and
smartmasters. Macros and VB in Excel and MS Access; VB and MS Access interface.
6. Database Interfaces in CAD CAM Software: Part Families creation; Data storage;
Accessing external databases; Viewing and editing table data from AutoCAD;
7. Introduction to Design analysis automation in ANSYS and Hypermesh: Introduction to
APDL; Introduction to TCL/TK
8. Introduction to OpenGL: 3D Graphics Fundamentals; What is OpenGL; Using OpenGL;
9. Artificial Intelligence (AI) in Design: Basic concepts, representing knowledge, Inference
schemes, Approaches to application of AI in design, Knowledge-Based Engineering,
Knowledge Fusion Application in UG/NX, Visual Prolog based applications for design
automation
10. Case studies: Design automation applications for design of bearings, couplings, springs,
mold-base, dies, gears, cams and other mechanical engineering parts and assemblies.
Term Work: Assignments based on the above syllabus.
Books:
1. McMahon, Chris and Jimmie Brown (2000): CAD CAM Principles, Practice and Manufacturing
Management, Addison-Wesley Longman Ltd/Pearson Education Asia Ltd.
2. Tickoo, Sham (2000): Customizing AutoCAD 2000, Autodesk Press, Thomson Learning.
3. Krammer, Bill and John Gibb (1999): AutoCAD VBA Programming – Tools and techniques,
CADENCE, Miller Freeman Books Publishers.
4. Wright, Richard S and Michael Sweet (2000): OpenGL Super bible, Waite Group Press/BPB
Publications.
5. Omura, George: Advanced AutoCAD, BPB Publications
6. AutoCAD and Autodesk Inventor Professional (AIP) Software Documentation
7. Solid Works Software Documentation
8. UG/NX Software Documentation on Knowledge Fusion
9. Solid Edge Software Documentation
10. MS Excel Software Documentation
11. MS Access Software Documentation
6
MICRO AND NANO MANUFACTURING TECHNIQUES (PR 414)
Introduction: Need, evolution, fundamentals and trends in micro and nano technologies;
Consequences of the technology and society; Moore’s law , challenges to manufacturing
technology; evolution of precision in manufacturing, tooling and current scenario; micro- nana
fabrication tool, requirements and scales. [8 Hrs]
Mecahnical Micro Machining: Introduction, principle, tools and application of : Micro -
Drilling, Turning, Milling, Diamond turning, Grinding, honing, lapping, and super finishing. [8
Hrs]
Non-conventional micro-nano manufacturing and finishing approaches: Manufacturing and
finishing approaches like, WAJM,USM, AFM, MAF micro: ECM, EDM, WEDM, LBM, EB,
Focused ion beams, Hybrid processes, ELID- process principle, application and technological
information, chemical machining and mechanochemical finishing. [12 hrs]
Modelling and Analysis approach and size effect for micro machining. Introduction to Nano
machining. [4 Hrs]
Generative and other processing routes: Lithography techniques, PVD, CVD, LIGA, Electro
and Electroless deposition; nano structured films and coatings, sputtering deposition [6 hrs]
Characterization and metrology tools: Introduction and example of SEM, XRD,AFM, TEM,
indentation, scanning tunneling microscope, etc, on machine measuring devices, micro CMM,
accuracy and precision introductory treatment and awareness. [4 hrs]
Micro assembly: MEMS, NEMS, Market prospects assembly problems, micro assembly systems
and example, micro robots and applications, flip-chip technology and joining of micro parts. [4
hrs]
Practical/Sessionals
It shall consists of: assignments (at least three) based on the syllabus, quizzes, term paper,
information regarding the recent advances and green areas (based on the classics and web pages)
etc.
References
Fundamentals of Machining Processes, Hassan El-Hofy, Taylor and Francis, 2007.
Nontraditional Manufacturing Processes – G.F.BENEDICT (MARCEL DEKKER JNC.)
Non-conventional machining by – P.K. MISHRA (NAROSA PUBLICATIONS)
Advanced Machining Processes, by V. K. Jain, Allied Publishers Pvt. Ltd, (2005)
Private communications: lecture notes of STTP on Micromachining, held at IIT Kanpur; June 2007
Private communications: lecture notes of SERC school on Micromachining, held at IIT, Bombay,
Mumbai; June 2008.
