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UNIVERSITY, BELGAUM
Elective – I
10 MPD 151 Applied Probability and Statistics
10 MPD 152 Simulation and modeling of manufacturing systems
10 MPD 153 Computer Applications in Design
10 MPD 154 Quality By Design
* Thirty marks for Internal assessment test – (Theory) and Twenty marks for
Laboratory
SCHEME OF TEACHING AND EXAMINATION 2010 -2011
M.TECH - PRODUCT DESIGN & MANUFACTURING (MPD)
II Semester (18 weeks)
Elective – II
10 MPD 251 Quality and Reliability Engineering
10 MPD 252 Virtual Design and Manufacturing
10 MPD 253 Rapid Proto Typing
* Between the II Semester and III semester. After availing a vacation of Two Weeks
** Thirty marks for Internal assessment test – (Theory) and Twenty marks for
Laboratory ( minimum ten exercises / experiments to be conducted for the subjects for
which Practicals is mentioned)
SCHEME OF TEACHING AND EXAMINATION 2010 -2011
M.TECH - PRODUCT DESIGN & MANUFACTURING (MPD)
Sub. Code Name of the Teaching hours / week Duration Marks for Total
Subject Lecture Practical / of Exam IA Exam Marks
s Field work / in hours
Assignment
10 MPD 31 Robust Design 4 2 3 50 100 150
Sub. Code Name of the Teaching hours / week Duration Marks for Total
Subject Lectures Practical / of Exam IA Exam Marks
Field work / in hours
Assignment
Seminar on - 3 - 50 - 50
10 MPD 41 Project Phase-II
Seminar on - 3 - 50 - 50
Project Phase –
10 MPD 42
III
Note:
1. The hours / week shown in the column of Field work / Assignment are the contract
hours for students, no load to be shown to the teachers. The teachers should provide
guidance.
2. The seminar Marks are to be awarded by the department committee constitute for the
purpose.
3. The project evaluation and Viva-Voce will be conducted by a committee consisting of the
following.
Product Planning: The product planning process, identify opportunities. Evaluate and
prioritize projects, allocate resources and plan timing, complete pre project planning, reflect
all the results and the process.
Identifying Customer Needs: Gather raw data from customers, interpret raw data in terms
of customer needs, organize the needs into a hierarchy, establish the relative importance of
the needs and reflect on the results and the process.
Concept Generation: The activity of concept generation clarify the problem, search
externally, search internally, explore systematically, reflect on the results and the process.
Concept Testing: Define the purpose of concept test, choose a survey population, choose a
survey format, communicate the concept, measure customer response, interpret the result,
reflect on the results and the process.
INDUSTRIAL DESIGN: Assessing the need for industrial design, the impact of industrial
design, industrial design process, managing the industrial design process, assessing the
quality of industrial design.
Design for Manufacturing: Definition, estimation of manufacturing cost, reducing the cost
of components, assembly, supporting production, impact of DFM on other factors.
TEXT BOOK:
REFERENCE BOOKS:
a. A C Chitale and R C Gupta, PH1, “Product Design and Manufacturing”,
3red Edition, 2003.
b. Timjones. Butterworth Heinmann, “New Product Development” Oxford.
UCI. 1997
c. Geoffery Boothroyd, Peter Dewhurst and Winston Knight, “Product Design
for Manufacture and Assembly”, 2002
PRODUCT LIFE CYCLE MANAGEMENT
Product life cycle management – Need for PLM, Components of PLM, Product Data and
Product workflow, Drivers for Change,
Change Management for PLM, Configuration management, cost of design changes, schemes
for concurrent engineering,
Design for manufacturing and assembly, robust design, failure mode and effect-analysis
Modeling, Current concepts, part design, sketching, use of datum's construction features, free
ovulation, pattering, copying, and modifying features, reference standards for datum
specification, Standards for Engineering data exchange
Tolerance mass property calculations, rapid prototyping and tooling, finite modeling and
analysis, general procedure, analysis techniques,
Finite element modeling. Applicability of FEM, Static analysis, thermal analysis, dynamic
analysis.
REFERENCE BOOKS:
Introduction, Evaluation of the four elastic moduli – Rule of mixture, ultimate strengths of
unidirectional lamina.
Manufacturing:
Layup and curing – open and closed mould processing – Hand lay –up techniques – Bag
moulding and filament winding. Pultrusion, pulforming, Thermoforming, Injection
moulding, Cutting, Machining and joining, tooling, Quality assurance – Introduction,
material qualification, types of defects, NDT methods.
Metal matrix composites: Reinforcement materials, types, Characteristics & selection, base metals-
selection, applications.
