Teaching Scheme of M. Tech.

(Production and Industrial Engineering)

(Full Time):

Semester I
S.N Course Exa Cred
o.
Title L T P IA Total
No. m its
EMPI10
1 Statistical Methods in Engg. 3 1 0 25 100 125 5
1
EMPI102
2 3 1 0 25 100 125 5
Adv. Materials Science
EMPI103
3 3 1 0 25 100 125 5
Production Operations Management
EMPI104
4 3 1 0 25 100 125 5
Production Engineering-I
Sessional
EMPI10
5 Production Engineering-I Lab 0 0 3 60 40 100 2
5
1 16
Total 4 3 440 600 22
2 0
Semester II
EMPI201 Work Science
1 3 1 0 25 100 125 5
EMPI202
2 Total Quality Management 3 1 0 25 100 125 5
EMPI203
3 Plant Layout & Material Handling 3 1 0 25 100 125 5
EMPI204
4 Production Engineering II 3 1 0 25 100 125 5
Sessional
5 EMPI205 Production Engineering II Lab 0 0 3 60 40 100 2
1 16
Total 4 3 440 600 22
2 0
Semester III
1 EMPI301 Advanced Welding Technology 3 1 0 25 100 125 5
2 EMPI302 Maintenance Management 3 1 0 25 100 125 5
Sessional
EMPI303 10
3 Dissertation Part-I 0 0
3 0 0 100 4
EMPI304 15
4 Seminar 0 0
3 0 0 150 6
30
Total 6 2 6 200 500 20
0
Semester IV

1 EMPI401 Dissertation Part-II 0 0 9 0 500 500 24

Total 0 0 9 0 500 500 24
3 1 2 62 158 220
Grand Total 88
0 0 1 0 0 0

1
 EMPI101 :STATISTICAL METHODS IN ENGINEERING
L T P
3 1 0

Unit-I
Frequency Distributions:
Graphic Representation of a Frequency Distribution-Histogram, Frequency Polygon, Cumulative
Frequency Curves, Diagrammatic Representation of Data-Bar diagrams, Pie diagram. Measures of
Central Tendency.Measures of Dispersion.

Unit-II
Bivariate Distribution, Correlation:
Scatter Diagram, Karl Pearson's Coefficient of correlation, Limits of correlation coefficient,
Spearman's Rank Correlation. Regression: Lines of Regression, Regression Curves, Regression
Coefficient, Properties of Regression Coefficients, Angle between two Regression Lines.

Unit-III
Tests of Significance:
Null hypothesis, Alternative Hypothesis, Errors in sampling, Z-Test, Student's t-Test, x2-Test for
Goodness of Fit and Independence of Attributes, F- test for Equality of Population Variances.

Unit-IV
Probability Distributions :
Discrete Probability Distributions, Binomial, Poisson, Geometric and uniform. Continuous Probability
Distributions-Normal, Gamma & Beta. Introduction to Central Limit Theorem (Without Proof)

Unit-V
Non-Parametric Tests :
Wilcoxon -Rank Sum Test, Mann-Whitney -Wilcoxon U-Test, Wilcoxon signed Rank Test, Kruskal-
Wallis test.

Books:
1. Fundamentals of Mathematical Statistics: Gupta and Kapoor Sultan Chand & Sons.

2
 2. An Introduction to probability and Mathematical Statistics: Rohatgi V.K., Wiley Eastern
Limited.
3. Non-Parametric Statistical Inference: Gibbons, J.D; McGraw Hill Inc.
4. Fundamentals of Applied Statistics: Gupta and Kapoor Sultan Chand & Sons.

EMPI102:ADVANCED MATERIALS SCIENCE

L T P
3 1 0

Unit-I
Crystalline Structures:
Lattice Positions, planes and directions, Metal structures, Ceramic structures, Polymeric structures,
Semiconductor structures.

Unit-II
Imperfections in Crystalline Solids:
Vacancies, dislocations: edge and screw dislocation, elementary treatment of strain field and stress
field, strain energy and line tension associated with a dislocation, partial dislocation, dislocation climb,
cross slip, LomerCottrel barriers.
Fracture:
Types and their characteristics, nucleation of cracks, growth and failure, variables influencing
fracture.
Unit-III
Polymers:
Polymerization, Structural features, Thermo plastics and thermosetting polymers, additives,
mechanical properties, optical properties.
Advances in Material Processing:
Advance in Powder Metallurgy, hot isostatic pressing, Super plastic forming sol-gel process, self-
propagatinghigh temperature synthesis, crystal growth techniques, epitaxy.