Related web pages.
7
ELECTIVE-III: PLANT ENGINEERING (PR 415 A)
LOCATION PLANNING Concept, factors governing location, locational economics, rural and urban sites : advantages and
limitations, location patterns of Indian industries, steps in plant location planning, methods of
choosing best alternative locations, methods for making decisions by techniques like dimensional
analysis, break even analysis etc. (6 hrs)
MATERIAL HANDLING Introduction, objectives, principles of material handling, computation of material handling cost,
MH survey check sheet, and details methods of material handling MH equipments: selection,
types, principle of unit load, concept of containerization and palletization, robots as MH devices,
AGVS: types and scope, analysis of handling. (4 hrs)
PLANT LAYOUT PLANNING
Introduction, types of production, features of layout, basic principles, basic types of layouts such
as process layout, product layout, fixed position layout, merits and demerits of each type, flow
lines, symptoms of bad layout, optimization of layout, problem solving in layout, cellular
manufacturing as a solution to conventional layout problems, cell formation methods, benefits
and limitations of cellular manufacturing. (6 hrs)
MAINTENANCE MANAGEMENT Introduction,
Objectives, economic aspect of maintenance, planning of maintenance work optimum degree of
maintenance efforts, types of failure probability distribution and their significance in formation of
maintenance policy.
Maintenance systems
Break down maintenance, routine maintenance, planned maintenance, preventive maintenance,
predictive maintenance, corrective maintenance, design out maintenance, proactive maintenance,
and total productive maintenance.
Defect/failure generation and analysis
Basics of failure, failure generation, fault tree analysis, ETA, RCA, failure mode and effects
analysis.
Condition monitoring
Condition signals and monitoring, condition monitoring techniques like performance, visual,
temperature, vibration, lubricant, leakage, crack, corrosion, noise/sound monitoring, SOAP, etc.
Maintenance evaluation Overall equipment effectiveness, equipment availability, maintenance performance measuring
indices, maintenance audit. (12 hrs)
REPLACEMENT ANALYSIS Introduction, reasons for replacement, factors affecting replacement methods used for selecting
alternatives, cost comparison for replacement analysis considering inflation and technological
advancements, present worth method, Annual cost method, rate of return method, depreciation
method, life average method etc. (6 hrs)
PLANT HOUSE KEEPING Introduction, need for house-keeping, planning aids for house-keeping employee participation,
Management responsibilities, cost of accidents, injured cost to Management, society statistics of
accidents, safety organizations, plant safety inspection, safety management, its significance
principles and guide lines. (2 hrs)
8
WASTE, SCRAP DISPOSAL AND SAMPLES MANAGEMENT
Basic concepts, causes and remedies of wastage, wastage resources and preventive step, wastage
control program, salvage operations, scrap disposal, organization, and samples management. (4
hrs)
TERM WORK
Minimum eight assignments based on the above syllabus.
