I semester 15PP01 statistics, quality control and reliability engineering 2 2 0 3 sampling concepts



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TIME STUDY: Equipment, forms, selecting the job and worker, basic steps, classification of elements, breaking the job into elements, determination of sample size. (6)
TECHNIQUES FOR WORK MEASUREMENTS: Stop watch time study, work sampling, PMTS, MTM, analytical estimation. (6)
INFLUENCE OF WORKING CONDITIONS IN WORK STUDY: Layout and housekeeping, lighting, noise, vibration, ergonomics, fire prevention and protection, OSHA. (8)
Total L: 45

REFERENCES:

              1. ILO, “Introduction to Work Study: Indian Adaptation”, Oxford and IBH Publishing Company Private Limited, 2008.

              2. Ralph M Barnes, “Motion and Time: Study Design and Measurement of Works”, John Wiley & Sons Inc., 2002.

              3. Benjamin W Niebel, “Motion and Time Study - An Introduction to Methods, Time Study and Wage Payment”, Richard Dirwin, Illinois, 1958.


15PP36 SIX-SIGMA

3 0 0 3
OVERVIEW OF SIX-SIGMA CONCEPT: History of Six- sigma; Benefits; Tools and Themes of Six-Sigma programme. Ingredients of six-sigma; Cost of quality. (4)
KEY CONCEPTS OF THE SIX-SIGMA SYSTEM: A six-sigma vision of business leadership; An introduction to sigma measurement; Six-Sigma improvement and management strategies; The DMAIC Six-Sigma improvement model; Six-Sigma v/s TQM (comparison with TQM). (7)
THE SIX-SIGMA ROAD MAP: Advantages of six-sigma roadmap; Steps in roadmap; over view and rationale behind each step.  Application of six-sigma in service: Comparison of service and manufacturing; challenges making six-sigma work in services; using lean sigma in service. (5)
ADOPTING SIX-SIGMA: Relevance of six sigma programme; Strategy phase of six-sigma program; preparing leaders to launch and guide effort. Preparing black belts and other key roles - Master Black belt; Champion and Green belts. (6)
TRAINING THE ORGANIZATION FOR SIX-SIGMA: Essentials of effective training; Planning curriculum; Selecting the right six-sigma projects-Essentials; process and Do’s & Don’ts.  (5)
IMPLEMENTING SIX-SIGMA: Identifying core process; Defining customer requirements; measuring current performance. Six sigma process improvement; six sigma process design/ redesign; expanding and integrating the six sigma system. (8)
DESIGN FOR SIX-SIGMA (DFSS): Introduction; Need for DFSS; DFSS Phases; Differences between six sigma and DFSS; Features of a sound DFSS strategy. (4)
SUSTAINABILITY OF DESIGN FOR SIX-SIGMA: Beyond six-sigma, keeping the capability, keep the customers in mind and involved, make the most of what you know, vision and leadership, infrastructure, reinforcement and control organizational culture, expanding DFSS beyond the organization managers checklist. (6)
Total L: 45

REFERENCES:

  1. Kai Yang and Basemel-Haik, “Design for Six-Sigma: A Roadmap for Product Development”, McGraw Hill, 2008.

  2. Mikel Harry and Richard Schroeder A, “Six-Sigma: The Break through Management Strategy”, Currency Book Published by Doubleday, 2006.

  3. Crrevelng C M, Slutsky J L and Antis D, “Design for Six Sigma”, Pearson Education, 2003.

  4. Michael L George, “Lean Six Sigma for Service”, Tata McGraw Hill, 2003.

  5. Greg Brue, “Design for Six Sigma”, Tata McGraw Hill, 2003.

  6. Peter S Pande, Robert P Neuman and Roland Cavanagh R, “The Six-Sigma Way-How GE, Motorola and Other Top Companies are Honing their Performance”, McGraw Hill, 2003.

