411081: Production Management
Teaching Scheme
Examination Scheme
Lectures: 4 hrs/week
Theory: 100 Marks
Practical: 2 hrs/week
Duration: 3 hours
Term Work: 50 Marks
Objectives
·
To learn and understand
Concepts and functions of Production Management
·
To learn and use
software packages for decision making
Prerequisites
·
Industrial Engineering
and Management
·
Production Planning and
Control
Scope of Production Management (4)
The evolution of Production management / Operations Management. Different production eras - Mass production, flexible and mass customization and customization. Relationship of Production / Operations Management with materials, maintenance, quality control, design engineering, production engineering, material and sales. Scope, Definition and its relationship with other management functions such as marketing, finance and personal management. Production organizations for single product, multi product, single location, multi location.
Product Design (4)
Product life cycle, Relationship between product design and product cost. Functional, Economic, manufacturing and marketing aspects in product design, Concept of Concurrent engineering.
Facility-location: Objectives, site selection, floor rating, center of gravity method.
Layout types, quantitative models for facility layout, locations, layout planning for distribution centers.
Material handling (3)
Material handling: Its relation with layout, Objectives, principles and types of material handling. Material handling analysis. Unit load concept.
Manpower forecasting, manpower inventory, capacity and level strategies, aggregate capacity planning, determining optimal operating levels and timing of capacity increments.
Productivity: factor productivity, total productivity, labour Productivity, measurement of productivity, improvement techniques of productivity. Development and implementation of Productivity improvement programme.
Concept of World Class Manufacturing, Emergence of information age, Manufacturing challenges of the information age, elements of business turbulent environment. Problems in the manufacturing sector. Evolution and principles of WCM. Contribution of Hall, Schoenberger, Gunn, Maskel, World class practices in the industry, WCM-Indian Scenario.
Organization, administration of maintenance function, types of maintenance, principles, operating policies, scope of maintenance management, Work authorization, work scheduling
maintenance budget and costs, Total productive maintenance.
Unit VI
Energy conservation and Energy audit, Eco development considerations, Green production, Lean and Agile manufacturing, Problems of technology choice and technology transfer, environmental pollution and control strategies, computerized production management systems.
1. Facility location models (any 3).
2. Study of Plant layouts: Manufacturing/Service unit using SLP
3. Computerized facility layout Planning – CorelaP, CRAFT, ADLEP,
4. Aggregate planning using MS Excel
5. Energy audit and Study of energy conservation practices for a specific industry
6. One Internet based assignment on any one of topics above
Text
Books:
1. J. L. Riggs, “Production Systems”, John Wiley and Sons.
2. Mayer, “Production Management”, Tata McGraw Hill Publications
3. M. Telsang, “Industrial Engineering and Production Management”, S. Chand Publication
Reference
Books:
1. H. B. Maynard and others, “Modem manufacturing”, IVth edition - McGraw Hill Publications, ISBN 0-07-041084-4.
2. H. B. Maynard and others, “Industrial Engineering Handbook”, IVth edition - McGraw Hill Publications, ISBN 0-07-041084-4.
3. L. R. Higgnis, R. K. Mobley, Smith Ricky, “Maintenance Engineering Handbook”, McGraw Hill Publications, ISBN 0-07-028819-4.
4. Kanter Jerome, “Management Information System”, Prentice Hall, ISBN 0-87692-358-9.
5. H. Noori and R. Radford, “Production and Operation Management”, Total Quality and
Responsiveness international Edition - 1995 - McGraw Hill Inc.
6. B.S. Sahay, K B C. Saxena, Ashish Kumar, “World Class Manufacturing-A Strategic perspective”,McMillan India Ltd.
7. F. L. Francis, J. A. White, L. F. McGinnis, “Facilities Layout and Location”, Prentice Hall of India Pvt. Ltd., ISBN 81-203-1460-3.
8. T. E. Vollmann, W. L. Bery, “Manufacturing Planning and control Systems”, Galgotia Publication New Delhi, ISBN 81-7515-084-X.