PRACTICAL EXAMINATION
It shall consist of oral based on the term work and the above syllabus
REFERENCE BOOKS
1. Industrial Engineering and Management - O.P. Khanna
2. Industrial Organization and Engineering Economics-T.R.Banga & S.C.Sharma.
3. Production Planning Control & Industrial Management. - K.C.Jain & L.N. Aggarwal.
4. Maintenance engineering and management –sushil kumar srivastav (chand)
5. Production and operation Management - Nair (TMH)
6. Production and operation Management – S N chary(TMH)
7. Production hand book - IVth Edition (Willey)
8. Fundamentals of Production Systems and Engineering. - Sekhan & A.S.Sachdeva.
9. Production Management - Lallan Prasad & A.M. Banerjee.
10. Maintenance & Spares Part Mgt. – P. Gopalkrishnan (PHI)
9
ELECTIVE-III: MODERN MANAGEMENT TECHNIQUES (PR 415 B)
Creativity
Definition, barriers to creativity lateral thinking : Definition, scope, mechanism of mind,
Techniques for lateral thinking, six thinking hats, practical thinking Techniques mathematical
thinking. (6hrs)
Kaizen
Continuous method improvement, Kaizen concept, Kaizen umbrella for quality improvement,
Kaizen and Management, implications of QC for Kaizen, Kaizen and TQC, Kaizenand
suggestion systems, Kaizen and competition, process oriented Management versus result
oriented Management, Kaizen and innovation, Kaizen and measurement, PDCA cycle, Kaizen
the practice, Kaizen Management. ( 8 hrs)
Just In Time
Concept, scope, objectives, push and pull system, reduced inventories and improved setup times,
source of profit is in the manufacturing process, TOYOTA production system, basic assumption
behind the TOYOTA production system, leveling - smoothing out the production system, JIT and
automation, workplace control through the Kaizen system. Concept of flexible manufacturing cell
and group technology, customization of manufacturing ( 05 hrs)
Single Minute Exchange of Dies
Aspects of setup activities, internal and external setup, fundamentals of SMED, setup
improvement conceptual stages, Techniques for streamlining the aspects of setup, effects of
SMED, one touch exchange of dies (OTED) ( 8 hrs)
Poka-Yoke Systems
Basic concept, approaching the zero quality control methods successive and self checks, cycle
for manufacturing errors and defects, checks based on sensory inspections, source inspection
and its significance. Inspection and automation, classification on poka-yoke systems, control
type, warning type, contact method, fixed value method, detection measures for poka-yoke
system, poka-yoke systems implementation and limitations, examples of poka-yoke system. (8
hrs)
LPG and Indian Undustry
Concept, its requirement for Indian Industry, need of fastening LPG, evaluation of LPG in
context of new industrial policy 1991, relevance of MMT for LPG. ( 5 hrs)
References
1. KANBAN - JIT at TOYOTA edited by J.M.A. translated by J.Lu.
2. Leteral Thinking - Mechanism of Mind - Edward De-bone.
3. JIT - David Hukhins.
4. SMED - Hingo Shingo - Singora Daudri, Tokyo.
5. Kaizen - Masaaki Imai.
6. Industrial Economy of India - Kuchal S.G.
7. Poka-yoka - Hiroyuti Hirame - Prodictivity Press, Cambridge.
8. ANON, 1987 Quick Changeover Training Module, Achiving Quick. - Productivity Inc., Connecticut.
10
ELECTIVE-III: AUTOMOTIVE MECHANICS (PR 415 C)
Automotive Drive Trains
Clutch construction, hydraulic and electronic controls, clutch noises, diagnosis and adjustments,
Gears and gearing, gear shifting and shift linkage, Transmission and transaxle construction and
operation, trouble diagnosis and service, Drive lines, universal joints, CV joints, half shafts, drive
axles, final drive gears and differential, diagnosis and service, All wheel drive, central
differential, viscous coupling, Torque convertor and torque convertor clutch, planetary gears,
hydraulic and electronic shift controls, continuously variable and other automatic transmissions,
Automotive Suspension Systems
MacPherson struts, ball joints and torsion bars, electronic ride control and air suspension systems,
sonar shock absorbers and active suspension system, inspecting suspension components
Automotive Steering Systems
Recirculating ball joints and rack and pinion steering gears, electronic power steering and four
wheel steering, wheel alignment angles, scrub radius and thrust angle, inspecting ball joints and
steering components
Automotive Brakes
Drum, disc, parking and power brakes, brake system valves and master cylinder, antilock braking
and traction control systems, diagnosis and service
Automotive Engine Performance and Driveability Controlling crankcase, evaporative and exhaust emissions, PCV, Evaporative, Air Injection and
EGR systems, Diagnosis of engine performance and driveability
Term Work
1. Study of Clutch assembly of a two wheeler
2. Study of Clutch assembly of a four wheeler
3. Study of complete drive mechanism of all wheel drive
4. Study of hydraulic / electronic gear shift control system
5. Study of complete assembly of one type of suspension system
6. Study of complete assembly of one type of steering system
7. Study of complete assembly of one type of braking system
8. Study of one type emission control system
Text Books and References Automobile Engineering (Vol. I & II) by Dr. Kirpal Singh, Standard Publishers
Fundamentals of Vehicle Dynamics by Thomas Gillespe
Automotive Technology by H. M. Sethi
Automobile Mechanics by W. H. Crouse, McGraw Hill Publishing Co.
