SHRI GURU GOBIND SINGHJI INSTITUTE OF ENGINEERING TECHNOLOGY VISHNUPURI, NANDED 431 606 B. Tech (PRODUCTION) w.e.f.

2008-09
Sr No 1 2 3 4 5 6 7 PR415 PR416 PR417 Course Code PR411 PR412 PR413 PR414 Theory Tutorial Practical/Sessional (Hrs/Week) (Hrs/Week) (Hrs/Week) Semester VII 4 4 4 4 3 3 3 3 ----1 --01 ----1 -01 Elective IV Finite Element Analysis Product Design Engg. Management Information System Plastic and Powder Metallurgy Processes 2 2 2 2 2 2 2 14 2 2 2 2 2 6 16

Course Name Production Management I Quality and Reliability Engineering Design and Automation Micro-Nano. Fabrication Techniques. Elective-III Project-I In plant Training

Credits

5 3 2 -2 -25 15 Semester VIII 4 4 4 4 5 4 25 Sr No 1 2 3 4 3 3 3 3 3 -15 Course Code PR425 A PR425 B PR425 C PR425 D

8 9 10 11 12 13

PR421 PR422 PR423

PR424 PR425 PR426

Production Management-II Total Quality Management Productivity Improvement Techniques Costing and Estimation Elective-IV Project-II Total Elective III Plant Engineering Modern Management Techniques Automotive Mechanics Entrepreneurship Development

Sr No 1 2 3 4

Course Code PR415 A PR415 B PR415 C PR415 D

Chairman, DUGPC and Head, Production Engineering Department

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

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, Shewarts 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.

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

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:
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 1.

MICRO AND NANO MANUFACTURING TECHNIQUES (PR 414)

Introduction: Need, evolution, fundamentals and trends in micro and nano technologies; Consequences of the technology and society; Moores 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.

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)

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. 2. 3. 4. 5. 6. 7. 8. 9. 10. Industrial Engineering and Management - O.P. Khanna Industrial Organization and Engineering Economics-T.R.Banga & S.C.Sharma. Production Planning Control & Industrial Management. - K.C.Jain & L.N. Aggarwal. Maintenance engineering and management sushil kumar srivastav (chand) Production and operation Management - Nair (TMH) Production and operation Management S N chary(TMH) Production hand book - IVth Edition (Willey) Fundamentals of Production Systems and Engineering. - Sekhan & A.S.Sachdeva. Production Management - Lallan Prasad & A.M. Banerjee. Maintenance & Spares Part Mgt. P. Gopalkrishnan (PHI)

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. 2. 3. 4. 5. 6. 7. 8. KANBAN - JIT at TOYOTA edited by J.M.A. translated by J.Lu. Leteral Thinking - Mechanism of Mind - Edward De-bone. JIT - David Hukhins. SMED - Hingo Shingo - Singora Daudri, Tokyo. Kaizen - Masaaki Imai. Industrial Economy of India - Kuchal S.G. Poka-yoka - Hiroyuti Hirame - Prodictivity Press, Cambridge. ANON, 1987 Quick Changeover Training Module, Achiving Quick. - Productivity Inc., Connecticut.

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.

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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. 2. 3. 4. 5. Small business management fundamentals, Dan Stienboff and John F Burgeess Developing new entrepreneurs- Entrepreneurship development Institute Ahmedabad A hand book for new entrepreneur- Entrepreneurship development Institute Ahmedabad Developing motivation through experiencing, Parikh and Rao Hand book of entrepreneurship- M V Nadkarni

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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 authors name in the text.

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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.

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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, Johnsons 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

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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, Taguchis recommended design techniques, O.A., Taguchis analysis techniques, performance measures, Shainins 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. 2. 3. 4. 5. 6. 7. 8. Quality planning & analysis - J.M. Juran, Frank M.Gryna. Total Quality Management Logothetis Total Quality Management Banks Total Quality Control Essentials - Sarv Singh Soin - McGraw Hill Ltd. Quality Circles Master Guide- Sud Ingle (PHI Publication) Taguchi Techniques for quality engineering - Philip J. Ross McGraw Hill Ltd. QFD linking a company with its customers- Ronald G.Day. McGraw Hill Ltd. The complete ISO Manual - Denniss Green.

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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. 2. 3. 4. 5. 6. Introduction to work study - ILO Motion & Time study Design & Measurement of Work - Ralph Barnes Eastern). Work Study - R.M. Currie & J.Faraday. (ELBS Pitman). Hand Book of Industrial Engineering - Irson & Grant. Productivity management - Concepts & Techniques- S.C.Sawhney. (Wiley

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COSTING AND ESTIMATION (PR 424)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Cost concepts and terminology Costing and Cost estimation fundamentals Cost-Volume-Profit analysis Cost comparison: Time value of money, Cost comparison with equal and unequal durations, concept of unacost and capitalized cost; Depreciation fund calculation methods Job costing Process cost estimation Activity-Based Costing Tools for planning and control: Budgets, Inventory costing and capacity analysis Cost allocation Investment decisions and management control systems

Term Work: Assignments based on the above syllabus. Books:

1. 2. 3. 4. 5. 6. 7. Cost Accounting A managerial emphasis, Horngren, Datar and Foster; 11th ed., Pearson Education. Cost Accounting, Edward B. Deakin and M.W. Maher, Richard D. Irwin Inc. Cost and Optimization Engineering, F.C. Jelen and J.H. Black, McGraw Hill Int. Competitive Manufacturing Management, John. M. Nicholas, McGraw Hill Int. Mechanical Estimation and Costing, Banga Sharma, Mechanical Estimation and Costing, D.Kannapan et.al., TTTI, Madras Mechanical Estimation and Costing, B.P. Sinha

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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. 2. 3. Introduction to Finite Element Method in Engineering by S.S.Rao, Butterworth Heinmann Publication. Finite Element Procedures by Bathe K.J., Prentice Hall of India, New Delhi. ANSYS & other software manuals.

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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. 2. 3. Engineering Design by Dieter George E. McGraw Hill Pub. Company, 2000. Product design and development by Ulrich Karl T and Eppinger Steven D., McGraw Hill Pub. Company 1995. 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

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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. 2. 3. 4. Jawadekar, W. S. (2002): Management Information Systems, Tata McGraw Hill Publishers. Davis, G.B. and Olson M.H. (1985): MISs Conceptual foundations, Structure and development, McGraw-Hill International editions. Hussain, K. M. and D. Hussain : Information Systems Analysis, Design and Implementation, Tata McGraw Hill Publishers. OBrien, James (2002): MISs Managing IT in the E-Business Enterprise, 5th Ed., Tata McGraw Hill Publishers.

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ELECTIVE-IV: PLASTIC AND POWDER METALLURGY PROCESSES (PR 425 D)

A] 1.

PLASTIC ENGINEERING 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) Processing of plastics by compression, transfer, injection, extrusion, and blow molding. Calendaring, rotational molding. (10L) Themorming, casting, forming, laminate forming, reinforced plastic, printing, embossing, welding and head sealing. (4L) Extrusion dies, simple shapes, tubing film and sheet, heating and cooling molding (3L) Design of plastic products. (6L)

2.

3.

4. 5.

B] 6.

POWDER METALLURGY: 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.

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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

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