9. Richard Muther, “Systematic Layout Planning”
411082: machine tool
design
Teaching Scheme
Examination Scheme
Lectures: 4 hrs/week
Theory: 100 Marks
Practical: 2 hrs/week
Duration: 3 hours
Term Work: 50 Marks
Oral: 50 Marks
Objectives
·
To learn and understand
Machine Tool Design
·
To learn and compute
design aspects for machine tools
Prerequisites
·
Design of Machine
Elements
·
Kinematics and Design of
Manufacturing Machines
Drives
(4)
Design considerations for drives based on continuous and intermittent requirement of power, Types and selection of motor for the drive, Regulation and range of speed based on preferred number series, geometric progression. Design of speed gear box for spindle drive and feed gear box.
Design considerations of Stepless drives, electromechanical system of regulation, friction, and ball variators, PIV drive, Epicyclic drive, principle of self locking,
Analysis of forces on machine tool structure, static and dynamic stiffness.
Design of beds, columns, housings, bases and tables.
Functions and types of guideways, design criteria and calculation for slideways, design of hydrodynamic, hydrostatic and aerostatic slideways, Stick-Slip motion in slideways. Design of power screws: Distribution of load and rigidity analysis.
Design of spindle and spindle support using deflection and rigidity analysis, analysis of anti-friction bearings, preloading of antifriction bearing.
Dynamic characteristic of the cutting process, Stability analysis, vibrations of machine tools.
Control Systems: Mechanical and Electrical, Adaptive Control System, relays, push button control, electrical brakes, drum control.
Design considerations for SPM, NC/CNC, and micro machining, Retrofitting, Recent trends in machine tools, Design Layout of machine tool using matrices.
Term work:
Term work shall consist of record of assignments on following topics. Oral shall be based on term work.
1. Design and working drawing of speed gear box
2. Design and working drawing of feed gear box
3. Study of stepless drives
4. Design of bed or column.
5. Design for spindle or power screw.
6. Design for guideways and slideways.
7. Internet assignment based on any one of the topics above.
Text Books:
1. N. K. Mehta, “Machine Tool Design”, Tata McGraw Hill, ISBN 0-07-451775-9.
2. A. Bhattacharya and S. G. Sen., “Principles of Machine Tool”, New central book agency Calcutta, ISBN 81-7381-1555.
3. D. K Pal, S. K. Basu, “Design of Machine Tool”, 4th Edition. Oxford IBH 2005, ISBN 81-204-0968.
Reference
Books:
1. N. S. Acherkan, “Machine Tool”, Vol. I, II, III and IV, MIR publications.
2. F. Koenigsberger, “Design Principles of Metal Cutting Machine Tools”, The Macmillan Company New York 1964.
411083: manufacturing automation and
control
Teaching Scheme
Examination Scheme
Lectures: 4 hrs/week
Theory: 100 Marks
Practical: 2 hrs/week
Duration: 3 hours
Oral: 50 Marks
Objectives
·
To learn and understand
Hard and Soft Automation
·
To learn and perform
experiments with hydraulic and pneumatic circuits
Prerequisites
·
Machine Tools and
Advance Manufacturing Systems
Basic concepts of automated system, Advanced automated functions, levels of automation, Principles of hydraulics, hydraulic fluids, filtration technology, hydraulic pumps, hydraulic valves, and hydraulic actuators.
Basic hydraulic circuits such as regenerative circuits, sequencing circuit, meter in and meter out circuit, standards in circuit diagram representation, power pack design layout, design of pumps, reservoir, accumulators and intensifiers, selection of standard components, hydraulic servo mechanism, proportional valves.
Operational principles and application, air compressors, pneumatic cylinders and air motors, pneumatic valves, Design of pneumatic circuits, hydro-pneumatic, control in pneumatic system.
Microprocessor, microprocessor instrumentation system for process control, logic gate and control, programmable logic control, computer process controls.
Electric control: - features and design principles of electrical circuits in drives, PLC, data conversion (ADC/DAC), interfacing circuits, actuating signals, relays, contactors, types of control systems, linear feedback control system, optimal control system.
Transfer systems-Continuous, intermittent, Indexing mechanisms, vibratory bowl feeders, non-vibratory feeders, hopper feeders, rotary disc feeder, centrifugal, revolving feeder, assembly systems, automated assembly, design for automated assembly, synchronous and non synchronous material transfer, industrial robots, Automated Guided Vehicles and FMS, automated warehouse.
Term Work:
The term work shall consist of record of any eight assignments on following topics.
1. Study of control valves, actuators, accumulators and pumps.
2.