Magazines like Automotive Engineering International, Overdrive, AutoIndia, etc.
11
ELECTIVE-III: ENTREPRENEURSHIP DEVELOPMENT (PR 415 D)
Introduction Entrepreneur, scope of entrepreneurship, significance of industry in wealth creation, role of
entrepreneur, facts versus myths about entrepreneurs [3 L]
Entrepreneurship awareness Qualities for entrepreneur, skills to be developed for entrepreneur, reality skills testing creativity,
high frustration tolerance, ambiguity tolerance skill, venture strategy skill, deal making skill,
contact network harvesting skill, environmental and ethical assessment skill, psychological
adoption for success [7 L]
Types of enterprises and ownership Role of SSI, government policies for SSI, causes for small firm failures, preparation for small
firm ownership, rewards for successful small firm owners, requirements for successful
management of small firms [4 L]
Planning a new business Fourteen basic steps in planning, surveying the market, objective of
market survey, types of market, procedure of market survey, significance of product design and
design styling [4 L]
Financing various sources of finance, how to get finance from govt. financial institutions, condition of govt.
finance interest, repayment etc. [3 L]
Selecting location Development and non-development zones, govt. infrastructural facilities, factors for selection
[3 L ]
Advertising and sales promotion Importance, nature of demand established and promoted, direct and indirect promotion of sales,
factors affecting prices of product and service [3 L]
Risk management Risks faced by the firm, devices to cope up with risk, coinsurance for business firms, other
insurances [3 L]
Study of existing laws for excise, customs, sales and income tax, govt. incentives for SSI, export
opportunities and need of exports [4 L]
Project Reports: Preparing a detailed project profile, registration and other formalities
[6 L]
Term work: It shall consist of detailed project report of any one product
Reference books 1. Small business management fundamentals, Dan Stienboff and John F Burgeess
2. Developing new entrepreneurs- Entrepreneurship development Institute Ahmedabad
3. A hand book for new entrepreneur- Entrepreneurship development Institute Ahmedabad
4. Developing motivation through experiencing, Parikh and Rao
5. Hand book of entrepreneurship- M V Nadkarni
12
PROJECT – I (PR 416)
The Project-I is intended to strengthen the final Project to be undertaken by the student/students
in II semester under Project-II. Hence it should be preferably treated as a preparatory work (in
consultation with guide) to fulfill the requirements for Project II in semester II.
The term work shall consist of the following:
1 A record containing the literature survey in relevant area. The candidate will have to
deliver a seminar in the presence of faculty and students based on his findings.
2 A preliminary report related to the project work to be completed under Project -II (for
part-II). This report should contain details of literature survey, collected data, details of
design and drawing, lists of components, fabrication details.
The term work will be assessed by two internal examiners appointed by the Principal of the
institution, one of whom will be his guide and a faculty of the concerned discipline. The student
shall be evaluated based on a seminar delivery, of about 30 minutes duration, on his Project-I
report.
The report should follow the guidelines as below:
a) The format of a standard Journal, e.g. ASME Trans., I.J.P.R., J. of Mtl. Pro.,
Productivity, etc., prescribed for technical paper should be followed for writing and
presenting the report.
b) The report shall consists of front cover and the title sheet, the introduction of the Project
work, the literature survey, report of any analytical or experimental work, discussions and
conclusions
c) The equations/figures should be numbered appropriately.
d) Tables should be typed in text. A separate sheet could be used if necessary.
e) The nomenclature, symbols and key words used should be mentioned separately.
f) No blank sheet be left anywhere in the report.
The references shall form the last section and would be followed by “Appendix”, if any.
References would contain list of works (papers, books etc.) refered to in the body of the text and
shall be arranged in the order in which they are cited in the text. The numbering shall be done in
numerals indicated as superscripts along with the author’s name in the text.
13
INPLANT TRAINING (PR 417)
Every student will be undergoing in-plant training for maximum 6 weeks in one Engineering
Industry immediately after T.E. examination and before admitted to final year B.E.
A student is expected to study the following aspects of the industry where he/she is undergoing
inplant training.
1. Organisation structures.
2. General plant layout.
3. Machine tools.
4. Production processes, etc.
He should submit a report on training along with the diary of activities to the head of the
department at the time of his admission to B.E. The report should be neatly typed on A-4 size
white papers with 1.5 spacing, hard or comb bound and should bear certificate of training from
the appropriate authority of the industry. The cover of comb bound copies should have
transparent front cover and non-transparent plastic back cover.
The Inplant training report shall be evaluated based on a seminar by the student or internal viva
conducted at the department.
14
PRODUCTION MANAGEMENT – II (PR 421)
Supply Chain Management
The management of supply chains, Distribution, Information Technology – A supply chain
enablers, Measuring supply chain performances.
Aggregate Planning
Process of aggregation, Relationship to other plans, Pure and mixed strategies, Chase demand and
leveling strategies, Techniques for aggregate planning.
Resource Planning
Overview of Material Requirement Planning (MRP), Master production schedule (MPS), Inputs
to MRP, The MRP process, Lot sizing in MRP systems, MRP outputs, Enterprise Resource
Planning (ERP).
Lean Production
Just in Time (JIT) and lean production.
The basic elements of lean production – Flexible resources, Cellular layouts, The Pull system,
Kanbans, Small lots, Quick setups, Uniform production levels, Quality at the source, Total
productive maintenance, Supplier networks.
Benefits and drawbacks of lean production.
Scheduling
Loading – Load profile, Gantt chart, Assignment method
Sequencing – Priority sequencing rules, Johnson’s rule, other criteria.
Scheduling – Gantt chart scheduling, Forward and backward scheduling, Theory of constraints.
Dynamics of Production / Operations Management
Rational / Technical / Behavioural change process, Strategies for behavioural change, Production
operations changes, Trends in production / operations management, System Dynamics.
Term Work
Minimum Six assignments based on the above syllabus.
Practical Examination
It shall consist of oral based on the term work and the above syllabus.
References Operations Management – Krajewski and Ritzman
Operations Management – Russell and Taylor
Production planning and Inventory Control – Narsimnhan, Maleavey, and Billington.
Operations Management – Stevenson
Production and operation management – Adam and Ebert
Production and operation management – Martinich
15
TOTAL QUALITY MANAGEMENT (PR 422)
Introduction (6 hrs)
Quality: eight dimensions of quality, Customer satisfaction and Quality concept of TQM, TQM
axioms, consequences, Key elements of TQC, Two dimensional of quality.TQM Philosophies of
Deming, Juran, P.Crossby, Imai, Ishikawa, Conway.
Assessment Of Quality Cost (5 hrs)
Objectives, Cost of poor quality, Quality cost classification, Analysis of quality cost, hidden
quality costs, Economic models of quality cost, guidelines to establish and cut down quality cost.
Off Line Quality Control (10 hrs)
Robust design, Loss function, parameter design, Taguchi’s recommended design techniques,
O.A., Taguchi’s analysis techniques, performance measures, Shainin’s approach,.
Design and Analysis of Experiments: Factorial experiments, Aliasing, Constructing fractional
factorial, Analysis of variance, Evolutionary Operations, RSM.
Tools for Quality Improvement (8 hrs)
Alternate Process Control: cusum control chart, chart for drifting process, multi-vari charts, pre
control. Seven old and new Q.C. tools, Benchmarking . Quality Circles, The PDCA cycle, Hoshin
Kanri Plan.
Quality Function Development (6 hrs)
Concept & defining QFD, product development system, QDF process, QFD matrix concept.
Deployment - part, process. T- type matrix.
