SCHEME OF TEACHING AND EXAMINATION 2010 -2011 M.

TECH - PRODUCTION MANAGEMENT (MPM) II Semester : (18 weeks) Subject Name of the subject No. of hrs /week Durati Code on of Lecture Practical Field Exam work/ in hrs Assign ment 10 MPM 21 Industrial Robotics 4 2 3 10 MPM 22 Advanced Joining Processes 4 2 3 10 MPM 23 Product Data Management 4 2 3 10 MPM 24 Finite Element Methods 4 2 3 10 MPM 25 Elective II 4 2 3 10 MPM 26 *Project Phase I (6 weeks duration) 10 MPM 27 Seminar -3 -Total 20 04 09 15 Elective II Name of the subject Non-Destructive Testing Surface Treatment & Finishing Agile Manufacturing Non-traditional Machining Processes Simulation & Modeling of Manufacturing Systems. Lean Manufacturing Systems

Marks for I.A Exam.

Total Marks

50 50 50 50 50 50 300

100 100 100 100 100 -500

150 150 150 150 150 50 800

Subject Code 10 MPM 251 10 MPM 252 10 MPM 253 10 MPM 254 10 MPM 255 10 MPM 256

* Between the II Semester and III semester. After availing a vacation of Two Weeks Note: The Internal Assessment marks for the core subjects with 2 hours of practical will have 30 marks for theory and 20 marks for practical work

II SEMISTER INDUSTRIAL ROBOTICS (Common to 10 MSE 21 / 10 MPT 21 / 10 MPE 21 / 10 MPM 21 / 10 MPY 21) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 21 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

FUNDAMENTAL CONCEPTS OF ROBOTICS: History, present status and future trends, Robotics. Robot, Definition. Robotics Systems and Robot Anatomy, Specification of Robotics. Resolution, Repeatability and Accuracy of a Manipulator ROBOT DRIVES: Power transmission systems and control Robot drive mechanisms, hydraulic-electricpenumatic drives. Mechanical transmission method Rotary-to-Rotary motion conversion. Rotary-to-linear motion conversion end effectors types-grip pind problem Remote-Centered compliance Devices-Control of Actuators in Robotic Mechanisms. SENSORS AND INTELLIGENT ROBOTS: Sensory devices Non-optical-Position sensors Optical position sensors velocity sensors proximity sensors: Contact and non-contact type-Touch and slip sensors Force and Torque Sensors AI and Robotics. COMPUTER VISION FOR ROBOTICS SYSTEMS: Robot vision systems Imaging components Image representation Hardware aspects-Picture coding Object Recognition and Categorization- Visual inspection software considerations applications commercial Robotics vision systems. COMPUTER CONSIDERATIONS FOR ROBOTIC SYSTEMS: Computer architecture for robts, hardware, Computational elements in robotic applications Robot programming sample programs path planning Robots computer system.

TRANSFORMATIONS AND KINEMATICS: Homogeneous Co-ordinates Co-ordinate Reference Frames Homogeneous Transformations for the manipulator the forward and inverse probleme of manipulator kinematics Motion generation Manipulator dynamics Jacobian in terms of D.H.Matrices controller architecture. ROBOT CELL DESIGN AND CONTROL: Specifications of Commerical Robots Robot Design and Process specifications motor selection in the design of a robotic joint Robot Cell layouts Economic and Social aspects of robotics. APPLICATIONS OF ROBOTS: Capabilities of Robots Robotics Applications Obstacle avoidance Robotics in India The future of Robotics Laboratory Exercises 01. Study of pick and place Robot- basic components, configuration, work volume. 02. Experiments with Robot. Kit for minimum four assembly activities and programming. 03. Programming of robots by manual, lead through and off line methods. 04. Programming languages for stacking of objects in increasing or decreasing size. Palletizing operations, assembly and inspection operation etc. 05. To become acquainted with the operation of a revolute-type 6 DOF robot. To program a robotic system uses a teaching pendant and a high level programming language. Emphasis is made on the constraints associated when positioning and orienting an object within a 3-D space the practical includes point-to-point tasks and continuous robot motion. TEXT BOOKS: 1. 2. Robotics Engineering An integrated approach - Richard D Klafter, Thomas A Chmielewski, Michael Negin Prentice Hall of India Pvt. Ltd. - Eastern Economy Edition, 1989. Robotics: Control Sensing, Vision, intelligence - Fu KS Gomaler R C, Lee C S G - McGraw Hill Book Co. - 1987.

REFERENCE BOOKS: 1. 2. Handbook of Industrial Robotics - Shuman Y. Nof - John Wiley & Sons, New York - 1985. Robotics Technology and Flexible Automation - Deb SR - McGraw Hill BookCo. - 1994.

ADVANCED METAL JOINING PROCESSES (Common to 10 MSE 22 / 10 MPT 22 / 10 MPE 22 / 10 MPM 22 / 10 MPY 22) Sub Code No. of Lecture Hrs/week Total Lecture Hrs 10 MPM 22 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Distortion, methods to avoid distortion. Stresses in Joint Design. Welding and Cladding of dissimilar materials, overlaying and surfacing. Electro Slag, Welding Electron Beam Welding, Plasma arc Welding, Laser Beam Welding, Explosion Welding, Diffusion Welding, Ultrasonic Welding, Friction welding and Thermit welding. Advanced soldering and Brazing processes different types. Welding of plastics. Inspection of Welds: Destructive techniques like Tensile, Bend,Nickbreak, Impact Hardness. Non-Destructive

techniques like 'X'rays, Ultrasonic, Magnetic particle, Dye

Penetrant, Gamma ray inspection.

Welding Symbols- Need for, Representing the welds, Basic weld symbols, Location of Weld, Supplementary symbols, Dimensions of welds, Examples Welding Design - Introduction, Principles of sound welding design, Welding joint design. Welding positions, Allowable strengths of welds, under steady loads. Quality Control in Welding - Introduction, Quality assurance v/s Quality control, Weld quality, Discontinuities in welds, their causes and remedies and Quality conflicts. Computer-Aided Welding Design - Introduction. Principles of sound welding design, Wilding joint design. Welding positions. Allowable strengths: of welds. 1D1der steady loads. Weld throat thickness. Solved and um solved examples. REFERENCE BOOKS: 1. 2. 3. 4. 5. Welding Engineering Handbook - A.W.S. Welding Engineering - Rossi - McGraw Hill. Advanced Welding processes - Nikodaco & Shansky - MIR Publications. Welding Technology - O.P. Khanna Welding for Engineers - Udin, Funk & Wulf PRODUCT DATA MANAGEMENT (Common to 10 MSE 23 / 10 MPT 23 / 10 MPE 23 / 10 MPM 23 / 10 MPY 23) : 10 MPM 23 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Sub Code No. of Lecture Hrs/week Total Lecture Hrs

Introduction: Introduction to PDM-present market constraints need for collaboration- Internet and developments in server-client computing. Components of PDM: Components of a typical PDM set-up hardware and software- document management creation and viewing of documents -creating parts-version control of parts and documents case studies. Configuration Management: Base lines-product structure configuration management -case studies.

Projects and Roles: Creation of projects and roles -life cycle of a product- life cycle management -automating information flow -work flows-Creation of work flow templates -life cycle -work flow integration -case studies.

Change Management: Change issue -change request-change investigation- change proposal-change activitycase studies. Generic Products and Variants: Products configuration comparison between sales configuration mild products generic-generic product modeling in configuration mode1er-use of order generator for variant creation registering ofvariants in product register-case studies. REFERENCE BOOKS: 1. Computer Integrated Design and Manufacturing - David Bed worth. Mark Henderson &. Philips Wolfe - McGraw Hill Inc. - 1991. Visual Modeling with Rational Rose and UML - Terry Quatrain - Addison Wesley - 1998. Wind-chill - RS.O Reference manuals - 2000.

2. 3.

FINITE ELEMENT METHODS (Common to 10 MSE 24 / 10 MPT 24 / 10 MPE 24 / 10 MPM 24 / 10 MPY 24) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 24 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Introduction: Equations of equilibrium, stress-strain relations for 2-D and equilibrium, Boundary conditions, Von Misses Stresses

3-D, Potential energy and

FEM for 1-D Problems: General procedure for FEA, Raleigh Ritz method, Galerkin Approach, shape functions, stiffness matrix, load vectors, temperature effects, Applications of boundary conditions using elimination, penalty and multi-constraint approaches, Application problems 1-D bar element. Trusses and beams FEM for 2-D Problems: Shape functions, stiffness matrix, strain matrix, load vectors for CST Elements and application problems FEM for Axisymmetric Problems: Axisymmetric formulation, triangular elements, PE approach, Body force term, application problems FEM for Scalar Field Problems: 1-D Steady state heat transfer, torsion, potential flow and fluid flow in ducts and application problems Dynamic Analysis: Equations of motion for dynamic problems --consistent and lumped mass matrices -formulation of element mass matrices free vibration and forced vibration problems formulation, Laboratory Exercises

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Static (Structural) Analysis of 1-D problems Static (Structural) Analysis of plane stress and Plane Strain problems Structural Analysis of Trusses Static Analysis of Axisymmetric problems Transient Heat Transfer Analysis of 1D problems Transient Heat Transfer Analysis of 2D problems Heat Transfer Analysis of Axisymmetric Problems Dynamic Analysis of 1D problems Free vibration Analysis Non-linear Static Analysis Typical problems in geometric and material non-linear Analysis Buckling Analysis of Shell Structures

REFERENCE BOOKS:

1. 2. 3. 4. 5. 6.