  7. Stamatis D H, “Six-Sigma and Beyond - Foundations of Excellent Performance”, St. Lucie Press, 2001.



15PP37 LEAN MANUFACTURING

3 0 0 3
INTRODUCTION: Holistic view of lean principles, five primary elements, road map. (5)
ORGANIZATION ELEMENT: Communication planning, product - focused responsibility, leadership development, operational roles and responsibilities, workforce preparation. (5)
METRICS ELEMENT: DuPont model, output-based measures, process - driven measures, goal alignment through policy deployment, measurement definition and understanding. (5)
LOGISTICS ELEMENT: Planning/control function, A,B,C material handling, service cells, customer/supplier alignment, JIT Kanban demand signals, cell team work plan, level loading, mix-model manufacturing, workable work. (7)
MANUFACTURING FLOW ELEMENT: Product/quantity analysis, process mapping, routing analysis, takt time, workload balancing and one-piece flow, cell design criteria, cell layout, kanban sizing. (7)
PROCESS CONTROL ELEMENT: Single minute exchange of dies, total productive maintenance, poka-yoke, 5S, visual controls, graphic work instructions. (7)
VALUE STREAM MAPPING: Introduction - Primary icons - Customer and supplier icons - Production control icon - Data box icon - Truck icon - Material direction arrow icon - Process icon - Push icon - Pull icon - Information and communication flow icons - Secondary icons - Developing the VSM - Example illustrating the development of VSM - Current state mapping - Future state mapping. (9)
Total L: 45

REFERENCES:

1. Devadasan S R, Mohan Sivakumar V, Murugesh R and Shalij P R, “Lean and Agile Manufacturing: Theoretical, Practical and Research Futurities”, Prentice Hall of India (PHI) Private Limited, New Delhi, India, 2012.

2. James P Womack and Daniel T Jones, “Lean Thinking, Banish Waste and Create Wealth in Your Corporation”, Simon & Schuster UK Limited, 2010.

3. William M Feld, “Lean Manufacturing, Tools, Techniques and How To Use Them”, The St. Lucie Press/APICS Series on Resource Management, 2001.



15PP38 AGILE MANUFACTURING

3 0 0 3
tHE AGILE PRODUCTION SYSTEM: The task aligned organisation - agile manufacturing production system - production, production support, production planning and control, quality assurance, purchasing, maintenance, overview of production support, business operations, engineering, marketing, human resource, finance and accounting. (5)
AGILE PRACTICES: Agile practice for product development - Manufacturing agile practices - understanding the value of investing in people, removing inappropriate fear from the shop floor - not sacrificing agility for perfectionism. (6)
IMPLEMENTING TECHNOLOGY TO ENHANCE AGILITY: Implementing new technology - reasons - guidelines preparation for technology implementation - A checklist, technology applications that enhance agility - agile technology make-or-buy decisions. (7)
STRATEGIC DIRECTION: Key concepts, strategic thinking, strategic learning approach to creating strategy - establishing the strategy team, collecting strategic information, creating strategic scenarios, developing strategy options, selecting the best strategy option, testing and refining the strategy, implementing the strategy, strategy partnering, conclusion. (7)
PERFORMANCE MEASURES: Historical view of performance measurement, dysfunctional impacts of cost-accounting performance measures, customer-centered paradigm, developing customer-based performance measures. (7)
CREATING THE LEARNING FACTORY: Imperative for success, factory becoming a learning factory, building a road map for becoming a learning factory - core capabilities, guiding vision, leadership that fits, ownership and commitment, pushing the envelope, prototypes, integration, learning challenges for learning manufacturing business, conclusion. (7)
MANAGEMENT IN THE AGILE ORGANIZATION: Old management styles, role of manger in an agile organization - vision champion, team leader, coach, business analyzer, supporting the new culture - performance appraisal systems, selection systems, reward and recognition systems, organizational measurement, organizational learning processes. (6)
Total L: 45

REFRENCES:

  1. Devadasan S R, Mohan Sivakumar V, Murugesh R and Shalij P R, “Lean and Agile Manufacturing: Theoretical, Practical and Research Futurities”, Prentice Hall of India (PHI) Private Limited, New Delhi, India, 2012.

  2. Gunasekaran A, “Agile Manufacturing, 21st Strategy Competitiveness Strategy”, Elsevier Publications, 2001.

  3. Montgomery J C and Levine L O, “The Transition to Agile Manufacturing - Staying Flexible for Competitive Advantage”, ASQC Quality Press, Wisconsin, 1995.

  4. Goldman S L, Nagal R N and Preiss K, “Agile Competitors and Virtual Organizations”, Van Nostrand Reinhold, 1995.

  5. Brian H Maskell, “Software and the Agile Manufacturer, Computer Systems and World Class Manufacturing”, Productivity Press, 1993.

ONE CREDIT COURSES
For the detailed syllabi of the electives and one credit courses offered by other departments refer to the syllabi of M.E- Automotive Engineering offered by Automobile Engineering Department.

ONE CREDIT COURSES

15PK01 PROCESS IMPROVEMENT AND PRODUCT DESIGN THROUGH LEAN SIX SIGMA

1 0 0 1

LEAN SIX SIGMA FUNDAMENTALS

  • Definition of term Sigma, Z Score, CTQ, Opportunity, Defect, DPMO

  • Types of data…importance of measurement, repeatability and reproducibility

  • Six Sigma Quality Level, Relationship between DPMO and Process Capability, Short/Long term Six Sigma, Z Shift

  • Six Sigma’s focus on inputs (X’s) over outputs (Y’s) using the formula Y=f (X)

  • Structure of execution team, Rhythm to sustain the improvement

  • Intro to DMAIC, DMADOV, Lean….how it is different from Traditional Quality ISO (4)



METHODOLOGIES OF LEAN SIX SIGMA

  • DMAIC

  • DMADOV (DFSS)

  • Lean (5)


TOOLS AND TECHNIQUES

DMAIC

  • QFD

  • FMEA

  • Fishbone Diagram

  • Hypothesis Test

  • DoE

  • SPC


DFSS

  • Kano Model

  • Decision Making Tools

    • Pugh Matrix

    • Robust Design Tools


LEAN

  • Value Stream Mapping

  • 5 S (6)


Total L: 15

TEXT BOOK:

  1. Alastair K Muir, “Lean Six Sigma Statistics”, McGraw Hill, 2006.


REFERENCE:

1. James T Schutta, “Business Performance through Lean Six Sigma”, ASQC Quality Press, 2006.



15PK02 DESIGN AND OPTIMIZATION TECHNOLOGY

1 0 0 1

OPTIMIZATION TECHNOLOGY

  • Fundamentals and requirements of design optimization (what, when and why of optimization)

  • Optimization semantics, terminologies

  • Optimization techniques in practice

  • Discussion on Gradient based vs. Stochastic based optimization techniques

  • Fundamentals, requirements and challenges in multiple objectives design optimization

  • Demonstration of optimization using EXCEL solver (5)


TRANSFER FUNCTIONS

  • Fundamental concepts of transfer function generation

  • Introduction to design of experiments

  • Importance of meta models in design optimization

      • What is a meta model?

      • Why meta models?

      • How to generate a meta model?

      • When to use a meta model? (4)


ROBUST DESIGN

  • Fundamental concepts of robust design methods

  • Uncertainty quantification - how variation impacts performance

  • Discussion on the importance of maintaining design margins on customer CTQ’s

  • Linking probabilistics with optimization – driving robust designs (4)


CASE STUDIES

Two case studies to be worked out in the class

Tool – Excel Solver (2)
Total L: 15

TEXT BOOK:

1. Ashok D Belegundu and Tirupathi R Chandrupatla, “Optimization Concepts and Applications in Engineering”, Prentice Hall, New Jersey, 1999.


REFERENCES:

        1. “Optimization in Practice”, Altair Users Conference, Bangalore, India, August 2007.

        2. “Dace based Probabilistic Optimization of Mechanical Components”, Proceedings of GT2006 ASME Turbo Expo 2006 : Power for Land, Sea & Air, Barcelona, Spain, May 8 – 11, 2006.

        3. Kalyanmoy Deb, “Optimization for Engineering Design, Algorithms and Examples”, Prentice Hall, 2004.

        4. Singiresu S Rao, “Engineering Optimization Theory and Practice”, New Age International, 1996.



15PK03 SUPPLY CHAIN MANAGEMENT

1 0 0 1

SCOPE AND OBJECTIVE: Introduction to Supply chain management, Understanding of the basic business concepts and importance, approaches and inputs on design and management of supply chain. Introduce the concept and establish the linkage between new product development and supply chain design. (1)
SUBJECT COVERAGE: Business Concepts, Definition of supply chain, organizational dynamics, production environment, manufacturing choices, etc., Management approaches, MRP, JIT, TQM, etc., Demand Planning, Design of the system, Capacity management, Includes Definition resources, capacity and measurement, capacity requirement planning, etc., Planning, Strategic and Business planning, Production and resource planning, Sales and operation planning, MRP, CRP, Basics of final assembly scheduling, MRP/CRP in repetitive production, Execution and control, Order processing, measuring quality, process capability, variation. Performance measurement, Fundamentals of Inventory management, Purchasing. (14)
Total L: 15

REFERENCES:

  1. Michael H Hugos, “Essentials of Supply Chain Management”, John Wiley & Sons, 2010.

  2. Chopra Sunil and Peter Meindl, “Supply Chain Management”, Pearson Education, 2009.

  3. Joel D Wisner and Keah-Choon Tan, “Principles of Supply Chain Management - A Balanced Approach”, South Western Cengage Learning, 2009.

  4. John T Mentzer, Matthew B Myers and Theodore P Stank, “Hand Book of Global Supply Chain Management”, Sage Publishers, 2007.

  5. John J Coyle, Edward J Bardi C and John L, “The Management of Business Logistics: A Supply Chain Perspective”, Thomson Learning, 2006.

  6. David Simchi Levi, Philip Kaminsky and Edith Simchi Levi, “Designing and Managing the Supply Chain – Concepts, Strategies and Case Studies”, McGraw Hill, 2003.

  7. Ronald H Ballou, “Business Logistics / Supply Chain Management”, Prentice Hall, 5e, 2003.

15PK04 INTRODUCTION TO PRECISION MACHINING

1 0 0 1

CNC Turning - Principles, types, machines, tools. (1)

CNC Milling - Basic principles of milling, concepts of 3/4/5 axes, High Speed Milling, machine and controller types. (2)

EDM - Wire and Sinking, principles, application. (1)

Work and Tool Holding - types, applications. (1)

CAM - Principles, softwares, examples. (1)

Metrology - Principles, measurements, examples. (1)

GD & T (1)

Quality Management – 8 principles, purpose, ISO, process orientation, non-quality dispositions etc. (1)

Conventional precision manufacturing methods of Jig Boring, Jig Milling, Jig Grinding, Surface and Cylindrical Grinding. (1)

Productivity Improvement - types, measurement, Overall equipment effectiveness /total effective equipment performance OEE/TEEP measurements, Machine utilisation etc. (1)

Shop visit and assessment. (4)



Total L: 15

REFERENCES:

  1. Material Provided by M/s. L&T, Coimbatore.

  2. David Dornfeld and Dae-Eun Le, “Precision Manufacturing”, Springer, 2007.

  3. Murty R L, “Precision Engineering in Manufacturing”, New Age International Publishers, 2005.



15PK05 THEORY OF CONSTRAINTS AND ITS THINKING PROCESS

1 0 0 1

FUNDAMENTALS OF THEORY OF CONSTRAINTS: 5 step process of TOC - Understanding the term “Bottleneck” - Identifying Bottlenecks - Project vs Process Environments (a) Drum buffer rope methodology (b) Critical chain project management. (3)

TOC TOOLS: Swim Lane Diagrams - Storyboarding - 5 Whys Technique - Root Cause Analysis - Pareto Analysis and Queuing Models. (2)
ACCOUNTING AND TOC: Throughput - Operating expense - Productivity ratio - COGS (4)
INTEGRATING TOC WITH LEAN: 5 S – Tooling - 6 sigma - Total Productivity Maintenance (2)
BUSINESS SIMULATION GAME (2)
IMPLEMENTATION CASE STUDY (2) Total L: 15

TEXT BOOKS:

  1. Eliyahu M Goldratt and Jeff Cox, “The Goal – Process of Ongoing Improvement”, Productivity & Quality Publishing Private Limited, 2010.

  2. Eliyahu M Goldratt, “The Goal 2 – It’s Not Luck”, Productivity & Quality Publishing Private Limited, 2010.

  3. Eliyahu M Goldratt, “Critical Chain”, Productivity & Quality Publishing Private Limited, 2010.


REFERENCE:

1. Anthony A Atkinson, Robert S Kaplan, Ella Mae Matsumura and Mark S Young, “Managerial Accounting”, Prentice Hall, 2007.



15PK06 PRESS TOOL DESIGN

1 0 0 1

Metal Cutting Theory, Materials and Criteria for Selection. (2)


TYPES OF PRESS TOOLS: Piercing and Blanking, Progressive, Bending, Multislide etc. (2)
DESIGN CONSIDERATIONS BENDING: Die - Basics + Practical (2)
DESIGN CONSIDERATIONS: Selection of Tool Type, Presses, Strip Layouts (3)

PIERCING AND BLANKING DIE DESIGN - PART 1: Blank Development, Cutting Load Calculations, Strip Layouts, Cutting Clearances. (2)
PIERCING AND BLANKING DIE DESIGN - PART 2: Design of Stripper, Punch, Die, Frame Design, Material Selection and Heat Treatment. (2)