ISO 9000 ( 5 hrs)
Concepts, methods & implementation. Quality management practices world wide, Quality,
Customers & ISO 9000, Company quality policy, interpretation of key ISO 9000 clauses,
Implementing ISO 9000, Indian equivalent for ISO 9000, The ISO 9001:2000 standard; steps for
certification under ISO9001:2000
References Books: 1. Quality planning & analysis - J.M. Juran, Frank M.Gryna.
2. Total Quality Management – Logothetis
3. Total Quality Management – Banks
4. Total Quality Control Essentials - Sarv Singh Soin - McGraw Hill Ltd.
5. Quality Circles Master Guide- Sud Ingle (PHI Publication)
6. Taguchi Techniques for quality engineering - Philip J. Ross -
McGraw Hill Ltd.
7. QFD linking a company with its customers- Ronald G.Day. -
McGraw Hill Ltd.
8. The complete ISO Manual - Denniss Green.
16
PRODUCTIVITY IMPROVEMENT TECHNIQUES (PR 423)
Introduction: Productivity, definitions of work study, scope, applications, relationship, between
Productivity & standard of living, basic work content, excess work content Management,
techniques to reduce excess work content due to product process and ineffective time in control
of workers and Management. (4 hrs)
Work Study: Definition, concept, relation with Productivity, human factors, good relations, work
study versus Management, supervisor, work study man, qualities of work study man, working
conditions, prevention accidents and hazards, lighting, ventilation, ergonomics etc. (6 hrs)
Method Study: Definition, objectives procedure factors affecting selection of work, recording
techniques such as outline process short, flow process chart, factory layout, flow diagrams,
developing new layout, materials handling its principles and equipment, movement of workers
and materials in working area, string diagram and its significance, travel chart, multiple activity
chart and their significance Micro motion study, two handed process chart, principles therbligs,
simochart, cycle graph, chronocylegraphs and use of films in method study. (10 hrs)
Work Measurement: Techniques, Purpose, use & basic procedure time study equipments
selection of jobs for time study, approach to workers, steps in time study data collection about
jobs, operator & surroundings breaking down jobs into elements, types of elements, selection and
measurement of each element. (6 hrs)
Job Evaluation And Merit Rating: (2 Hrs).
Introduction, Different techniques of job evaluation, Merits, Demerits, Techniques of Merit
rating, Significance of Job evaluation/merit rating with work measurement.
Time Study Rating And Allowances: Definition of rating, system of rating, wasting house
system of rating skill & effort, synthetic rating & objective rating, use of rating, factor, rating the
job, normalizing observations, types of allowances, applying the allowances. (2 hrs)
Use of the Standards: Define work covered by allowance time, work specification, work unit,
programme planning & utilization of plant & labor, estimation, standard costing, budgetary
control & incentive schemes. (2 hrs)
Other Works Measurement Techniques: Work sampling - need, establishing confidence levels,
determination of simple size, random observation, conduct of study, use of work sampling.
General study of standard data & PTS. MOST. Methods of improving Materials Productivity,
Introduction, factors affecting materials productivity. Introduction to Business Process
Reengineering. (6 Hrs)
Term Work: Minimum Eight assignments based on the above syllabus.
Practical Examination: It shall consist of oral based on the term work and the above syllabus.
Reference Books 1. Introduction to work study - ILO
2. Motion & Time study Design & Measurement of Work - Ralph Barnes (Wiley
3. Eastern).
4. Work Study - R.M. Currie & J.Faraday. (ELBS Pitman).
5. Hand Book of Industrial Engineering - Irson & Grant.
6. Productivity management - Concepts & Techniques- S.C.Sawhney.
17
COSTING AND ESTIMATION (PR 424)
1. Cost concepts and terminology
2. Costing and Cost estimation fundamentals
3. Cost-Volume-Profit analysis
4. Cost comparison: Time value of money, Cost comparison with equal and unequal
durations, concept of unacost and capitalized cost; Depreciation fund calculation methods
5. Job costing
6. Process cost estimation
7. Activity-Based Costing
8. Tools for planning and control: Budgets, Inventory costing and capacity analysis
9. Cost allocation
10. Investment decisions and management control systems
Term Work: Assignments based on the above syllabus.