Unit-IV
Composite Materials:
Method of preparation of fibers and fiber reinforced composites, micromechanics of composites,
prediction of composite properties from its constituents, laminates and their applications, Basic stress-
strain relationships, failure behaviors.
Unit-V
Ceramics:
Types, structures, development and fabrication techniques, mechanical properties, optical properties.
Powder Metallurgy:
Sintering, process description, various process developments of W, Mo & heavy based materials e.g.
cementedcarbides, cermet, selection of contact materials for tool materials.

Books:
3
 1. Mechanical Metallurgy: Dieter CE
2. Physical Metallurgy Principles: Reed-Hill RE 3. Dislocation & Plastic in
Crystals: Cottrell AH 4. Mechanics of Composite Materials: Jones RM
5. Physical Methods for Materials characterization Method: PEJ & Wild RK

EMPI103 :PRODUCTION OPERATIONS MANAGEMENT

LTP 31
0

Unit-I
Sales Forecasting :
Techniques used judgmental and causal forecasting. Market survey. Trend lines, time series, Moving
average, Exponential Smoothing, Forecast error, Confidence limits for seasonal variations, Analysis of
actual order forecasting under fluctuating demands. Cost and accuracy of forecast.

Unit-II
Product and Process Design :
Product Life cycle, Product Policy and selection. Product development and design process. Product
analysis. Cost estimation and cost reduction. Standardization, Process planning, manpower
requirements, line balancing. Problems of production planning and control. Break-Even Analysis.
Capacity Planning :
Capacity measures, capacity planning, estimating future capacity needs, Aggregate planning,
guidelines for aggregate planning. Linear programming approach to aggregate planning. Master
production schedule.

Unit-III
Material Requirement Planning (MRP) :
Introduction, MRP objectives, Functions served by MRP. Terminology, System outputs and MRP
logic. Manufacturing resource planning (MRP-II), Capacity requirement planning (CRP).
Project Scheduling with CPM and PERT :
Introduction, CPM and PERT, Time-cost tradeoff (Crashing). Resource allocation.

Unit-IV
Production Control :
Introduction, Loading sequencing and scheduling. Priority sequencing, Assignment models,
Scheduling, Dispatching , Expediting and Progress reporting (follow-up). In-process order control.
Machine load control by use of Gantt chart, Schedule boards, Machine allocation methods, Manpower
loading and scheduling.

Unit-V
Inventory Control:
Introduction, Meaning and types of Inventories, Inventory control objectives, Models, Inventory cost
relationships. Inventory control systems, selective control of inventory. ABC analysis, Reorder point.
Consideration of quantity discounts, Treatment of back orders. Probabilistic models with constant
4
lead time.
Computer Aided Production Planning and Control :
Information processing, JIT system, Designing fast response organizations.

EMPI104 :PRODUCTION ENGINEERING-I

LT P
31 0

METAL CUTTING

Unit -I
Introduction:
Types of cutting tools, tool geometry in ASA system, continental system and British maximum rake
system, Cutting tool materials, Orthogonal and oblique cutting. Orthogonal rake and angle of
inclination calculations.

Unit –II

Mechanics of chip formation, Maximum orthogonal rake, Types of chips, Merchant's force circle,
Shear angle relation, Tool wear and Tool life, Variables affecting tool life, Thermal aspects of metal
machining. Cutting tool temperature calculation. Limits of tool wear.

Unit-III

Economics of metal machining, Design of a single point cutting tool, Friction in metal cutting.
Grinding: Wheel specifications, Grinding ratio, Wheel wear, Buffing and Honing, Machine Tool
vibrations andchatter.

METAL FORMING
Unit –IV

Yield criteria, and theory of plasticity, Wire drawing with friction and back-pull, Extrusion with
friction and back pull for circular rods.
Unit –V

Sheet Metal working, Dies, Shear angle on punch. Direct compression processes, Forming and Rolling
Analysis, Analysis of sheet metal forming processes, Discussion on defects in metal forming
processes. CAD/CAM applications in forming.

5
Books:

1. Manufacturing Science Vol I and II M.I. Khan, P.H.I. New Delhi.

2. Manufacturing Science: Ghosh and Mallick. East West Press.
3. A Text Book of Production Engineering Sciences, PC. Pandey & C.K. Singh, Standard
Publishers / Distributors, NaiSarak, New Delhi.