Study of hydraulic circuits: - hydraulic press, machine tools,
automobile systems,
etc
3.
Performance analysis
of positive displacement
pumps.
4.
Comparative studies on
hydraulic circuit design for suitable industrial
applications.
5.
Study of pneumatic circuits.
6. Study of automation in material handling system.
7. Use of microprocessors: applications in manufacturing engineering.
8. Study and experiments in programmable logic controllers: ladder logic programming
9. Study of displacement, level and pressure controls
10.Measurement and design
circuits for speed and temperature measurement.
Oral shall be based on the above Term work. ,
Text Books:
1. B. C Kuo, “Automatic control systems”, Prentice Hall India Pvt. Ltd., ISBN 0-87692-480-1.
2. Peter Rohner, “Industrial hydraulic control”
3. Mikell P Groover, “Automation, Production System and Computer Integrated Manufacturing”, Prentice Hall Publications, ISBN 81-203-0618-X.
4. S. R. Mujumdar, “Pneumatic system”, Tata McGraw Hill 2002 Edition.
5. Gopal, “Control systems Engineering”, Willey Eastern Ltd., ISBN 0-85226-605-7.
Reference Books:
1. E. O Doebelin., “Measurement System, Application and Design”, Tata McGraw Hill Publications Ltd., New Delhi, ISBN 0-07—17338-9.
2. W Bolton., “Mechatronics Electronic Control Systems in Mechanical and Electrical
Engineering”, Pearson Education (Singapore) Pvt Ltd., ISBN 81-7808-339-6.
3. C S Rangan, G R Sharma, V S Mani, “Instrumentation - Devices and Systems”, Tata
McGraw Hill Publications Ltd., New Delhi, ISBN 0-07-463350-3.
4. B H Histand, D G Alciatore, “Introduction to Mechatronics and Measurement Systems”, ISBN 0-07-052910-8.
5. C D Johnson, “Process Control Instrumentation Technology”, Prentice Hall of India Pvt. Ltd., New Delhi, ISBN 81-203-0987-1.
6. HMT Mechatronics, HMT, ISBN 0-07-462147-5..
7. Vickers manual on hydraulics
8. G. Boothroyd , C. Poli, L. Murch, “Automatic Assembly”, Marcel Dekker Inc. 1982.
9. Ramesh Gaonkar, “Microprocessor”, Penram International Pub. Pvt. Ltd., ISBN 81-900-828-7-6.
10. Werner Deport and Kurt Stool, "Mechanization by pneumatic control", Vol. I and II
411084: operations
research
Teaching Scheme
Examination Scheme
Lectures: 4 hrs/week
Theory: 100 Marks
Practical: 2 hrs/week
Duration: 3 hours
Term Work: 50 Marks
Objectives
·
To learn and understand
Quantitative Techniques
·
To learn and use
software packages for quantitative techniques
Prerequisites
·
Production Planning and
Control
·
Data Base and
Information Technology for Production Engineers
Definition of Operations Research: objectives, formulation of problem, graphical method, simplex methods for maximization and minimization problems, degeneracy in L.P., duality in L. P.; Sensitivity analysis,
Structure, industrial and business application Transportation problems- use of various methods for solving transportation problem, degeneracy and its solution, transhipment problem. Assignment problem- solutions of various types of problems, travelling salesman Problem.
Introduction to Integer,
Dynamic and Non-linear programming
(6)
Simulation
(3)
Introduction, application, Monte Carlo simulation of queuing system, inventory system, capital budgeting, new product planning etc.
Introduction to Geometric and
Goal Programming.
(3)
Replacement of capital equipments that deteriorates with time,
time value of money (a) remains same (b) changes with constant rates during period.
Equipment renewal policy, group and individual replacement.
Operating characteristics,
Poisson single and multi channel queuing system M/M/1:
Introduction, two -person zero sum game, minimax and maximin principle, saddle point, methods for solving game problems with mixed strategies, Graphical and iterative methods.
Fundamentals of CPM. and PERT networks.
CPM (3)
Construction of networks, critical paths, forward and backward pass, floats and
their significance, crashing for optimum and minimum duration and the cost, resource
allocation and leveling
PERT (3)
Time estimates, construction of networks, probability of completing projects by given date.
One exercise on each unit. At least one Computer software package such as Lindo/Lingo, MATLAB, MS-Excel and Tora should be used.
Oral shall be based on the term work.
Text Books:
1. S. D. Sharma, “Operations Research”, Kedarnath Ramnath and company Publications.
2. P. K. Gupta, D. S. Hira, “Operations Research”, S Chand and Co. Ltd., ISBN 81-219-0281-9.
3. H. A Taha., “Operations Research”, An introduction Prentice Hall Pvt. Ltd., ISBN 81-203-1222-8.
Reference
Books:
1. F. S. Hillier, G. J Lieberman, “Introduction to Operations Research”, Tata McGraw-Hill, ISBN 0-07-047387-0.
2. H. M. Wagner, “Principles of Operations Research”, Prentice-Hall India, ISBN 81-203-0162-5.
3. A. Ravindran, “Operations Research”, Tata McGraw-Hill.
4. S. K. Basu, D. K. Pal, H. Bagchi, “Operations Research for Engineers”, Oxford and IBH Publishing Co. Pvt. Ltd., ISBN 81-204-1251-6.
5. R. Panneerselvam, “Operations Research”, Prentice Hall of India Ltd., ISBN 81-203-
1923-0.
411085: reliability
engineering
elective
I
Teaching Scheme
Examination Scheme
Lectures: 4 hrs/week
Theory: 100 Marks
Duration: 3 hours
Objectives
·
To learn and understand
Reliability Engineering
Prerequisites
·
Metrology and Quality
Control
Introduction to Reliability
(8)
Importance of reliability, performance cost and reliability, quality and safety, system configuration with examples, stochastic processes, bathtub concept, MTBF, MTTR, hazard rate, failure rate, probability and sampling, cumulative probability distribution function, data and distributions.
Fault tree and event tree concept, construction and analysis, failure modes effects and criticality analysis, systems approach, techno-physio constraints, typical failure analysis, risk priority number and its allocation.
Reliability in design and Life
Cycle costing
(8)
Survival rate, bath-tub curve analysis of characteristics of failure regimes, design synthesis, reliability effort function, safety margin, allocation of reliabilities by AGREE, ARINC, proportional distribution of unreliability, heuristic method, mean and median methods.
Active and Passive Redundancy, redundancy allocation and limitations, Evaluation of overall system reliability, Conditional probability, Matrix methods, set theory analysis of system reliability.
Reliability and safety factors, Repetitive loading, Preventive maintenance, Testing and repair, reliability centered maintenance, system availability and maintainability.
Reliability growth models, grouped. and ungrouped data, censored data, accelerated life testing, Markov analysis .of two independent components, reliability with standby system, multicomponent systems, DTMC and CTMS models.
Text Books:
1. E. E. Lewis, “Introduction to Reliability Engineering”, John Wiley and Sons.
2. L. S. Srinath, “Reliability Engineering”, Affiliated East-West Press Pvt. Ltd., ISBN 81-85336-39-3.
3. S. S. Rao, “Reliability Engineering”.
References Books:
1. S. K. Basu, B. Bhadury, “Terotechnology-Reliability Engineering and maintenance”, Asian books Pvt. Ltd (2003), ISBN 81-86299-40-6.
2. Sheldon M. Ross, “Stochastic Processes”, John Wiley and Sons.
411085: powder
metallurgy
elective
I
Teaching Scheme
Examination Scheme
Lectures: 4 hrs/week
Theory: 100 Marks
Duration: 3 hours
Objectives
·
To learn and understand
Powder Metallurgy and Applications
Prerequisites
·
Engineering
Metallurgy-I
·
Material Science and
Composite Materials
Powder Metallurgy
(8)
Historical development, Introduction, Basic principles, techniques, classification, applications, merits and demerits. Production of metal powders: reduction, atomization, and electrolysis etc. Characteristics of powders and properties, production methodology and quality control. Preparation of powder: grading, sizing, blending, handling and storage. Testing of powders. Particle size distribution, surface conditions, purity, flow properties, porosity, true and apparent density, Green compact strength.
fundamentals of compaction, presses used, selection of presses, Automation and Handling of powder, tool clearances, Die design principles, wear reclamation, Die and punch materials selection and heat treatment, surface treatment properties, compact density variations, effect of blending powders, lubricants and lubrication in process.
Sintering (8)
principle, time temperature effects, theories of sintering mechanism. Sintering methods, sintering furnaces-characteristics and selection. Dimensional and property changes after sintering, sintering atmosphere and its impact on process performance. Hot compaction, hot and cold pressing, spot sintering operations, impregnation.
Hot isostatic pressing, merits, demerits and typical applications. Powder Metal products with polymer blends, expendable and retaining roll compaction. P.M. forging, Spray, deposition and surface structure development.
As structural parts, gears, levers, ratchets, etc. lamp filament and filament support, refractory metal components, electrical contact material, Cemented Carbide tools and wear parts, brakes and clutch lining material, porous bearings and filters, catalytic components etc.
Unit VI
Economics, Quality, Manufacturing Competitiveness due to conservation of energy, Materials, Operations, Durability, rigidity, near net – shape, surface finish and machining.
Heat treatment of Powder Metallurgy parts, advantages and limitations, typical applications.
Quality control and quality assurance. Newer materials, production of nano-composites.
Text Books:
1. A.K Sinha, “A textbook of power Metallurgy”, D.P. Tai.
2. Schartz Kopf, “Powder Metallurgy”, McmilJar Company.
3. W.D Jone, “Fundametal principals of power Metallurgy”, Edword Arnold (UK)
Reference Books:
1. J. S Hirschhorn, “Introduction to powder Metallurgy”, America P .M. Institute New York
2. H. H. Hausner, M. kumar Lal, “Handbook of Powder Metallurgy”, Chemical Publishing Company, New York, ISBN 0-8206-0301-5.
3. Goetzel C. G., “Treatise on power Metallurgy “, Vol I to IV Inter Science publisher Company, New York.
4. A.R. Poster (Editor), “Handbook of Metal powder Van Norstar Rembold Company”, New York.
5. “A practical Guide to Metal Powder”, Hogans India Ltd.
6. Yarten, Argly, “Power Metallurgy”, Machinery Publishing U.K.
7. Hari Singh Nalwa (Editor), “Handbook of Nano-structured Materials and Nanotechnology”Vol 1-5, Springer Verlang
411085: plant engineereing and
maintainance
elective
I
Teaching Scheme
Examination Scheme
Lectures: 4 hrs/week
Theory: 100 Marks
Duration: 3 hours
Objectives
·
To learn and understand
Plant Engineering function
Prerequisites
Introduction
(4)
Scope and importance of plant engineering. function – estimation of capacity for services like manpower, water resource, power, choice of factors involving environment, pollution control, sewage and waste disposal. Importance of location,
Location (4)
Economics, social, climatological, legal, political and industrial factors affecting site selection. Establishing various kind of weighing coefficients of these factors in relation to the nature of plant.
Plant Layout (4)
Types of production and their influence on layout, layout planning for various types of production- functional layout, cellular layout, PQ analysis, PQRST analysis, Space requirement analysis and space diagram, REL chart, Material flow analysis; layout analysis for operation and maintenance of auxiliary services; Systematic layout planning (SLP), Computer aided planning for layout design- types of layout problems, use of computers in planning and solving layout problems.
Plant Safety (4)
Planning for safety against mechanical, chemical hazards, pollution, sewage and waste disposal, prevention practices against accident, fire, pollution, noise- safety codes introduction, introduction to industrial safety Acts.
Material handling (4)
Analysis and design of material flow; principles of material handling analysis system- unit load concept, system approach – flow process charts; development of new systems/ quantitative analysis of material flow. Line balancing technique with optimal material flow configuration, layout material handling and transportation and maintenance function on productivity improvement.
Auxiliary Services Planning (4)
Planning and maintenance of auxiliary services like security service, Transportation service, water supply, recycling of disposal, effluent water treatment, Sewage water treatment, scrap disposal or recycling.
Maintenance Organization and Management (4)
Responsibilities and functions - operating policies-work allocation and scheduling- distribution of work load –centralized Vs decentralized; organizational structures of maintenance department- maintenance- history cards for equipments-maintenance manual records- utilities generation.
Types of Maintenance (4)
Concept of life cycle, maintenance- Breakdown, Corrective, Predictive, Elimination (Design out) maintenance and Maintenance indication. Condition based maintenance
Monitoring of Maintenance System &nbs