Books:
1. Cost Accounting – A managerial emphasis, Horngren, Datar and Foster; 11th ed., Pearson
Education.
2. Cost Accounting, Edward B. Deakin and M.W. Maher, Richard D. Irwin Inc.
3. Cost and Optimization Engineering, F.C. Jelen and J.H. Black, McGraw Hill Int.
4. Competitive Manufacturing Management, John. M. Nicholas, McGraw Hill Int.
5. Mechanical Estimation and Costing, Banga Sharma,
6. Mechanical Estimation and Costing, D.Kannapan et.al., TTTI, Madras
7. Mechanical Estimation and Costing, B.P. Sinha
18
ELECTIVE-IV: FINITE ELEMENT ANALYSIS (PR 425 A)
FUNDAMENTAL CONCEPT OF FEM Introduction, History background, stresses & equilibrium boundary conditions, strain
displacement relations, stress – strain relations, temperature, effects, variational approach solution
techniques. (6 hrs)
DESCRIPTION OF THE METHOD
Step wise procedure of Finite element method, variational techniques for derivation of finite
element equations, assembly procedure, solution methods. (7 hrs)
FEA OF ONE DIMENSIONAL PROBLEMS Introduction, finite element modeling, shape functions, variational approach, weighted residual
approach, Assembly of finite element equations, Higher- order element, Boundary conditions,
Temperature effects. (5 hrs)
FEA OF TWO DIMENSIONAL PROBLEMS Introduction, FE modeling, formulation of constant strain triangular element, problem modeling
& boundary conditions. (6 hrs)
ISOPARAMETRIC ELEMENTS
Introduction, 2-D Isoparametric elements, the 4-nodes quadrilateral, computation of stiffness
matrix & load vectors, numerical integration, Higher Order Elements convergence criteria. (8 hrs)
PREPROCESSOR AND POST PROCESSORS
Introduction, Mesh Generation, post processing, requirements of a pre processor and post
processor, preprocessor and post processors in analysis softwares. (4 hrs)
Introduction to FEA Software like ANSYS, NASTRAN, COSMOS-WORKS (4 hrs)
TERM WORK
The term work shall consist of the following assignments, using ANSYS, Nastran, Hypermesh
and other analysis softwares.
♦ Assignment on mesh generation for different geometries
♦ Assignment on static structural analysis.
♦ Assignment on steady state thermal analysis
♦ Assignment on thermo-structural analysis
REFERENCE BOOKS
1. Introduction to Finite Element Method in Engineering by S.S.Rao, Butterworth Heinmann
Publication.
2. Finite Element Procedures by Bathe K.J., Prentice Hall of India, New Delhi.
3. ANSYS & other software manuals.
19
ELECTIVE-IV: PRODUCT DESIGN ENGINEERING (PR 425 B)
Introduction: Types of design, importance of design, design considerations, product life cycle,
technology life cycle, benchmarking and mass customization.
Product Design Process: Steps in design: need identification & problem definition, Functional
requirement analysis, defining a product development team, gathering information, concept
generation & evaluation, embodiment design, and detailed design.
Material And Manufacturing Process Selection In Design: Factors influencing material and
process selection, approaches, tools and software used in selection.
Design for ‘X’: Need, definition, Design for assembly and dissemble, Design for manufacture
(casting, forging, machining and sheet metal forming), design for reliability, Deign for
maintainability and serviceability, design for environment, design for aesthetic, design for
packaging, design for handling, design for safety, etc.
Design Cost Estimation: Need, methods, design to cost and life cycle costing and use of
software for estimation.
Product Development Approaches: Concurrent engineering, partnership with supplier,
collaborative and Internet based design.
Design Project Management: PDM, PLM and related software tools.
Case studies based on Concurrent and collaborative product development approaches,
Introduction to VRML, modular product design, mechanical and electronic products design.
Tutorial /Term Work
It shall consist of tutorial and case presentation based on the syllabus.
Text Books 1. Engineering Design by Dieter George E. McGraw Hill Pub. Company, 2000.
2. Product design and development by Ulrich Karl T and Eppinger Steven D., McGraw Hill Pub.
Company 1995.