Latest developments in press tooling. (2)



Total L: 15

TEXT BOOK:

1. Cyrll Donaldson, George H Lecain and Goold V C, “Tool Design”, Tata McGraw Hill, New Delhi, 2009.


REFERENCES:

1. Joshi P H, “Press Tools - Design and Construction”, S Chand, New Delhi, 2010.

2. Vukota Boljanovic, Paquin and Crowley, “Die Design Fundamentals”, Industrial Press, New York, 2006.

3. Vukota Boljanovic, “Sheet Metal Forming Processes and Die Design”, Industrial Press, 2004.

4. Ivana Suchy, “Handbook of Die Design”, McGraw Hill, Inc., 1998.

15PK07 INJECTION MOLD DESIGN

1 0 0 1

Tooling materials and Heat treatment. (1)


BASICS: Various Engineering and Commercial Grade Thermoplastics: Properties and Applications. (2)
BASICS: Moulding Process, Parts of a Mould, Mould Materials. (2)
FUNDAMENTALS OF MOULD DESIGN - PART 1: Introduction to Subsystems: Feed Systems and Ejection Systems. (2)
FUNDAMENTALS OF MOULD DESIGN - PART 2: Introduction to Subsystems: Cooling Systems, Guidance Systems. (2)
DESIGN CONSIDERATIONS - PART 1: Selection of Cavity Layouts, 2 Plate, 3 Plate, Parting Line Selection, Standard and Custom Mold Bases and other aspects of design. (2)
DESIGN CONSIDERATIONS - PART 2: Selection of Machines, Sections, Sizes, Materials and their selection criteria. (2)

Design Discussions with an Example. (2)



Total L: 15

TEXT BOOK:

1. Pye R G W, “Injection Mould Design”, East West Press, 2000.


REFERENCES:

1. Prabodh C Bolur, “A Guide to Injection Moulding of Plastics”, Allied Publishers Limited, 2000.

2. Bown J, “Injection Moulding of Plastic Components : A Guide”, McGraw Hill, Inc., 1979.

3. Athalye A S, “Injection Moulding”, Multi-Tech Publishers and Company, Mumbai, 1997.

4. Whelan A, “Injection Moulding Machines”, CBS Publishers & Distributors, 1984.

15PK08 ADVANCED METROLOGY AND CALIBRATION

1 0 0 1

  GENERAL INTRODUCTION:



  • Automotive and Aerospace requirements in areas of Metrology

  • Measurement systems Errors- Explanations with Examples

  • Traceability and its importance

  • Introduction and important clauses ISO Standard 17025:2005

  • Selection of Length Standards

  • Advancement in CMM technology and its calibration

  • Drawing Study (GD & T)

  • Calibration of Verniers, Micrometers

  • Calibration of Dial gauges, Lever Dials. Height gauges


PRACTICAL WITH EXERCISE:

  • NABL criteria for Accommodation and Environment (Metrology lab requirements)

  • Selection of MASTER EQUIPMENT and REFERENCE MATERIALS

  • Calibration of non contact measuring Instruments

  • Calibration of Plain and Thread gauges

  • Calibration of machines (VMC etc)

  • Fixing Calibration periodicity

  • Interpretation of Calibration Reports/Certificates

  • Surface Roughness

  • Uncertainty Calculations as per latest NABL 141

 Total L: 15

REFERENCES:

  1. “Metrology Manual” by Tespa Tools Pvt. Ltd.

  2. Hume K J, “Engineering Metrology”, Macmillan Company Publishers.

  3. Connie Dotson and Roger Harlow, “Fundamentals of Dimensional Metrology”, Thomson Learning Publishers, New York, 2003.

  4. Galyer J F W and Shotbolt C R, “Metrology for Engineers”, Cassel and Company publishers, London, 1990.

  5. Astme and Wilson A W, “Hand Book of Industrial Metrology”, Prentice Hall, INC publishers, New Delhi, 1988.

  6. Parsons S H J, “Metrology and Gauging”, Macmillan Company Publishers, London, 1960.

  7. Hume K J and Sharp G H, “Practical Metrology - Vol 1 & VoL 2”, Macmillan Company Publishers


ONE CREDIT COURSES
For the detailed syllabi of the electives and one credit courses offered by other departments refer to the syllabi of M.E- Automotive Engineering offered by Automobile Engineering Department.



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