Reference Books:
1. Mein Schwartz “Composite Materials handbook” Mc Graw Hill Book Company, 1984.
2. Autar K. Kaw “Mechanics of composite materials” CRC Press New York. 1 edition (June
30, 1997);
Reference Books:
Introduction: Equations of equilibrium, stress-strain relations for 2-D and 3-D, Potential
energy and equilibrium, Boundary conditions, Von Misses Stresses
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 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,
REFERENCE BOOKS:
Introduction to DOE: Completely Randomised Block Design (CBD) and Randomised Block
Design(RBD)
REFERENCE BOOKS:
1 Applied statistics and Probability for Engineers – Douglas C Montgomery, George C
Runger, 2nd Edn, John Wiley and Sons, ISBN-0-471-17027-5.
2 Statistics for Management, Richard I Levin, David S Rubin, 6th Edn, Prentice Hall
India, ISBN-81-203-0893-X.
3 Probability and Statistics in Engineering, William W Hines, Douglas C Montgomery,
2nd Edn, John Wiley and Sons. ISBN: 0471240877
4 Business Statistics for Management and Economics, Daniel, Terrell, 6th Edn,
Houghton Mifflin Company, ISBN-0-395-62835-0.
5 Probability and Statistics by Walpole & Mayer, MacMillan Publishing
Company, 1989.
Discrete Event Simulation: Concepts in discrete event simulation, manual simulation using
event scheduling, single channel queue, two server queue , simulation of inventory problem.
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-Smirnov
test -the Chi-square test.
REFERENCE BOOKS
1. Jerry Banks & .John S Carson II, "Discrete Event System Simulation", Prentice
Hall Inc..1984.
2. Gordan. G. "Systems Simulation", Prentice Hall India Ltd, 1991.
Text Book:
1. Kunwoo Lee, “Principles of CAD/CAM/CAE systems”, Addison Wesley, 1999
2. Radhakrishnan P., et al., “CAD/CAM/CIM”, New Age International, 2008
Reference Books:
1. Ibrahim Zeid, “CAD/CAM – Theory & Practice”, McGraw Hill, 1998
2. Bedworth, Mark Henderson & Philip Wolfe, “Computer Integrated Design and
Manufacturing”, McGraw hill inc., 1991.
3. Pro-Engineer, Part modeling Users Guide, 1998
QUALITY BY DESIGN
TEXT BOOKS:
REFERENCE BOOKS:
1. Marcel Dekker Inc, “Velocity Function Deployment”, New York. First Indian
Edition 2005
2. Techniques for value analysis and Engineering, 1972.
3. Management for quality improvement, productivity press.
4. Design, addition -Wesley, wokingham, 1991.
5. Matar, “Designing For Quality”, chapman & hall. New York (1990).
6. Indolence through quality and reliability, applied 1989.
7. McGraw -Hill Inc, “Design for excellence” New York, 1996.
8. Function development -productivity process.
II SEMESTER
Ergonomics and Industrial Design: Introduction -general approach to the man- machine
relationship- workstation design-working position.
Control and Displays: Shapes and sizes of various controls and displays-multiple, displays
and control situations -design of major controls in automobiles, machine tools etc., design of
furniture -redesign of instruments.
Colour: Colour and light -colour and objects- colour and the eye -colour consistency- colour
terms- reactions to colour and colour continuation -colour on engineering equipments.
Aesthetic Concepts: Concept of unity- concept of order with variety -concept of purpose
style and environment-Aesthetic expressions. Style-components of style- house style,
observation style in capital goods, case study.
Industrial Design in Practice: General design -specifying design equipments- rating the
importance of industrial design -industrial design in the design process.
REFERENCE BOOKS:
1. Mayall W.H. "Industrial Design for Engineers", London Hiffee books Ltd. 1988.
Centralized systems: Client Server Systems, Parallel Systems, Distributed Systems, Network
Types, Parallel Database, Distributed Database, Security and Integrity, Standardization
views
Product Data Management, Product life cycle, Complexity in Product Development, General
Description of PDM
Basic functionality of PDM, Information architecture, PDM System architecture,
Applications used in PDM systems. Trends in PDM
Document Management Systems, Document management and PDM, Document life cycle,
Content Management, Document management and related technologies, Document
management resources on the Internet
Workflow Management in PDM: Structure Management, Engineering Change Management,
Release Management, Version Management, Configuration Management
Creating Product Structures, Part centric approach, CAD centric approach, Product Structure
configuration, Managing Product Structures
PDM Tools: Matrix One, TeamCenter, Windchill.Enovia, PDM resources on the Internet
PDM Implementation Case Studies: Sun Microsystems, Inc., Mentor Graphics Corporation,
Ericsson Radio Systems AB, Ericsson Mobile Communications AB, ABB Automation
Technology Products, SaabTech Electronics AB
Reference Books:
Implementing and Integrating Product Data Management and Software Configuration
Management by Ivica Cmkovic Ulf Asklund, Annita Persson Dahlqvist, Archtech House
Publishers
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.