3. Product Design and Manufacture by Chitale AK and Gupta RC, Prentice-Hall of India, New Delhi
Reference Book • Handbook of Product Design for Manufacturing, Bralla, James G., McGraw Hill Pub. 1986
20
ELECTIVE-IV: MANAGEMENT INFORMATION SYSTEMS (PR 425 C)
1. Introduction to Management Information System (MIS): Introduction; Role and
importance; Overview and structure of MIS; Strategic management of business;
2. Basics of MIS: Decision making; Information; Systems; Systems Analysis and Design;
Development of MIS; Choice of IT;
3. Applications of MIS: Applications in Manufacturing and Service sectors; Decision
Support Systems (DSS); Enterprise Management systems;
4. Technology in MIS: Technology; DBMS; Client-server architecture and networks; BPR;
data warehouse; Electronic business technology; Web based business management;
5. Case studies of MIS in various types of organizations;
6. Development, Implementation and Management of MIS resources;
Term Work: Assignments based on the above syllabus.
Books: 1. Jawadekar, W. S. (2002): Management Information Systems, Tata McGraw Hill Publishers.
2. Davis, G.B. and Olson M.H. (1985): MISs – Conceptual foundations, Structure and development,
McGraw-Hill International editions.
3. Hussain, K. M. and D. Hussain : Information Systems – Analysis, Design and Implementation,
Tata McGraw Hill Publishers.
4. O’Brien, James (2002): MISs – Managing IT in the E-Business Enterprise, 5th Ed., Tata McGraw
Hill Publishers.
21
ELECTIVE-IV: PLASTIC AND POWDER METALLURGY PROCESSES
(PR 425 D)
A] PLASTIC ENGINEERING
1. Classification of plastic on the basis of heat hardening and heat softening properties
application and methods of heat identification of thermosetting and thermoplastic
materials. Materials Additive and their effects on properties. (6L)
2. Processing of plastics by compression, transfer, injection, extrusion, and blow molding.
Calendaring, rotational molding. (10L)
3. Themorming, casting, forming, laminate forming, reinforced plastic, printing, embossing,
welding and head sealing. (4L)
4. Extrusion dies, simple shapes, tubing film and sheet, heating and cooling molding (3L)
5. Design of plastic products. (6L)
B] POWDER METALLURGY:
6. Process – Production of metal powder, powder mixing, bonding and coherence of metal
powders, the compacting operation, sintering etc.
Applications such as manufacturing of cemented carbides, self lubricated bearings,
diamond hupergnated tools etc. Advantages and limitations of the processes. (8L)
7. Application to powder metallurgical processes- (3L)
References Book:
Injection Molding _ H.C. Munnes
Theory of Plastics – Bernherd
Mould Design _ Duboise
Plastic Engineers. R.J. Crawford Elsevier ( 2006)
Engineering Metallurgy ( Part I & II) By- R.A. Higgins ( BLBS Publications)
Material Science and Metallurgy for Engineers. By- Dr. V.D. Kotgire
Composite Materials By- R.M.Jones.
Production Technology By. R.K Jain & S.C. Gupta ( Khanna Publication)
Elements of Metallurgy By- Swarup & Dr. Saxena.
22
PROJECT – II (PR 426)
This is an extension of the work already done by the student in the first term under Project - I.
The project work may be performed in the institute or in industry.
The term work shall consist of:
1. Experiment based projects
Fabrication of models, machines, prototypes based on new ideas, robots and machines based on
Hi-tech systems, experimental setups, fabrication of testing equipment/rigs. Renovation of
machines, testing equipments etc. (Above work to be taken individually or in groups.)
OR
2. Projects work with the help of softwares
Extensive analysis of some problems solved with the help of computer.
OR
3. Study projects
The project work may consist of an extensive study or analysis of field problems with
suggestions/solutions.
Project Report
The project report shall be hard bound. It is a report on the work done including design, process
charts, costing, etc. as may be relevant.
Examination
The practical examination of the project-II shall consist of an oral examination and demonstration
of the work, based on the term work