6
 EMPI105 :PRODUCTION ENGINEERING - I LAB

List of Practical:

1. Study of Orthogonal cutting and

determination of shear plane angle
for mild steel.
2. Study of variation of diameter of a
cylinder along its axis. Study of
roundness of a turned cylinder.
3. Measurement of PCD of a V-
thread. Pin board experiment on
time study.

7
 EMPI201 :WORK SCIENCE
LT P
310

Unit –I

Introduction: Introduction to work science, Basic concepts, work organization, work study, Objective
benefits and scope of work study, Purpose and Advantages of work study, Fitting the tack to the
characteristics, Capabilities and Limitations of the Person.

Unit –II

Method Study: Objectives and scope, Basic procedure in conducting method study, Steps involved in
Method Study: Select, record, examine develop, install and Maintain, Job selection for study,
Recording techniques, Micro-and memo-motion study, Fundamental hand motions (therbligs),
Principles of motion economy, CriticalExamination, Development of proposed method, its installation
and maintenance.

Unit-III

Work Measurement: Objectives, Work measurement procedures (steps), Work measurement systems,
Concept of standard rating, Breaking the task into elements, Rating and Basic Time, Requirements of
satisfactory rating, Time study procedure, Tools for time study, Number of cycles to be timed,
Synthesis of standard time from elemental data, Activity sampling, sample size, Standard time by work
sampling, Control charts applied to work sampling.

Unit -IV
Workplace design : Muscular work, Nervous control of movements, Anthropometric data, Reach and
clearance dimensions, percentiles to be accommodated, workplace designcomfortable work postures,
Room to grasp and moves things and operate controls, sedentary work, sedentary workplace design,
Design of tools for skilledwork, VDT workstation design and design of keyboards, Heavy work,
Handling loads, skilled work..

Unit -V
Man-Machine System, Display equipment, controls, Relation between control and display instruments,
Human visual system, eye movements, artificial lighting, light for manual fine work and VDT
workstations, Noise Physiological and psychological effects of noise, damage to hearing, Protection
against noise, Effects of vibrations on human performance, Thermo-regulation in human body, comfort
indoors, Air quality and dryness, Air pollution and ventilation at work, Recommendations for comfort
in-doors.

8
 EMPI202 :TOTAL QUALITY MANAGEMENT
LT P
31 0

Unit-I
Fundamentals of Quality Management :
Quality as the new competitive weapon, Evolution of quality management, Definition of quality,
Dimensions of quality in production system, Quality and Profitability, Quality Costing.
Quality Management Philosophies:
Deming Philosophy, Crosby Philosophy, Taguchi quality loss functions, Six sigma approach for
quality.

Unit-II
Managing Quality:
Quality control, Quality assurance, Total quality control, Total quality management (TQM), Basic
concept of TQM, Overview of TQM, Necessity for TQM, Elements of TQM, Benefits of TQM.
Tools for the Quality Journey :
Check sheet, Pareto diagram, Cause-and -effect diagram, Histogram, Control charts, Scatter diagram,
Flow Chart, Relationship between the tools and the PDCA Cycle, Design of experiments. Quality
function
Deployment.

Unit-III
Leadership and Strategic planning for TQM :
Leadership for quality, quality and organizational structure, Role of quality in strategic planning,
Strategicquality management (SQM)
Human Resources Development & Strategic Information Management for
TQM. :
Human Resources Development for TQM, Strategic Information management for TQM. The strategic
value of information, The scope of quality and operational performance, Role of Information,
Technology.

Unit-IV
Organizing for TQM:
Organizing for TQM, Teams, Quality circles, Developing a quality culture, Change management.
Statistical Quality Control:
Theory of Control Chart for variable and attribute acceptance sampling plans for attribute and
variable.

Unit-IV
Quality system and ISO 9000 Series:
ISO 9000 Pre-requisites, different quality system and their structure, Quality policies and objectives,
management responsibility, documentation methodology of implementation, quality audit and
assessments.
Miscellaneous:
Relevance of JIT t o TQM, Benchmarking, Relevance of TQM to world class manufacturing.

9
Books:
1. Quality Planning and Analysis, Juran J.M., EGryan Jr., TMH, New Delhi.
2. Total Quality Management, Dr. K. Raja, Eswar Press.
3. Total Quality Management, A practical Approach, H. Lal, New Age.
4. Total Quality Management, K Shridhar Bhatt, PHI

10
 EMPI203 :PLANT LAYOUT AND MATERIALS HANDLING
LT P
310

Unit-I
Introduction :
Definition, objective, principles of plant layout, need for re-layout decisions, types of layout problems,
factors influencing plant layout, Types of layout-product, process, fixed, combination and group
layout.

Unit-II
Procedure for Plant Layout:
Basic Steps in layout procedure; procuring basic data, product analysis and design of production
process, calculation for equipment requirements, plan general flow pattern, selection of material
handling equipment, determine the space required, construct master layout.

Unit-III
Techniques and Tools for Planning Layout:
Assembly chart, operation process chart, multi product process chart, flow diagram, Man machine
chart, string diagram, travel diagram, drafting, template and block.
Quantitative Layout Analysis:
Techniques of analysis, computerized layout planning, allocation method, activity relationships chart.

Unit-IV
Improving and Revising Existing Layout:
Need for changing layout, reasons for redesign, procedure for revision and improvement.
Evaluation for an Effective Layout:
Evaluation of a layout, measurement of effectiveness, methods of evaluation.

Unit-V
Material Handling:
Material handling principles, analysis of material handling system, unit load concept, factor-affecting
selectionof material handling equipment, layout and materials handling system.

Books:
1. Facility layout and Location, An Analytical
Approach: Francis. Etal., 2nd ed., PHI

2. Material Handling Handbook: David E.

Mulcahy, 1999, TMH.
3. Facilities Planning: Tompkins, J.A and
White, J. A Eds., 1nd ed., John Wiley &
Sons, New York, 1996.
4. Handling of Bulk Solid: Theory and
Practice: Shamlou, P.A. butter Worths,
London, 1998.
5. Handbook of Commercial and Facilities
Managemetn: Wrenmall, W., and Q. Lee,
eds Mc Graw Hill, New York, 1994, pp
201-240.
6. Plant Layout and Materials Handling: S.C Sharma, Khanna Publishers., Delhi.
11
7. Plant Layout and Material Handling: G.K. Agarwal, Jain Brothers, Delhi.

12
 EMPI204: PRODUCTION ENGINEERING-II
LT P
31 0
Unit –I

Introduction: Casting compared with other processes, steps involved in a casting process. Basic
factors involved in casting processes, Patterns: Design (Allowances) and design considerations. Sand
Testing. Fluidity of molten metal and its measurement, Molten metal characteristics, Casting
parameters, mould design, sprue, runner, riser, degree of superheat and rate of pouring. Comparative
study of various casting processes.
Unit –II

Principles of Gating Design: Types of gates, pouring basins design, Metal flow-rate and velocity
calculations, Sprue terminology and design. Design of runners and gates.
Principles of Risering (Feeder heads): Design of Risers, Chvorinow's rule and solidification time
calculations for different shapes, Caines method, shape Factor method of riser size calculations
Solidification of castings: Large casting in insulated mould, Directional solidification, Calculations for
top and bottom gating systems.
Unit-III

Casting Design considerations: Metallurgical, mechanical and economic considerations, Casting

defects and inspection, Finishing and cleaning of castings.
Metal joining Processes: Introduction: Classification of welding Processes conditions for obtaining
satisfactory welds, Importance of welding, selection of a welding process.
Welding Science: Arc Characteristics. Arc Length control and welding power sources characteristics,
constant current and constant potential power sources and their applications, Arc welding Power
Supply Equipments, Power source selection, Welding Energy Input, Energy sources( types), Metal
Transfer.

Unit –IV

Welding Parameters and their effects: Metallurgical aspects in Welding, Weld-microstrures: fusion
zone, Heat affected-zone (HAZ) and base metal. Weld-metal solidification, Residual stresses and
distortion of welds, Stress-relieving methods, Thermal and mechanical treatment of welds.

Unit –V

Advanced welding processes : Laser beam welding, Electron Beam Welding, Plasma Arc Welding,
High Frequency Welding and Underwater welding processes, Analytical and Mathematical analysis:
Calculation of heat input and relation between weld cross-section and energy input, Heat flow
equations, width of heat affected zone, cooling rates, contact resistance, heat source, weld quality:
undercuts, cracks, porosity, slag inclusion, Lack of fusion, Lack of penetration Faulty weld profile
Testing and Inspection of welds.
Welding of materials: Cast Iron, Aluminum and its alloys, Stainless steels, Dissimilar Metals
welding, Cladding and Hard facing, Welding of plastics.

Books :
1. Flinn, R.A., Fundamentals of Metal Casting, Addison-wesley, Reading, Mass.
2. Little, Welding and Welding Technology, McGraw Hill; 2004
3. Khan, M.I. Welding Science and Technology, New -Age Int. 2007
4. Heine, Principles of Metal casting, McGraw Hill, 2nd Ed. 2001
5. Jain, P.L. Principles of Foundry Technology McGraw Hill 5th Ed. 2009

13
EMPI205: PRODUCTION ENGINEERING -II LAB

1. Study of weld-bead geometry.

2. Study of moisture and clay content
variation on mould hardness.
3. Study of weld-bead microstructure in
weld-zone HAZ and microstructure of
the base metal for Air Welded
Specimen.
4. Study of weld-bead microstructure in
weld-zone HAZ and microstructure of
the base metal for UW(underwater)
welded specimen.
5. Study of weld defects through X-ray
reference radiographs.

14
 List of Electives for M. Tech.

(Production and Industrial Engineering)

EMPI301
Elective -I

EMPI301.1Advanced Manufacturing Processes

EMPI301.2 Advanced Metal Casting Technology
EMPI301.3 Advanced Welding Technology.
EMPI301.4 Design for Manufacture

EMPI302
Elective -II

EMPI302 .1. Robotics and Control

EMPI302.2 Flexible Manufacturing Systems
EMPI302.3 Advanced Computer Aided Manufacturing
EMPI302.4 Maintenance Management

15
 EMPI301.1: ADVANCED MANUFACTURING PROCESSES
LTP
310
Unit-I
Machining processes:
Classification of advanced machining processes; consideration in process selection.
Mechanical Metal Removal Process:
Ultrasonic machining; elements of the process; mechanics of metal removal; tool design economic
consideration; applications and limitations.

Unit-II
Abrasive Jet and Abrasive Water Jet
Machining:
Basic principles; mechanism of metal removal; design of nozzles;
variables governing therocesses; applications.
Electro-chemical Process:
Fundamentals of the ECM and ECG techniques; mechanism of metal removal; design of tooling;
choice of process parameters; surface finish and accuracy; economic aspects of ECM; electro-chemical
deburring; and honing.

Unit-III
Thermal Metal Removal Processes:
Classification; general principles and applications of EDM, EBM. PAM and LBM, power circuits of
EDM; mechanism of metal removal EDM; selection of EDM pulse generator, tool electrode and
dielectric; machining accuracy, surface finish and surface damage in EDM; process parameters, wire
EDM.
Generation and control of electron beam for machining; applications; advantages and limitations.

Unit-IV
Generation and application of plasma for metal cutting; plasma torches.
Basics of laser beam machining; thermal phenomenon due to laser work surface interaction; cutting
speeds and accuracy of cut; applications and limitations. Improving the efficiency of laser machining
process. Process details of ion beam machining and its applications.
Introduction to hybrid unconventional machining processing. ECDM, ECAM, Abrasive EDM, etc.
Unit-V
Metal Forming:
Theory and application of Contour roll forming, stretch forming explosive forming etc.
Welding:
Theory and applications of electron beam welding, Laser beam welding, Ultrasonic welding, Solid
state diffusion and explosive welding process.
Books:
1. Non Traditional Machining Processes Springborn:
ASTME Michigam.

2. Modern Machining Processes: Pandey

and Shan, THM
3. Electrochemical Machining: De Bar,
Mc Donald
4. Metals Handbook Forming: - ASM
16
5. Advance Machining Processes : Jain, Allied Publishers.

17
 EMPI301.2: ADVANCED METAL CASTING TECHNOLOGY
LTP
310
Unit-I
Introduction:
The features of casting problem; a survey and scope of foundry industry.
Solidification:
Solidification of pure metals and alloys; nucleation and growth in alloys; solidification of actual
castings; progressive and directional solidification; centerline feeding resistance; rate of solidification;
Chvorinov's Rule, electrical analog of solidification problem.
Patterns :
Pattern design; developments in pattern design; materials and construction.

Unit-II
Risering :
Riser design; risering curves; method of riser design; feeding distance; risering of complex casting;
risering of alloys other than steel; recent developments e.g. riser design by the application of
geometrical programming.
Gating :
Gating systems and their characteristics; the effect of gates on aspiration; turbulence and dross trap;
recent
trends.
Unit-III
Molding and Core Making processes:
Review and critical comparison of various established processes; recent developments eg. Low
pressure and ferrous die casting; high pressure molding; full mold process; flaskless-molding, hot and
coldbox molding; ceramic shell molding; V-preocess; continous casting squeeze and pressed casting;
New moulding and core making process.
Unit-IV
Melting:
Selection and control of melting furnaces; melting, refining and pouring; recent trends: cupola design.
Fluidity:
Measurement of fluidity; effects of various parameters on fluidity.
Internal Stress, Defects and Surface Finish:
Residual stresses; hot tears and cracks in castings; stress relief; defects causes and remedies; various
parameters affecting surface finish and related defects e.g. rough casting, sand bum-on sand bum-in
and metal penetration; facting and washes; mold wall movement; vapor transport zones; expansion
scabbing etc.

Unit-V
Gases in Metal:
Methods of elimination and control of dissolved gases in castings.
Foundry Practice:
Casting of different types of cast irons; aluminum; zinc; brass etc; mechanization in factory; use of
computer in foundry.
Inspection and Quality Control:
Review of x-ray radiography; magnetic particle; penetrant and ultrasonic inspections; use of statistical
quality control in foundry.

Books:

18
1. Metal Casting Computer Aided Design and Analysis: Ravi B. Prentice Hall of India.
2. Fundamentals of Metal Casting: Flinn, R.A., Addison-wesley Reading, Massachusetts, 1963.
3. Transport Phenomena in Metallurgy: Geiger. G.H. and Poirier, D.R. Addison Wesley, Reading.
4. Thermodynamics for the Foundaryaman: Veynik, A.I. Mac Laren, London, 1968.

19
 EMPI301.3: ADVANCED WELDING TECHNOLOGY
LTP
310

Unit-I
Introduction:
Welding as compared with other fabrication processes, Classification and review of conventional
Welding Processes.
Physics of Welding Arc:
Welding arc, arc initiation and maintenance voltage distribution along the arc, cathode and anode
drops, Arc column. Characteristics of welding power sources, arc characteristics, arc efficiency, heat
generation at cathode and anode Effect of shielding gas on metal transfer, isotherms of arcs.

Unit-II
Metal Transfer:
Mechanism and types of metal transfer in various arc welding processes, arc length regulation in
mechanized welding processes, Transformer, rectifier and generators, Duty cycle and power factor,
Static and dynamic characteristics of welding power sources.

Unit-III
Welding Processes:
Critical review and analysis of MMA; TIG MIG and C02 welding processes plasma arc, submerged
arc welding, electro-gas and electro-slag welding; resistance welding. Theory and mechanism of solid
state welding; technique and scope of friction welding, diffusion welding; cold pressure welding and
ultrasonic welding, scope and application of electron beam and laser beam welding processes.

Unit-IV
Heat Flow in Welding:
Analysis of Heat transfer and temperature distribution in electric arc welding; width of Heat Affected
Zone; cooling rate and solidification rates; weld thermal cycles; residual stresses and their
measurement; weld distortion and its prevention.

Unit-V
Weldability of Metals:
Effects of alloying elements on weldability, welding of plain carbon steel, stainless steel, Cast Iron and
aluminium. Evaluation of weldability. Testing and inspection of welds. Welding of PVC plastics.
Welding under the influence of Magnetic field.

Books:

1. Welding Handbook-AWS, Vol. 1-5

2. Welding Science and Technology-M.I. Khan, New-Age International.
3. Welding For Engineer. Udin, Fruk and Wulif, John Wiley.
4. Welding Technology, Rossi, McGraw Hill.

20
 EMPI301.4: DESIGN FOR MANUFACTURE
LTP
310

Unit-I
Introduction:
Introduction, concept of concurrent engineering, need of concurrent engineering, Automation of design
and manufacturing functions in CIM, computer aided process panning, Design for Manufacture ,
Approaches toDFM & DFM, Design for Automated Manufacturing and Design for Economic
Manufacturing.

Unit-II
Design Quality:
Quality by Design, QFD, Taguchi's concept of Quality Loss function parameter design, comparing
alternative design, tolerance design, system optimization, Robust design.

Unit-III
Design for Reliability:
Basic concepts, reliability analysis during design phase, failure mode analysis, reliability analysis of
mechanical systems, design guidelines for reliability, maintainability and testability, reliability tests,
quality reliability assurance during production phase.

Unit-IV
Design Knowledge Representation:
Design for manufacturing and re-design considerations in automated CAD/CAM systems, Design and
manufacturing knowledge representation, knowledge representation for DFM support, intelligent
evaluation ofdesign for manufacturing cost.

Unit-V
Evaluation of Manufacturability:
Evaluation of the manufacturability of a part design, various methods of defining manufacturability
index, interpretation of the MI value, Manufacturability evaluation; a multi criteria approach.

Books:

1. Integrated Product Development : M.M. Andersen and L. Mein, IFS Pub.

2. Product Design for manufacture: G Boothroyd, P Dewhurst and W. Knight, Marcel Dekker
3. Handbook of Product Design for Manufacture, A practical Guide to low Cost Production: J. G.
Bralla,McGraw Hill
4. G.D. Huang, Chapman & Hall
5. Concurrent Engineering: Kusiak, Wiley
6. Competitive Product Design for Manufacturability: Barkan and Ishui Mc Millon.

21
 EMPI302 .1: ROBOTICS AND CONTROL
LTP
310
Unit-I
Introduction:
Different tools and programming aspects of robotics and its applications. Robots applied to various
manufacturing processes and work.
Definition; Classification of Robots; Geometric Classification and Control Classification.

Unit-II
Robot Elements:
Drive systems, Control systems, Sensors, End effectors, Gripper actuators and Gripper design.
Robot Coordinate Systems and Manipulator Kinematics:
Robot coordinate system representation, Transformation, Homogeneous Transforms and its inverse,
Relating
the Robot to its World.

Unit-III

Manipulators Kinematics, Parameters of Links and Joints, Kinematics chains, Dynamics of Kinematics
chains,
Trajectory planning and Control.

Unit-IV
Robot Control :
Fundamental Principles, classification, position, path and speed control systems, adaptive control.
Robot
integration with CAD and CAM, Collision free motion planning.

Unit-V
Robot Programming:
Level of Robot programming, Language based programming, Task level programming, Robot
Programme
synthesis, Robot programming for foundry, press work, heat treatment, welding, machine tools,
material
handling, warehousing assembly etc., automatic storage and retrieval system, robot economics and
safety.

Books:

1. Robotic Technology: Vol I-V, Phillipe

Collet, Prentice Hall
2. An Introduction to Robot: Coiffet and
Chirooza, Kagan page Technology
3. Industrial Robots : Korean Mir
4. Industrial Robotics : Groover, Mitchell
22
 Weiss, Nagel Octrey, McGraw Hill. Automation
5. Robots and Manufacturing: Asfahl, Wiley

23
 EMPI302.2: FLEXIBLE MANUFACTURING SYSTEM
L T P
3 1 0

Unit-I
Introduction:
Concepts of flexibilities and its importance in batch manufacturing Various type of FMS
configurations, their planning and control.
FMS definition and Classification of manufacturing systems Fundamentals of automated Production
Cycle,
Need of Flexibility, Concept of Flexibility, various Types of Flexibility and Measures of Flexibility.

Unit-II
FMS Equipment:
FMS and its importance, Factors responsible for the growth of the FMS, FMS types, Application of
FMS, Economic Justification for FMS and FMC Functional requirements of FMS equipment, FMS
processing and
Q.A. Equipment e.g. turning and machining centers,

Unit-III
Co-ordinate measuring machines, cleaning and deburring machines. FMS system support equipment:
automated material handling and storage equipment, cutting tools and tools management, work-
holding considerations, fixture consideration in FMS environment.

Unit-IV
Group Technology and FMS:
GT concepts, advantages of GT, part family formation-coding and classifications systems; Part-
machine group analysis; methods for cell formation, model of different algorithms, mathematical
programming and graph
theoretic model approach for part grouping, cellular production.

Unit-V
FMS planning problems: Strategic planning, part type, selection, machine grouping, production ratio
and resource allocation, machine loading problems.Operational & Controls problems: Scheduling of
parts, machines, robots and AGVS. Process monitoring and control. FMS Implementation: Objectives,
Acceptance Testing Performance Goals and Expectations, Maintenance Concerns.

Books:
1. Automation, Production System and CAM : Grover, Englewood
2. Design and Operation of FMS: Rankey, IFS
3. Flexible Manufacturing System: Wernecks, Springer-Gerlag
4. FMS in Practice: Bonctto, Northox Ford
5. Flexible Manufacturing Cells and System: W.W. Luggen, Prentice Hall
6. Performance Modeling of Automated Manufacturing System: Viswanathan Narahari,
Prentice Hall.
7. Flexible Manufacturing Systems in Practice: Talavage and Hamman

24
 EMPI302.3: ADVANCED COMPUTER AIDED MANUFACTURING

LTP
310
Unit-I
Introduction:
Introduction to Automaton, Need and future of NC systems and CAM, Advantages and Disadvantages,
Classification of open and closed loop system Historical Development and Future Trends.
Future of NC machines, difference between ordinary and NC machine tools, Methods for improving
accuracy
and productivity.

Unit-II
Control of NC Systems:
Types of CNC Machine tools systems and devices e.g. encoders and interpolators, Features of CNC
systems,
Direct Numerical Control (DNC), Standard Controllers and General Programming Features available
in CNC
systems, Computer Process Monitoring Control. Adaptive control system.

Unit-III
NC Part Programming:
Manual Programming for sample parts e.g. turning, milling, drilling etc. Computer aided NC
programming in APT language, Use of canned cycles.
Generation of NC Programmes through CAD/CAM systems
Design and implementation of post processors.

Unit-IV
Robots in Manufacturing:
Major Components and functions of robots, Types of Robots and their selection for manufacturing
applications, Performance capabilities, Robot programming, methods, Robot programming language
(VAL & AML), Application of industrial robots in manufacturing, Integration of the robot into a
machining cell, Robot path
planning and control, Collision free motion planning.

Unit-V
Computer Integrated Manufacturing:
Introduction, Features of CIM, Key elements of CIM, Advantages and Disadvantages.
AI in Manufacturing:
Introduction to Artificial Intelligence,Elements of expert systems and Introduction to neural networks,
Expert
systems application in manufacturing; case studies.

Books:
1. Computer conrol of Manufacturing Systems: Koren
2. Robots :Koren
3. CAD/CAM : Groover
4. NC machine tools: S.J. Martin
5. CAD/CAM : P. Radha Krishna, S. Subramanyam, V. Raju
25
6. Group Technology; Applications to Kproduction Management: Ham and Hitomi Kluwer-
Nijhoff
7. Systems approach to computer integrated design and manufacturing, N. Singh, Wiley 8.
Computer Aided Manufacturing: Chang, Wysk and Wang, Prentice Hall.

26
 EMPI302.4: MAINTENANCE MANAGEMENT
LT P
310
Unit-I
Introduction:
Importance, definition, meaning and scope of maintenance, objectives, duties, functions and
responsibilities of maintenance engineering department, organization and structure of maintenance
systems, types of maintenance, replacement need, case studies and simple probabilistic models for
items that fail completely, crew size determination.
Management Policies for Maintenance: Policies for work allocation, interplant relations, workforce
and control.

Unit-II
Maintenance Planning and Scheduling:
Maintenance planning, strategies and scheduling, reliability oriented maintenance systems, reliability
programme, reliability improvement, quantitative estimation of reliability, failure modes effects and
critically analysis (FMECA), reliability models and indices.
Introducing standby unit into production system, optimum design of a series/parallel system,
breakdown time distribution.

Unit-III

Total Productive Maintenance (TPM): Objectives, waste elimination , equipment maintenance

techniques. Benefits of TPM, pillars of TPM, performance measures of maintenance systems.
Maintenance Activities:
Optimal overhaul/repair or replacement, Maintenance budgeting and control, production maintenance
integration.

Unit-IV
Maintainability and Availability:
Economical aspects of maintainability and reliability, maintainability increment, overall equipment
effectiveness, productivity and maintenance, condition based maintenance, equipment availability.

Unit-V
Computer Aided Maintenance:
Introduction, benefits, selection process for software, use of computers in decision making for
maintenance, system implementation, and key maintenance features, functions of computer
maintenance management system (CMMS), Integration of CMMS with overall organizations
network,
Software and hardware failure, future course of CMMS.

Books:
1. Maintenance Engineering and Management, K. Venkataraman, PHI
2. Reliability and Maintenance Engineering, R. C. Mishra, New Age International
3. Production and operations Management, R. Panneerselram, PHI
4. Maintenance Engineering Handbook, L R Higgins, Mcgraw Hill Inc.
5. Management of Industrial Maintenance, Kelly A and M J Harris, Butterworth & Co.