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.
Failure Data Analysis : Introduction, Failure Data, Quantitative measures, MTTF, MTBF,
Bathtub Curve, Mean Life, Life Testing, Problems, Introduction to Failure Mode and Effect
Analysis.
System Reliability: Series, parallel and mixed configuration, Block diagram concept, r- out-
of-n structure solving problems using mathematical models.
REFERENCE BOOKS:
VR Devices: Input devices-track balls, 3D Mouse, data gloves, Virtual hand and trackers,
output devices graph terminal, stereo glasses, head mounting devices, vision dome, caves.
Virtual Modeling language: History, Concepts, syntax, basic nodes-group, transform switch,
LOD etc, geometry nodes-indexed face set, indexed line set, coordinate, coordindwx, textures
etc. sensor nodes-time sensor touch sensor, sphere sensor, cylinder sensor and proximity
sensor, scriping- VRML Script and JAVA Script.
Tutorials and samples: VRML authoring tools-3D studio MAX, cosmo World, VRML Pad
(editor) VRML Viewing tools-cosmo player, auto Vue, SGI's open inventor, virtual
collaborative tools-V collab.
TEXT BOOKS:
Selective Laser Sintering and Fusion Deposition Modeling: Type of machine, Principle of
operation, process parameters, Data preparation for SLS, Applications, Principle of Fusion
deposition modeling, Process parameter, Path generation, Applications
Concepts Modelers: Principle, Thermal jet printer, Sander's model market, 3-D printer.
Genisys Xs printer HP system 5, object Quadra systems.
Rapid Tooling: Indirect Rapid tooling -Silicone rubber tooling –Aluminum filled epoxy
tooling Spray metal tooling, Cast kirksite, 3Q keltool, etc >Direct Rapid Tooling Direct.
AIM, Quick cast process, Copper polyamide, Rapid Tool, DMILS, Prometal, Sand casting
tooling, Laminate tooling soft Tooling vs. hard tooling.
. `
TEXT BOOKS:
1. Paul F. Jacobs: "Stereo lithography and other RP & M Technologies", SME, NY
1996.
2. Flham D.T & Dinjoy S.S "Rapid Manufacturing" Verlog London 2001.
3. Lament wood, “Rapid automated”, Indus press New York
REFERENCE BOOKS:
1. Terry Wohlers "Wohler's Report 2000" Wohler's Association 2000.
III SEMESTER
ROBUST DESIGN
Quality by Experimental Design : Quality, western and Taguchi quality philosophy, Elements of
cost, Noise factors causes of variation, Quadratic loss function and variation of quadratic loss
functions. Robust Design : Steps in robust design : parameter design and tolerance design, reliability
improvement through experiments, illustration through numerical examples.
6 Hours
2. Experimental Design: Classical experiments: factorial experiments, terminology, factors.
Levels, Interactions, Treatment combination, randomization, 2-level experimental design for two
factors and three factors. 3-level experiment deigns for two factors and three factors, factor effects,
factor interactions, Fractional factorial design, Saturated design, Central composite designs,
Illustration through numerical examples.
7 Hours
3. Measures of Variability : Measures of variability, Concept of confidence level, Statistical
distributions : normal, log normal and Weibull distributions. Hipothesis testing, Probability plots,
choice of sample size illustration through numerical examples.
7 Hours
4. Analysis and interpretation of experimental data: Measures of variability, Ranking method,
column effect method and ploting method, Analysis of variance (ANOVA), in factorial experiments :
YATE’s algorithm for ANOVA,Regression analysis, Mathematical models from experimental data,
illustration through numerical examples.
7 Hours
5. Taguchi’s Orthogonal Arrays : Types orthogonal arrays, Selection of standard orthogonal
arrays, Linear graphs and interaction assignment, dummy level technique, Compound factor method,
modification of linear graphs, Column merging method, Branching design, Strategies for
constructing orthogonal arrays.
8 Hours
6. Signal to Noise ratio (S-N Ratios) : Evaluation of sensitivity to noise, Signal to noise ratios for
static problems, Smaller – the – better types, Nominal – the – better – type, larger – the- better – type.
Signal to noise ratios for dynamic problems, Illustrations through numerical examples.
6 Hours
7. Parameter Design and Tolerance Design : Parameter and tolerance design concepts, Taguchi’s
inner and outer arrays, Parameter design strategy, Tolerance deign strategy, Illustrations through
numerical examples.