Introduction to Finite Elements in Engineering - Tirupathi R. Chandrupatla, Ashok D Belegundu - Prentice Hall India Pvt. Ltd., New Delhi Third Edition, 2003. Concepts and Applications of finite Element Analysis - Cook R.D, Malkus D.S & Plesha M.E John Wiley & Sons - 1989. Applied Finite Element Analysis - Segerlind L .J - John Wiley & Sons Edition - 1984. The Finite Element Method in Engineering - Rao SS - Pergomon Press, Oxford - 2nd Edition, 1984. Finite Element Procedures in Engineering Analysis - Bathe K .J - prentice Hall, NewJersey 1982. Energy and Finite Element Methods in Structural mechanics - Shames III & Dym C L Wiley eastern ltd 1995.

Elective - II NON DESTRUCTIVE TESTING (Common to 10 MSE 251 / 10 MPT 251 / 10 MPE 251 / 10 MPM 251 / 10 MPY 251) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 251 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Introduction to ND testing: selection of ND methods, visual inspection, leak testing, Liquid penetration inspection, its advantages and limitation. Magnetic particle inspection: Methods of generating magnetic field, types of magnetic particles and suspension liquids steps in inspection application and limitations Eddy current inspection: principles, operation variables, procedure, inspection coils, and detectable discounts by the method. Microwave inspection: Microwave holography, applications and limitations. Ultrasonic inspection: Basic equipment characteristics of ultrasonic waves, variables inspection, inspection methods pulse echo A,B,C scans transmission, resonance techniques, transducer elements couplets, search units, contact types and immersion types inspection standards-standard reference blocks, Radiography inspection: principles, radiation source X-rays and gamma rays, X-ray-tube, radio graphic films, neutron radiography, Thermal inspection principles, equipment inspection methods applications. Optical Holography: Basics of Holography, recording and reconstruction - Acoustical Holography: systems and techniques applications. Indian standards for NDT. REFERENCE BOOKS: 1. 2. 3. Non Destructive Testing - Mc Gonnagle JJ Garden and reach New York. Non Destructive Evolution and Quality Control - volume 17 of metals hand book 9 edition Asia internal 1989. The Testing instruction of Engineering materials - Davis H.E Troxel G.E wiskovil C.T - McGraw hill.

SURFACE TREATMENT AND FINISHING (Common to 10 MSE 252 / 10 MPT 252 / 10 MPE 252 / 10 MPM 252/ 10 MPY 252) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 252 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Fundamentals of Electro plating, galvanizing, Hot dip metal coating, thin coating, thin coating, chromium plating, Nickel plating. Vacuum coating, FVD & CVD metal spraying - Methods, surface preparation, mechanical Properties of sprayed metals, plasma coating. Plastic coating of metal - PVC coating Spherodising process details, phosphate coating - mechanism of formation. Testing of surface coating-methods. Heat treatment methods, Aneleaing, Normalizing, Tempering, Case hardening methods, flame hardening sub zero treatment.

Heat treatment methods for gears, spindles, cutting tools. Advanced coating technologies: Hard facing, electro deposition technique, nanocoatings, coating characterization REFERENCE BOOKS: 1. 2. 3. 4. 5. Surface preparations & finishes for Metals - James A Murphy - McGraw Hill. Principles of metal surface treatment and protection - Pergamon Press Gabe, David Russell Description, Oxford ; New York - 2d ed., 1978. Handbook of metal treatment and testing - John wiley & sons. Heat Treatment of Metals Zakrov - MlR Publications. Metals Hand Book ASM.

AGILE MANUFACTURING (Common to 10 MSE 253 / 10 MPT 253 / 10 MPE 253 / 10 MPM 253 / 10 MPY 253) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 253 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Introduction - What is agile Manufacturing? - Competitive environment of the future the business case for agile manufacturing conceptual frame work for agile manufacturing. Four Core Concepts: Strategy driven approach - integrating organization, people technology interdisciplinary design methodology. Agile Manufacturing and Change Management: The change implications. Post failures in advanced manufacturing, changes on the way, traditional management accounting, paradigm, investment appraisal, product costing - performance, measurement and control systems, Traditional organization, control technological and design paradigms traditional problems in workplace- organizational issues - role of technology. Agile Manufacturing Enterprise Design: Agile manufacturing - enterprise design .. system concepts as the basic manufacturing theory - joint technical & organizational design and a model for the design of agile manufacturing enterprise, enterprise design process insights into design processes, what is interdisciplinary design, Main issues - simple design example. Skill & Knowledge Enhancing Technologies for Agile Manufacturing: Skill and Knowledge enhancing Technologies - scheduling - technology design strategic-Design Concepts. Design and Skill of Knowledge enhancing Technologies for machine tool systems - Historical overview, Lessons, problems and Future development. REFERENCE BOOKS: 1. 2. 3. 4. 5. Agile manufacturing - Forging new Frontiers - Paul T. Kidd - Addison Wesley Publication -1994. Agile Manufacturing Proceedings of International Conference - Dr. M.P Chowdiah (Editor) Tata Mc Graw Hill Publications - 1996. On agile manufacturing - Tata McGraw Hill Publications -1996 Agile manufacturing - Forging Neat Furniture's - Paul T Kidd Addition Wesley Pub 1994. World Class Manufacturing - Paul T Kidd - Washington: National - 1994

NON - TRADITIONAL MACHINING PROCESSES (Common to 10 MSE 254 / 10 MPT 254 / 10 MPE 254 / 10 MPM 254 / 10 MPY 254) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 254 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Introduction: Need for non-traditional machining processes. Processes selection c1assification on comparative study of different processes. Mechanical Process: Ultrasonic Machining-Definition-Mechanism of metal elements of the process- Tool feed mechanism. theories of mechanics of causing effect of parameter applications. Abrasive Jet Machining: Principles - parameters of the process applications-advantages and advantages. Thermal Metal Removal Process: Electric discharge machining Principle of operation mechanism of meta removal basic EDM circuitry-spark erosion get Analysis of relaxation type of circuit material removal rate in relaxation circuits- critical resistance parameters in Ro Circuit-Die electric fluids-Electrodes for sparl surface finish. Applications. Electro Chemical and Chemical Processes: Electro chemical machining (ECM) Classification ECM processprinciple of ECM Chemistry of the ECM parameters of the processes-determination of the metal removal rate dynamics of ECM process-Hydrodynamics of ECM process-polarization-.Tool Design-advantages and disadvantages - applications. Electro Chemical Grinding-Electro Chemical holding Electrochemical deburring.

Chemical Machining: Introduction-fundamental principle types of chemical machining Maskants- Etchenes- Advantages and disadvantages-applications. Plasma arc Machining: Introduction-Plasma-Generation of Plasma and equipment Mechanism of metals removal, PAN parameters-process characteristics - type of torches applications. Electron Beam Machining (EBM): Introduction-Equipment for production of Electron beam - Theory of electron beam machining Thermal & Non thermal types characteristics - applications. Laser Beam Machining (LBM): Introduction-principle of generation of lasers Equipment and Machining procedure-Types of Lasers-Process characteristics-advantages and limitations-applications Ion Beam Machining: Introduction-Mechanism of metal removal and associated equipment-process characteristics applications High Velocity Forming Process: introduction - development of specific process selection-comparison of conventional and high velocity forming methods - Types of high velocity forming methods- explosion forming process-elector hydraulics forming magnetic pulse forming. REFERENCE BOOKS: 1. 2. 3. 4. 5. 6. 7. New technology Institution of Engineers - Bhattacharya - India Production Technology - HMT - Tata Mc Graw Hill - ISBN-10; 0070964432 Modern Machining Process - P.C Pandy & H.S. Shan - Tata McGraw Hill - ISBN: 0070965536 - Publishing Date: Feb-80 Metals Hand Book - ASM - Vol-3. High Velocity Forming of Metals - F.M Wilson - ASTME Pretice Hall. Modern Manufacturing Method - Adithan - New Age International (p) Limited - ISBN: 8122408176, 2007. Modern Machining Processes - P.K. Mishra - Narosa Publishing House, New Delhi - 1997.

4 Hrs

SIMULATION AND MODELING OF MANUFACTURING SYSTEMS (Common to 10 MSE 255 / 10 MPT 255 / 10 MPE 255 / 10 MPM 255 / 10 MPY 255) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 255 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

PRINCIPLE OF COMPUTER MODELLING AND SIMULATION: Monte Carlo simulation. Nature of computer- modeling and simulation. Limitations of simulation, areas of applications. SYSTEM AND ENVIRONMENT: Components of a system -discrete and continuous systems, Models of a system -a variety of modeling approaches. DISCRETE EVENT SIMULATION: Concepts in discrete event simulation, manual simulation using event scheduling, single channel queue, too server queue, simulation of inventory problem. STATISTICAL MODELS IN SIMULATION: Discrete distributions, continuous distributions. RANDOM NUMBER GENERATION: Techniques for generating random numbers- Mid square method -the mod product method -Constant multiplier technique -Additive congruential method -Linear congruential method -Tests for random numbers -The Kolmogorov-Smimov test -the Chi-square test. *** Ivica Cmkovic, Ulfaskluna and Annita borsen Dohlgvist Publisher Artechhouse. RANDOM VARIABLE GENERATION: Inversion transforms technique-exponential distribution. uniform distribution, weibull distribution, continuous distribution, generating approximate normal varieties -Erlang distribution. EMPIRICAL DISCRETE DISTRIBUTION: Discrete uniform -distribution Poisson distribution -geometric distribution -acceptance -rejection technique for Poisson distribution gamma distribution. DESIGN AND EVALUTION OF SIMULATION EXPERIMENTS: variance reduction techniques antithetic variables, variables-verification and validation of simulation models. SIMULATION SOFTWARE: Selection of simulation software, simulation packages. TEXT BOOKS: 1. 2. Discrete Event System Simulation - Jerry Banks & .John S Carson II - Prentice Hall Inc.-1984. Systems Simulation - Gordan. G. - Prentice Hall India Ltd - 1991.

REFERENCE BOOKS: 1. 2. 3. System Simulation with Digital Computer - Nusing Deo - Prentice Hall of India - 1979. Computer Simulation and Modeling - Francis Neelamkovil - John Wilely & Sons - 1987. Simulation Modeling with Pascal - Rath M.Davis & Robert M O Keefe - Prentice Hall Inc. - 1989.

LEAN MANUFACTURING SYSTEMS (Common to 10 MSE 256 / 10 MPT 256 / 10 MPE 256 / 10 MPM 256 / 10 MPY 256) Sub Code No. of Lecture Hrs/week Total Lecture Hrs : 10 MPM 256 : 04 : 52 IA Marks Exam Hours Exam Marks : 50 : 03 : 100

Just in time production system. JIT Logic -Pull system Japanese approach to production elimination of waste JIT implementation requirements JIT application for job shops, Case studies Kanban system:- Kanban rules supplier Kanban and sequence schedule used by supplier. Monthly information & daily information. Later replenish system by Kanban sequenced withdrawal P system by sequence schedule table -problems & counter measures in applying Kanban system to subcontractors -Supplier Kanban circulation in the paternal manufacturer -structure of supplier Kanban sorting office. The rise & fall of Mass Production Mass production, work force, organization, tools, product logical limits of mass production, Sloan as a necessary compliment to Ford. Case study:- Rouge Production Plant. The rise of lean production: - Birth place, concrete example, company as community, Final assembly plant, product development and engineering. Changing customer demand, dealing with the customer, future of lean production. Shortening of production lead times -reduction of setup times, practical procedures for reducing setup time. Standardization of operations. Machine layout, multi function workers and job rotation. Improvement activities to reduce work force and increase worker morale -foundation for improvements. Elements of lean production viz G M Framingharn -Toyota Takaoka Mass Production V /s lean production, diffusing lean production. Managing lean enterprise:- Finance, Career ladders, geographic spread and advantages of global enterprise. Prospects for catching up. Simplicity in the natural state -institutional factors -life time employment -educational commodities -quality & productivity in full circle.

An action plan : Getting started - Creating an organization to channel your streams. Install business system to encourage lean thinking. The inevitable results of 5 year commitment.

REFERENCE BOOKS: 1. 2. 3. 4. 5. 6. Productions and Operations Management - Chasel Aquilino - Mcgra-hill company 9th edition 2001. Toyoto Production System -An integrated approach to Just in Time - Yasuhiro Monden Engineering aild Management Press, Institute of Industrial Engineers Norcross Georgia.- 1983 The Machine that changed the World. The Story of Lean Production - James P Womack, Daniel T Jones, and Daniel Roos - Harper Perennial edition published - 1991. Lean Thinking - James Womack - Simon & Schuster Adult - ISBN: 0743249275, 2003. Japanese Manufacturing Techniques. The Nine Hidden Lessons by simplicity - Richard Schourberger. - Free Press - 1st edition, ISBN-10: 0029291003, 1982. Quality Function Development - James Bossert - ASQC Press 2000.