06 Hours
8. Reliability Improvement Through Robust Design : Role of S-N ratios in reliability
improvement ; Case study; Illustrating the reliability improvement of routing process of a printed
wiring boards using robust design concepts.
5 Hours
TEXT BOOKS:
REFERENCE BOOKS:
Direct Methods: The complex method, cutting plane method, methods of Feasible
directions.
TEXT BOOKS:
REFERENCE BOOKS:
Product strategy and planning product, Market evolution, Successful product development.
New product strategy, a proactive new product development process, Market definition and
entry strategy.
TEXT BOOKS:
1. Glen L. Urban. .John R. Hauser, “Design and Marketing of new products”
2. William L. Moore & Edgar, “Product Planning and Management”, A. Pessemier
AGILE MANUFACTURING
Subject Code : 10MPD323 IA Marks : 50
No. of Lecture
: 04 Exam Hours : 03
Hours/Week
Total No. of Lecture Hours : 52 Exam Marks : 100
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.
Skill & Knowledge Enhancing Technologies For Agile Manufacturing: Skill and
Knowledge enhancing Technologies -scheduling -technology design strategic-
Design Concepts. Design & Skill of Knowledge enhancing Technologies for machine tool
systems- Historical Overview, Lessons, Problems and Future Development.
REFERENCE BOOKS:
Introduction: New products, new product strategy -market definition Idea generation
introduction to the design process -forecasting sales potential -product engineering and
markets-monopoly competitive.
Value Analysis: Steps in selection, analysis and implementation, Selection of cutting speed
for optimum cost -problems.
Cost Accounting: Cost estimation -difference -types -steps involved in cost estimation.
Types of Cost: Cost Centres, Direct –indirect, material cost -direct indirect material cost
Overhead cost, Elements in overheads: Preparation of cost sheet, machine hour rate,
apportioning methods
Variance Analysis – Labour variance, Material variance and Overhead variance, Activity
based costing - Introduction to target costing.
Cost Calculation: Cost calculation for machined components, welding, casting and forged
components illustrations -calculation of sales cost.
TEXT BOOKS:
1. Glen L Urban, John R Hauser, "Design and Marketing of New Products"- Prentice
Hall. New Jersey, 1980
2. Narang CBS & Kumar V., "Production and Costing", Khanna Publishers, 2001
REFERENCE BOOKS:
1. Yasuhiro Monden, "Cost management in the New Manufacturing Age",
ProductivityPress-1992
2. "Manufacturing Engineers Handbook", S M E 1984.
3. Miles Lewrence.D, “Technique for Value Analysis And Engineering.” McGraw
Hill, New york-1972
ADVANCED MANUFACTURING PRACTICE
Subject Code : 10MPD332 IA Marks : 50
No. of Lecture
: 04 Exam Hours : 03
Hours/Week
Total No. of Lecture Hours : 52 Exam Marks : 100
Need of CPC for a company, what CPC can do, CPC-getting the right tool.
JIT – Introduction – The spread of JIT Movement, some definitions of JIT, core Japanese
practices of JIT, Creating continuous Flow Manufacture, Enabling JIT to occur, Basic
elements of JIT, Benefits of JIT.
Just in Time Production – Primary purpose, profit through cost reduction, Elimination of
over production, Quality control, Quality Assurance, Respect for Humanity, Flexible work
Force, JIT Production Adapting to changing production Quantities, process layout for
shortened lead Times, Standardization of operation, Automation.
Sequence and scheduling used by suppliers: Monthly and daily Information. Sequenced
withdrawal system by sequenced schedule table, problems and counter measures in applying
the Kanban system to sub contractors.
Toyota Production System-The philosophy of TPS, Basic Frame work of TPS, Kanban,
Determining the Number of Kanban in Toyota Production System.
Just-in-Time Production with Total Quality Control just in time concept, cutting lot sizes,
cutting set-up times, cutting purchase order costs, the JIT cause-Effect chain, Scrap/Quality
Improvements, Motivational effects, Responsibility effects, small Group improvement
Activities, withdrawal of Buffer Inventory, the total Quality Control Concept.
REFERENCE BOOKS:
Use of Predicate Logic: Representing simple facts, Instance and is a relationships, Syntax
and Semantics for Propositional logic, FOPL, and properties of Wffs, conversion to causal
form, Resolution, Natural deduction
Expert Systems: Introduction, Structure and uses, Representing and using domain
knowledge, Expert System shells. Pattern recognition, introduction, Recognition and
classification process, learning classification patterns, recognizing and understanding speech.
.
TEXT BOOKS: