Bansilal Ramnath Agarwal Charitable Trust’s Vishwakarma ... · Project 1:-Development of process...

Vishwakarma Institute of Technology Issue 01 : Rev No. 1 : Dt. 24/03/17

Structure and syllabus of Final Year B. Tech. Production Engineering. Pattern A14 Revised, A.Y. 2017-18 (P a g e | 1)

Bansilal Ramnath Agarwal Charitable Trust’s

Vishwakarma Institute of Technology (An Autonomous Institute affiliated to Savitribai Phule Pune University)

Structure & Syllabus of

B. Tech. (Production Engineering)

Pattern ‘A14 Revised’

Effective from Academic Year 2017-18

Prepared by: - Board of Studies in Industrial & Production Engineering



Final Year B. Tech. Production Engineering AY 2017-18 (A14 Revised)

Module 7

Course Code

Course Name

Contact Hours / Week

Credits Th.

Proj. Based Lab

Regular Lab

Semester - I

S1 IP451THP Process Engineering 3 2 -- 4

S2 IP452THL Die & Mould Design 3 -- 2 4

S3 IP458TLP Elective 2 Machine Tool Design 3 2

4

S4

IP455TLP Elective1 Modern Manufacturing

Processes 3 2 -- 4 IP456TLP Elective1 Finite Element Method & CAD

IP454THP Elective 1 Powder Metallurgy

Proj IP457PRJ Project -- 2 -- 5

TOTAL 12 8 2 21

Semester - II

S1 IP475INT Semester Internship -- -- -- 21

TOTAL 21

OR S1 IP476GIP Global Internship Program -- -- -- 21

TOTAL 21

OR S1 IP477PRJ Research Project -- -- -- 21

TOTAL -- -- -- 21

Module 8

Course Code

Course Name Contact Hours / Week

Credits Th.

Proj. Based Lab

Regular Lab

S1 IP453THP Elective 1 Tribology 3 2 -- 4

S2

IP475TLP Elective 2 Manufacturing Systems

3 2 -- 4 IP489TLP Elective 2 Computer Integrated Manufacturing

IP477TLP Elective 2 Manufacturing automation

S3

IP479THP Elective 3 Logistics & Supply Chain Management

4 -- -- 4 IP476THP Elective 3 Materials & Operations Mgmt

IP480THP Elective 3 Operations Research

S4

IP481THP Elective 4 Project Management

4 -- -- 4 IP482THP Elective 4 World Class Manufacturing

IP483THP Elective 4 Industrial Robotics

Proj IP480PRJ Project -- -- -- 5

TOTAL 14 4 0 21



List of Electives

Code Subject Name

IP475TH Manufacturing Systems

IP476TH Materials & Operations Management

IP477TH Manufacturing automation

IP478TH Quality Management

IP479TH Supply Chain Management

IP480TH Operations Research

IP481TH Project Management

IP482TH World Class Manufacturing

IP483TH Industrial Robotics

IP485TH Product Development

IP486TH Costing and cost control

IP487TH Financial Management & Management Accounting IP488TH Industrial and Commercial Law



FF No. : 654

IP451THP::PROCESS ENGINEERING

Credits: 04 Teaching Scheme: 3 Hours / Week

Unit 1: Product and Process Engineering (…..6 Hours)

Preliminary part print analysis,, Types of dimensions, Measuring geometry of form –

Flatness, parallelism, straightness squareness, angularity, roundness, concentricity and

eccentricity, symmetry surface quality and surface integrity, surface finish affecting product

properties and product cost,

Unit 2: Product Engineering (….9. Hours)

Geometric and Dimensional and tolerance analysis , Types of dimensions, Tolerance

analysis-causes of work piece variations, to express limits and tolerance, tolerance stack,

purpose of tolerance chart, Rules for adding and subtracting, layout of tolerance chart

Unit 3 Work piece Control &Classifying operations (…6.. Hours) Work piece Control & Classifying operations, concept of location, geometrical control,

dimensional control, mechanical control, alternate location, Classifying operations, , Basic

process operations, principal process operations, major operations, auxiliary process

operations qualifying and re-qualifying operations

Unit 4: Selection of Equipment and tooling (….6. Hours)

Selection of Equipment and tooling, Process selection and machine selection, sources for

selection, Process selection and machine selection, sources for selection, factors in

machine selection in terms of cost and design factors, cost analysis, operating cost,

comparative cost analysis, classification of tooling : sources of tooling, tool holders, work

piece holders, General purpose, special purpose machines

Unit 5: Selecting and planning the process (…6 Hours)

Selecting and planning the process, Function, Economy and appearance, fundamental rules

for manufacturing process, eliminating operations, combined operations, selecting proper

tooling, availability of equipment, effect of operations speed on performance of economy,

make or buy decision. Computer aided process planning. Engineering approach, basic

design of product, influence of process engineering on product design, specifications,

materials and its cost analysis.

Unit 6: Process sheet design (…7.. Hours) Process sheet design, Determining manufacturing sequence, Factors for operation

sequence, major process sequence, Operation routing, process picture, process picture

sheet, processing dimensions and views, squaring graph, feature interaction graph, process

planning graph.

List of Project areas:

1. Project 1:-Development of process sheet for prismatic component

2. Project 2:- Development of process sheet for cylindrical component

3. Project3:- Development of process sheet for complex casting component

4. Project 4:- Development of process sheet for machining on CNC machining centre



Text Books:

Text Books

1. Process engineering for manufacturing, D. F. Eary, G. E. Johnson, Prentice-Hall

2. Computer aided process planning, P. W. Wang, J. Kelly

3. System approach to computer integrated design and manufacturing, Nanua singh

Reference Books 1. Manufacturing Engineering, H. W. Wage, McGraw hill

2. Manufacturing catalogues for cutting tools and inspection equipments

3. CAD\CAM\CIM - P. Radhakrishnan , S. Subrmaniyum, V. Raju, New Age

International Pvt Ltd

4. Manufacturing Systems Engg, K. Hitomi, John Willey Groover Mikell. P.

5. Fundamentals of modern manufacturing- materials, processes and systems, 2nd edition,

Willey 2002

Course Outcomes:

The student will be able to –

1 .Perform preliminary part print analysis of part.

2 Understand concepts of geometric dimensioning and tolerancing in product engineering.

3 Classify operations and achieve work piece control for manufacturing of industrial

products

4 Manage equipment, tools, gauges, manpower and time economically, required for

manufacture of industrial products

5 Select and plan process for manufacturing of industrial products cost effectively.

6 Design process sheet for machined component



FF No. 654A

Credits: 04 Teaching Scheme: - 5 Hrs /Week (Theory 3 Hrs/Week +Lab 2hrs/Week)

Hrs/Week

Prerequisites: Material Forming

Unit 1 (7 Hrs)

Design of simple blanking and piercing die

Press working terminology, Basic press working operations, types of presses- mechanical,

hydraulic, pneumatic and their mechanisms, elements of die sets, types of die sets, types of

dies - simple, compound and inverted dies, types of punches, methods of mounting of

punches, center of pressure Mechanism of shear and methods of reduction of shear force,

types of strip layouts, types of strippers, types of stoppers, selection of dowel pins and allen

screws.

Unit 2 (7Hrs)

Design of Progressive die

Progressive and combination dies Shearing forces and staggering of punches, press capacity,

clearances, die & punch size types of strippers, types of pilots, types of stoppers, selection of

dowel pins & allen screws, center of pressure of progressive die. Problems on progressive

and blanking die design.

Unit 3 (6 Hrs)

Design of deep drawing & Bending Dies

Deep drawing mechanism, Design of deep drawing die: blank size, no of draws, drawing

punch and die size, drawing force, press capacity and ironing. Types of Bending dies,

developed length calculation, bending force, spring back & methods used to overcome it,

press brake.

Unit 4 (7 Hrs)

Design of Forging Dies

Design of forging die for multi-impression die-: selection of parting line, drafts, fillet &

comer radii, ribs & webs, stock size calculation, flash & gutter, design of fullering, edging,

blocking, finishing impressions, trimming dies, Die block dimensions, die inserts. Design

of upset forging die: Up setters, stock size calculation, Rules for upset forging.

Unit 5 (6 Hrs)

Design of Injection Molds

Injection molding types, machines, Design of core and cavity, Determination of number of

cavities, types of cooling system, design of cooling channels, heat transfer considerations,

types of ejectors, determination of mould opening force & ejection force

IP452THL:: DIE & MOULD DESIGN



Unit 6

Design of Die casting Dies (7 Hrs)

Comparison of die casting with other processes, die casting machines: Plunger type, Goose

neck air type machines, die casting alloys: Al base, lead tin base, zinc base, Mg base, Cu

base, Classification of die casting dies: single impression, combination and multi

impression, details of die design, gating system, details of die construction, die steels.

List of Practical

Design report and drawing of dies and moulds (Any 5)

1. Simple Blanking die Design.

2. Progressive die design.

3. Deep Drawing die design

4. Estimation of developed length and Bending die design.

5. Upset forging design.

6. Forging die design- Closed impression die by CAD

7. Injection mould design by CAD.

8. Die casting die design by CAD

Text Books

1. Donaldson, Lecain and Goold, Tool Design, Tata McGraw Hill, ISBN 0 07 099274

2. J R Paquin, Die design Fundamentals, Industrial Press Inc., ISBN 0 8311 1172 0.

3. Doehler H. H, Die Casting, McGraw Hill

4. P. N. Rao, Manufacturing Technology, Foundry, Forming and Welding, Tata

McGrawHill.

Reference Books 1. P. H. Joshi, Press Tools Design & Construction, Wheeler Pub

2. P. C. Sharma, Production Engineering, S. Chand

3. Dr. Surender Kumar, Production Engg. Design (Tool Design), Satya Prakashan

4. R. G. W. Pye, Injection Mould Design (Design manual for plastic industry), EWP

5. A. S. Athalye, Plastics Materials handbook, Multitech Pub. Co., ISBN 81 7671 007

Course Outcomes :

Student will be able to

1. Understand mechanism of shearing of sheet metals, elements of dies and equipment.

2. Select and design appropriate die set and equipment for shearing operations of sheet

metal.

3. Understand principles of sheet metal forming and design of tools for deep drawing and

bending operations.

4. Apply basic forging operations and design of forging dies.

5. Design elements of injection molding dies and understand working of injection machine.

6. Understand and apply fundamentals of die casting die design principles.



FF No. : 654

IP458TLP: MACHINE TOOL DESIGN

Credits: 04 Teaching Scheme: Theory: 3 Hours/ Week

Lab: 2 Hours/Week

Unit 1: Design of Machine Tool Drives (10 Hours)

Stepped Regulation of Speed, Laws of Stepped Regulation, Why Geometric Progression is

used against Arithmetic, Harmonic & Logarithmic despite shortcomings, Relation between

Range ratio, Geometric Progression Ratio and No. of Speed Steps, 3) Design of Stepped

Drives: Break up of Speed Steps, Structural Formulae, Structural Diagram, Selection of

Best Structural Diagram, Ray Diagram, Speed Chart, General recommendations for

Developing the Gearing Diagram, Determining the number of teeth of Gears. 4) Speed/

Feed Gear box : Limiting Transmission Ratio of Speed / Feed Gear Box.

Unit 2: Design of Spindle (10 Hours) Function & Requirements of Spindle Units, their Materials, Effect of Machine Tool

Compliance on Machining accuracy Design of Spindle for Bending Stiffness: Deflection of

Spindle Axis due to a) Bending, b) - due to Compliance of Spindle Supports, c) - due to

Compliance of the Tapered Joint. Optimum Spacing between Spindle Supports,

Permissible Deflection & Design for stiffness: Additional Check for Strength like

Additional Supports, Location of Bearings and Drive elements

Unit 3: Design of Spindle Supports (6 Hours) Requirements of Spindle Supports, Features of Anti-friction Bearings, Load bearing

abilities of Ball & Roller Bearings. Parameters which assess the viability of combination of

roller & Ball & Roller Bearings in Spindle Units. Preloading of Anti Friction Bearing & its

method Design of Sliding Bearings: Sleeve, Hydrodynamic Journal, Hydrostatic Journal,

Air-Lubricated (Aerodynamic, Aerostatic).

Unit 4: Design of Machine Tool Structure (6 Hours)

Function & Requirement of Machine Tool Structure, Design Criteria from Strength &

Stiffness considerations, Concept of Unit Rigidity, Unit Strength under Tension, Unit

Strength under Torsion & Unit Strength under Bending for Material of Machine Tool

Structures, Compare Steel & Cast Iron on the basis of Material Properties, Manufacturing

Problems and Economy, Role of Static & Dynamic Stiffness in the design of elements of

machine tools, Profiles of Machine Tool Structures, Factors affecting stiffness of machine

tool structures & methods of improving it, Basic Design procedure of machine tool

structures

Unit 5: Design of Guide-ways (6 Hours)

Design Criteria (Wear Resistance & Stiffness) and Calculations for Slide-ways operating

under semi liquid friction condition, ‘Stick Slip’ phenomena affects accuracy of setting &

working motions. Comparison of Design & stiffness of Hydrodynamic, Hydrostatic &

Aerostatic Slide-ways, Design of Antifriction Guide-way, Concept of Combination Guide-

ways. Function & Types of Guide-ways, Types of Slide-ways & Antifriction Ways, Functional

features of Slide-ways, its Shapes & Materials, Methods of adjusting Clearance;

Unit 6: Design of Power Screws (4 Hours)

Design of Sliding friction Power Screw for Wear Resistance, Strength, Stiffness &



Buckling Stability. Design of Rolling friction Power Screw for Strength under static

loading, Strength under cyclic loading, & Stiffness

List of Practicals: 1. Design and Working Drawing of Speed Gear Box for Lathe

2. Design and Working Drawing of Feed Gear Box for Drilling Machine

3. Design and Working Drawing of Spindle for Lathe

4. Design and Working Drawing of Spindle-Support for Lathe

5. Design and Working Drawing of Sliding Friction Power Screw

6. Design and Working Drawing of Rolling Friction Power Screw

….


1. Design Case Studies of Bed of Lathe Column & Base of Milling Machine

2. Design Case Studies of Column of Milling Machine

3. Design Case Studies of Base of Milling Machine

4. Analyze and Design Lathe machine stepped gearbox

Text Books:

1. N. K. Mehta, Machine Tool

Design, 2

nd Edition, Tata McGraw Hill, 2011

2. D. K Pal, S. K. Basu, Design of

Machine Tool, 4

th Edition, Oxford, 2005

3. G. C. Sen, A. Bhattacharya

Principles of Machine Tool

2nd

Edition New central book agency Calcutta

1967

Reference Books: 1. N. S. Acherkan, V.

Vermakov

Machine Tool Design Vol

2, 1

st Edition, MIR

publication, 2000

2. F. Koenigsberger, Design Principles of

Metal Cutting Machine

Tools,

1st Edition The Macmillan

Company,

1964

Course Outcomes: The student will be able to –

1. Design stepped speed gear boxes.

2. Design spindles using minimum deflection criterion

3. Design suitable bearings for spindle supports.

4. Analyze and design various machine tool structure using principle of free body diagram

and using minimum deflection design criterion

5. Design sliding and rolling friction guideways

6. Design sliding and rolling friction power screws



FF No. : 654

IP455TLP MODERN MANUFACTURING PROCESSES

Credits: 04 Teaching

Scheme:

3 Hours / Week +

2 Hours/ Week (Lab) + Project

Unit 1: Introduction (6 Hours) Introduction to nontraditional machining methods - Need for non - traditional machining -

Sources of metal removal -Classification on the basis of energy sources - Parameters

influencing selection of process.

Unit 2: Mechanical Processes (10 Hours)

Abrasive Jet Machining – Water Jet Machining – Abrasive Water Jet Machining. (AJM,

WJM and AWJM). Operating principles -Equipment -Parameters influencing metal

removal - Applications -Advantages and Limitations. Ultrasonic Machining, Operating

Principle and Process characteristics.

Unit 3: Thermo Electrical Energy Techniques Electrical

Discharge Machining (EDM)

(8 Hours)

Fundamental principle of EDM, Equipment’s required for EDM process parameters,

process capabilities. Application example trouble shooting, Introduction to wire EDM,

Process principle and parameters, process capacities and its applications.EDM tool design,

Machine tool selection, EDM accessories / applications, electrical discharge grinding.

Unit 4: Thermal Energy Techniques (8 Hours) Operating principles - Equipment and sub systems - Parameters influencing metal removal-

Benefits - Applications - Advantages and limitations of Electron beam machining (EBM),

Plasma ARC Machining (PAM) and laser beam machining (LBM). Electron Beam

Machining, EBM Principle and process characteristics.

Unit 5: Electro Chemical Machining (ECM) (4 Hours) Background of ECM process, Classification of ECM processes. Electrochemistry of ECM,

Equipment required in ECM. Process capabilities and processes parameters. Evaluation of

MRR. Parameters influencing metal removal- Applications - Advantages and limitations.

Electro Chemical Grinding: Process principles, process parameters, Applications.

Unit 6: Chemical Machining (CHM) (4 Hours) Introduction, Elements of process Chemical blanking process:-Preparation of workpiece.

Preparation of masters, masking with photo resists, etching for blanking, applications of

chemical blanking, chemical milling (Contour machining):- Process steps – masking,

Etching, process characteristics of CHM :-material removal rate accuracy, surface finish,

Advantages & application of CHM. Electro-chemical Drilling and De-burring operations.



List of Practicals: Student will do exercises based modeling of following processes in order to predict

MRR, Surface roughness etc. and also they will study parametric correlations of the

process.

1. Exercise on Ultrasonic machining (USM), Abrasive Jet Machining (AJM) and

Abrasive water jet machining (AWJM)

2. Exercise on MRR and surface roughness modeling of EDM process and wire-EDM

process.

3. Exercise on Laser Beam Machining (LBM), Plasma Arc Machining (PAM) and

Electron Beam Machining (EBM)

4. Exercise on Electro Chemical Machining (ECM) and Chemical Metal removal process

5. Case study on Hybrid material Removal process (ECDM, ECG, EDG etc.)

AND


Students will perform projects of following processes (Any Two) for experimental

investigation of the process, modeling of the process and process optimization.

1. Abrasive water jet Machining

2. Electro Discharge Machining

3. Laser Beam Machining

4. Wire- Electro discharge Machining

Text Books: 1. V. K. Jain, Advanced Machining

Processes,

Allied Publishers Pvt. Ltd.,

New Delhi,

2007

2. P. K. Mishra, Non-Conventional

Machining,

The Institution of Engineers

(India), Text Book Series, New

Delhi,

1997

3. P. C. Pandey

and H. S. Shan

Modern Machining

Processes,

Tata McGraw-Hill, New Delhi 2007

Reference Books:

1. G. F. Benedict, Unconventional

Machining Process,

Marcel Dekker

Publication, New York,

1987

2. McGeough, Advanced Methods of

Machining

Chapman and Hall,

London,

1998

3. P. C. Sharma, A Text book of

Production Engineering

New Delhi, 1995

4. P. DeGarmo, J.

T. Black, and

R. A. Kohser,

Material and Processes

in Manufacturing

Edition

No. 8

Prentice Hall of India

Pvt. Ltd., New Delhi

2001

Course Outcomes: Students will be able to:

1. Understand need of advanced machining processes and select process for any industrial

job based on its complexity, cost and specifications required.

2. Apply the working principles and processing characteristics of mechanical type advanced

machining processes such as USM, AJM, WJM and Develop experimental, regression

based, mathematical and physics based models for the advanced machining processes and

predict MRR and surface roughness.



3. Apply the working principles and processing characteristics of electro-thermal type

advanced machining processes such as EDM, wire-EDM and Develop experimental,

regression based, mathematical and physics based models for the advanced machining

processes and predict MRR and surface roughness.

4. Apply the working principles and processing characteristics of thermal type advanced

machining processes such as PAM, LBM, EBM machining to the production of precision

components.

5. Apply the working principles and processing characteristics of chemical type advanced

machining processes such as Electrochemical Machining to the production of precision

micro and macro components.

6. Apply the working principles and processing characteristics of chemical type advanced

machining process for production of precision components.



FF No. : 654

IP456TLP FINITE ELEMENT METHOD & CAD

Credits: 04 Teaching Scheme: 3 Hrs/Wk + 2 Hrs/Wk (Lab) + Project

Prerequisite: Mathematics for Engineering Applications, Analysis of Machine Elements

Unit 1: Introduction to FEM (6 Hours)

Introduction to FEA, Basic Steps in FEM, Stresses and equilibrium, boundary conditions,

potential energy approach-Rayleigh Ritz method, Saint Venant’s principle, Von Mises

stresses, Stress-strain relations.

Plane stress and plain strain, Galerkin’s method.

Unit 2: One Dimensional FEM Problems (10 Hours)

One Dimensional Elements: Linear element, shape function & local coordinates, solution

by potential energy & Galerkin’s method, elemental stiffness and load matrices. Assembly

of Global stiffness matrix and Load vector, treatment of boundary conditions –

elimination & penalty approaches, multipoint constraints, quadratic shape functions, plane

trusses, beams & frames.

Application of the above concepts for Problems like truss analysis, temperature

distribution analysis etc.

Unit 3: Two Dimensional FEM Problems (8 Hours) Two Dimensional Elements: Constant strain triangle, Isoparametric representation, shape

functions, Co-ordinate systems – Local & natural, their significance, problem formulation

and solutions by potential energy & Galerkin’s methods, orthotropic materials, four node

quadrilateral. Introduction to three dimensional elements & axisymmetric problems.

Application of above concepts for two dimensional and axisymmetric problems.

Unit 4: Geometric Transformations (8 Hours)

Introduction to Basic Transformations - Translation, Rotation, Scaling, Reflection,

Homogenous Coordinate system, Concatenated Transformation, Mapping of Geometric

Models, Inverse Transformations. Projections - Orthographic, Isometric. Oblique,

Perspective.

Unit 5: Generation and Analysis of Curves (4 Hours)

Introduction to Parametric representation of curves & its advantages, Analytic Curves-

Line, Circle, Parabolas, Hyperbolas, Ellipses, Conics. Synthetic Curves- Hermite Cubic

Spline, Bezier Curve, B-Spline Curve.

Unit 6: Generation and Analysis of Surfaces (4 Hours) Introduction to Parametric representation of Surfaces, Analytic Surfaces - Plane, Ruled,

Tabulated, Revolved surfaces, Synthetic Surfaces- Bezier Surface, B-Spline Surface.

Introduction to different volume modelling techniques.

List of Practicals:

1. Formulation of FEM problem by potential energy approach

2. Problems on obtaining elemental stiffness and load matrices

3. Problems on 1D elements- using elimination approach

4. Problems on 1D elements- using penalty approach

5. Evaluation of Shape function for Linear triangular elements



6. Problems on 2D elements – constant strain triangle

7. Problems on 2D elements – plates with and without temperature distribution

8. Problems on basic transformations - Translation, Rotation, Scaling, Reflection

9. Parametric representation of curves

10. Problem on synthetic curves

11. Different volume modeling techniques

AND


Students will perform projects of following processes (Any Two) for experimental

investigation of the process, modeling of the process and process optimization.

1. One Dimensional FEM Problem

2. Two Dimensional FEM Problem

3. Geometric Transformations

4. Generation curves & surfaces

Text Books: 1. Chandrupatla,

Belegundu

Introduction to Finite

Elements in Engineering

8th

Edition

Pearson

Education

2014

2. Groover,

Zimmer

CAD/CAM: Computer-aided

Design & Manufacturing

7th

Edition

Pearson

Education

2010

3 Segerlind L J Applied Finite Element

Analysis

John Wiley &

Sons New York

1984

4 Cook R D,

Malkus D S &

Plesha M E

Concepts & Applications Of

Finite Element Analysis

New York. John

Wiley & Sons

1989

5 Ibrahim Zeid CAD/CAM - Theory &

Practice

Tata McGraw

Hill

Reference Books:

1. Hughes

Thomas J

Finite Element Method -

Linear Static and Dynamic

Finite Element Analysis

Dover Pub.

New York

2007

2. Rao P N Introduction to CAD/CAM Tata McGraw

Hill Publishing

Co.

2011

Course Outcomes : Our students will be able to:

1. Understand theories and principles of FEM.

2. Apply potential energy approach for solving one dimensional structural problems

3. Apply potential energy approach for solving two dimensional structural problems

4. Understand and apply the concepts of transformations for representation in CAD

5. Understand concepts of parametric representation of curves and surfaces



FF No. : 654

IP454THP POWDER METALLURGY

Credits: 04 Teaching Scheme: 3 Hrs/Wk

Unit 1: Powder Production (07 Hours) Historical development , Basic principles of Powder Metallurgy

Classification of metal powder production methods. Reduction, Atomization &

developments in it. 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.

Unit 2: Compaction (06 Hours)

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.

Pressure less powder shaping.

Improvement of press tool life

Unit 3: Sintering (07 Hours)

Principle, time temperature effects, Theories of sintering mechanism. Sintering methods,

sintering furnaces-characteristics and selection. Dimensional and property changes after

sintering, Rapid sintering processes, impregnation. Liquid phase sintering, Activated

sintering. Dimensional changes during sintering

Sintering atmosphere and its impact on process performance.

Unit 4: Special Powder Metallurgy Processes (07 Hours) Special PM processes like Hot Compaction, Iso static pressing, Hot Iso static compaction

merits, demerits and typical applications. Powder metal products with polymer blends,

Powder roll compaction. P.M. Forging, Powder Extrusion, Injection molding , Hot

powder forging ,Hot powder extrusion

Comparison between various special PM processes

Unit 5: Secondary Operations & Economics of Powder Metallurgy (06 Hours)

Secondary operations like sizing, coining Oil impregnation, heat treatments, Steam

treatment Economics, Quality assurance, Manufacturing Competitiveness due to

conservation of energy, Materials, Operations, Durability, rigidity, near net – shape,

surface finish and machining. Advantages and limitations of Powder Metallurgy.

Unit 6: Powder Metallurgy Applications (07 Hours)

Production details of common PM structural parts like 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. Production of nano composites



AND

List of Project areas: Students will perform projects:

1. Study the effect of cold compaction pressure on density

2. Characterization of metal powder

3. Study of defects in P/M parts

Text Books: 1. A.K Sinha, D.P. Tai, A Textbook of Power Metallurgy

2. A, F. Thummler and R. Oberacker, An Introduction to Powder Metallurgy, The Institute

of Materials, London

3. Anish Upadhyaya & G. S. Upadhyaya, Powder Metallurgy Science, Technology &

Materials

Reference Books: 1. Powder Metallurgy, ASM Handbook Vol.VII

Course Outcomes : Our students will be able to:

1. Select most appropriate powder manufacturing technique for cost effective

manufacturing of powder component & characterize metal powder.

2. Select & apply different compaction techniques

3. Sintering techniques to obtain near net shape powder metallurgy parts.

4. Understand various special powder metallurgy techniques and secondary operations

5. Understand advantages, limitations and economics of powder metallurgy process

6. Understand typical applications of Powder Metallurgy



FF No. : 654

IP457PRJ :: PROJECT

Credits: 05 Teaching Scheme: - Practical 2 Hr/Week

The project work could be of the following nature:

1. Manufacturing /Fabrication of a prototype machine' including selection, concept,

design, material, manufacturing the components, assembly of components, testing and

performance evaluation.

2. Improvement of existing machine / equipment / process.

3. Design and fabrication of Jigs and Fixtures, dies, tools, special purpose equipment,

inspection gauges, measuring instruments for machine tools.

4. Computer aided design, analysis of components such as stress analysis.

5. Problems related to Productivity improvements.

6. Problems related to value engineering.

7. Problems relating to material handling system.

8. Energy Audit of organization, Industrial evaluation of machine devices.

9. Design of a test rig for performance evaluation of machine devices.

10. Product design and development.

11. Analysis, evaluation and experimental verification of any engineering problem

encountered.

12. Quality systems and management. Total Quality Management.

13. Quality improvements, In-process Inspection, Online gauging.

14. Low cost automation, Computer Aided Automation in Manufacturing.

15. Time and Motion study, Job evaluation.

16. Ergonomics and safety aspects under industrial environment

17. Management Information System.

18. Market Analysis in conjunction with Production Planning and Control.

OR

Fabrication of models, machines, prototypes based on new ideas, robots and machine

based on hitech systems and automation, experimental set-up, fabrication of testing

equipment, renovation of machines, etc. Computer based design / analysis or modeling /

simulation of product(s), mechanism(s) or system (s) and its validation or comparison

with available benchmarks / results. Modelling/simulation of product(s), mechanism(s) or

system(s) and its validation or comparison with available bench marks / results.

Design/development and Fabrication of models, machines, and prototypes based on new

ideas, robotic and automation systems, Experimental set ups, test rigs/ equipments.

The project work shall be taken up individually or in a group consisting of not more than 4

students.

A report containing maximum 30 pages shall be submitted based on the background, need

and scope of the project, project specifications, activities involved in the project and

activity plan, study of literature and basic theory, and work completed (if any).

Guidelines:

• Report shall be typed or printed.

• Figures and tables shall be on separate pages and attached at respective positions.

• Project title and approval sheets shall be attached at the beginning of the report



followed by index and synopsis of the project.

• References shall be mentioned at the end followed by appendices (if any).

• When a group of students is doing a project, names of all the students shall be

included on every certified report copy.

Each group of students shall submit two copies of reports to the institute and one copy

shall be prepared for each individual student.

Course Outcomes :

Students will be able to:

1. Survey literature for problem identification

2. Cultivate the habit of working in a team, communicate effectively and attempt a

problem solution in a right approach

3. Correlate the theoretical and experimental/simulations results and draw the proper

inferences.

4. Apply engineering knowledge in carrying out project starting from design, drafting,

process planning, project management, costing, manufacturing, QC and inspection,

down to assembly, testing and evaluation.

5. To practice data collection and analysis using different measurement equipment’s and

software packages.

6. Prepare project report as per guideline and present it effectively



FF No. : 654

IP453THP TRIBOLOGY

Credits: 04 Teaching Scheme: Theory: 3 Hours / Week

Lab: 2 Hours / Week

Unit 1: Hydrodynamic Lubrication- Pad bearings (8 Hours) Mechanics of fluid flow, Reynold’s equation; Simplifying assumptions, Equilibrium of

an element, Continuity of flow in a column, Simplifications to the Reynolds equation,

Unidirectional velocity approximation, Steady film thickness approximation,

Isoviscous approximation, Infinitely long bearing approximation, Narrow bearing

approximation, Bearing parameters predicted from Reynolds equation. Infinitely long

pad bearings, Infinite Rayleigh step bearing, Finite pad bearings. Pivoted pad bearing.

Unit 2: Hydrodynamic Lubrication – Journal bearings and

squeeze film bearings

(8 Hours)

Converging-diverging wedges- Bearing geometry Pressure distribution- Full-

Sommerfeld boundary condition, Half-Sommerfeld boundary condition, Reynolds

boundary condition. Journal bearings, Evaluation of the main parameters- Bearing

geometry, Pressure distribution, Load capacity Friction force, Coefficient of friction

Lubricant flow rate, Practical and operational aspects of journal bearings.

Hydrodynamic squeeze film bearings

Unit 3: Friction and wear (6 Hours)

Theories of friction, types of wear, Abrasive wear, mechanism and modes of abrasive

wear, Analytical models of abrasive wear. Mechanism of erosive wear. Cavitation wear

mechanism. Adhesive wear mechanism, metal to metal adhesion, Effect of adhesion

between wearing surfaces. Control of adhesive wear. Abrasive Wear Resistance of

Materials, Transfer films in Adhesion

Unit 4: Hetrzian contact (6 Hours)

Hetrz contact stress theory, Contact between two elastic spherical or spheroidal bodies,

Geometry of contacting elastic bodies, Contact area, pressure, maximum deflection and

position of the maximum shear stress - Contact between two spheres, Contact between

a sphere and a plane surface, Contact between two parallel cylinders, Contact between

two parallel cylinders, Elliptical contact between two elastic bodies, general case.

Elastohydrodynamic lubricating films

Unit 5: Elasto-hydrodynamic lubrication (6 Hours)

Effects contributing to the generation of elastohydrodynamic films- Hydrodynamic film

formation, Modification of film geometry by elastic deformation, Transformation of

lubricant viscosity and rheology under pressure. Approximate solution of Reynolds

equation with simultaneous elastic deformation and viscosity rise, Pressure distribution

in elastohydrodynamic films, Elastohydrodynamic film thickness formulae,

Elastohydrodynamic film thickness measurements

Unit 6: Hydrostatic bearings (6 Hours) Hydrostatic bearing analysis, Flat circular hydrostatic pad bearing- Pressure

distribution, Lubricant flow, Load capacity, Friction torque Friction power loss. Non-



flat circular hydrostatic pad bearings -Pressure distribution, Lubricant flow, Load

capacity, Friction torque, Friction power loss. Generalized approach to hydrostatic

bearing analysis- Flat circular pad bearings, Flat square pad bearings. Optimization of

hydrostatic bearing design -- Minimization of power(Low speed recessed bearings,

High speed recessed bearings), Control of lubricant film thickness and bearing stiffness

(Stiffness with constant flow method, Stiffness with capillary restrictors, Stiffness with

an orifice, Stiffness with pressure sensors) Gas lubricated bearings- Aerostatic

bearings, Pressure distribution, Gas flow, Load capacity, Friction torque, Power loss

List of Projects

1. Journal Bearing Test: Parametric study of the pressure distribution and frictional

torque in the journal bearing.

2. Pin-on-Disc Test: Investigation of the Tribological behavior of various marerials in

terms of Friction and Wear measurement

3. Four-Ball Test: To investigate the Wear preventive ability (WP), Extreme pressure

capacity (EP), and Friction behavior of lubricants operating under non-conformal (point

contact) contact condition.

Text Books: 1. G. W. Stachowiak,

A. W. Batchelor

Engineering

Tribology, 2nd Edition, Butterworth

Heineman, 2001.

2. A. Cameron, Basic Lubrication

Theory,

3rd Edition Longman, 1971.

3. P. Sahoo, Engineering

Tribology 2

nd Edition Prentice

Hall of India 2005.

Reference Books: 1. D. A. Rigney, Fundamentals of

Friction and wear of

Materials

2nd

Edition American

Society of

Metals

1980

2. N. S. Grassam, J.

W. Powell

Gas Bearings, 1st Edition Butterworths 1964

Course Outcomes:


1. Apply the principles of dry sliding wear in order to minimize friction and wear in mating

surfaces.

2. Analyze hydrodynamic pad bearings using principles of hydrodynamics.

3. Analyze hydrodynamic journal bearings using principles of hydrodynamics.

4. Analyze surfaces in Hertzian contact.

5. Analyze lubrication phenomenon in non-conformal contacts using elasto-hydro dynamics

principles.

6. Design hydro-static bearings.



FF No. : 654

IP475TLP :: MANUFACTURING SYSTEMS


Unit 1: Hard automation (…8.. Hours) Automation and mechanization, levels of automation, types of automation, hard automation-

Capstan and Turret lathes, single spindle automats, multispimdle automats, spms, Transfer

lines, types, work part transfer mechanisms, control of production line, transfer line

performance

Unit 2: Soft automation (….8. Hours) Soft automation, CNC, NC/CNC machine programming: construction, classification, various

axes in NC machines, G & M code programming

machining centers, computer aided programming

Unit 3: ROBOTICS: (….7. Hours)

Robotic system, Components, Configuration, Drive systems, grippers, sensors, Machine

vision system, direct and inverse kinematics ,Applications of robots.

Unit 4: Computer aided manufacturing, CIM and FMS (…5.. Hours)

Computer aided manufacturing, CIM and FMS, DNC, cellular manufacturing, group

technology, flexible manufacturing systems. FMS planning and implementation, Elements of

CIM system

Unit 5: Automatic material handling and inspection (…6.. Hours)

Automatic material handling and inspection, Automated guided vehicles systems, analysis

conveyor systems, automated inspection, carousel storage systems, automatic gauging system

Unit 6: Factory automation , Assembly systems (6….. Hours)

Factory automation, Assembly systems, automated assembly, design for automated

assembly, vibratory bowl feeders, hopper feeders, rotary disc feeders.

Synchronous and non synchronous material transfer, centrifugal, revolving feeders

List of Practicals: (For THL, TLP courses) 1. Programming using linear interpolation on CNC machine.

2. Programming using circular interpolation on CNC machine.

3. Programming using automatic canned cycles on CNC machine

4. Programming using complex functions on CNC machine

5. Analysis of transfer lines with no internal storage

And

List of Project areas: (For THP, TLP courses)

1.Project 1:-Manufacturing of simple job on Technofour CNC TMW200 machine

2.Project 2:- Manufacturing of complex job on Technofour CNC TMW200 machine



Text Books:

1. Automation,Production Systems and Computer Integrated Manufacturing-Mikell P

Groover ,Pearson Education Asia,2001

2. CNC Technology & Programming- Krar, Gill- McGraw- Hill International Editions-

1990.

Reference Books:

1. Mechanisation by pneumatic control-Werner Deport and Kurt Stool,Vol.1,2

2. Manufacturing Engineering & Technology- Kalpak Jian- Addison Wesley Publishing

Company Third Edition-1995

3. P. Radhakrishnan , S.Subrmaniyum, V.Raju, “CAD\CAM\CIM”- New Age International

Pvt Ltd


A student should be able to

1. Understand hard and soft automation

2. Study construction and working of CNC machines

3. Study various elements and applications of industrial robots

4 Understand concepts of CAM, CIM and FMS

5. Understand and Analyze performance of automated conveyance and inspection systems

6. Understand principles of automated assembly systems



FF No. : 654

IP489TLP :: COMPUTER INTEGRATED MANUFACTURING

Credits: 04 Teaching Scheme: 3 Hours/Week + 2 Hrs/week

Unit 1: Computer Aided Manufacturing- (…8.. Hours)

Manufacturing Planning and Manufacturing Control, CAD/CAM, Process definition and

manufacturing planning – Structures of a process plan – CAD based process planning –

Coding systems – Methods of CAPP – Process planning systems.

Unit 2: Introduction to CIM & MRP-II (….7 Hours)

Nature of the CIM system – Types of manufacturing systems – Evolution of CIM –

Computers in CIM. Background – Role of MRP – II in CIM systems, Major modules of

MRP – II software – Manufacturing, engineering, financial, marketing and misc.

applications

Unit 3: NC & CNC Machine tools Basic (….7. Hours)

Principle of Numerical Control – Types of CNC machine tools – Features and

programming of CNC machine tools – CNC programming based on CAD – Applications

and economics of usage of CNC machine – Capabilities of a typical NC, CAM software –

Integration of computers in CIM environment

Unit 4 : Computer Communications (….6. Hours) . Principles of networking, Techniques, components of networking and wiring methods –

Network interface cards – Network standards, examples – Operating system – Security –

Managing remote systems – Design activity in a networked environment, Case Study on

Networking in manufacturing company

Unit 5: Flexible Manufacturing System (….6. Hours) . Introduction, types, major elements and optimization of FMS – Operational elements in a

typical FMC – Typical FMS layout ,database and DBMS requirements – Features and

architecture of a DBMS – Query language – SQL – SQL as a knowledge base query

language. Integration and Implementation issues in CAD/CAM/CIM – Introduction –

Requirements for integrated manufacturing systems – Economic justification of

CAD/CAM/CIM technologies – Steps to implement CIM. Conceptual understanding of

Lean manufacturing , Agile manufacturing

Unit 6: Artificial Intelligence (….6. Hours) Robots – Elements, types and specifications of robots – Robot programming methods –

Robot operation – Applications of industrial robots – Integration of robots in CIM systems

– Expert system – DSS in CIM environment, . AI in vision system and scheduling, AI in

vision system and scheduling

List of Practicals:

1. Programming using linear interpolation on CNC machine.

2. Programming using circular interpolation on CNC machine.

3. Programming using automatic canned cycles on CNC machine

4. Programming using complex functions on CNC machine



And


Project 1:- Manufacturing of simple job on Technofour CNC TMW200 machine

Project 2:- Manufacturing of complex job on Technofour CNC TMW200 machine

Text Books:

1. Ibrahim Zeidi, CAD/CAM – Theory and Practice, TMH, 1991

2. Groover, Automation of Production Systems, PHI, 2003.

Reference Books: 1. Eric Teicholz, Computer Integrated Manufacturing Handbook, 1st Edition, McGraw

Hill, 1987.

2. Radhakrishnan P, Subramanyan S, CAD/CAM/CIM, Wiley Eastern Limited,1994


1. Understand hard and soft automation and CAM

2. Understand MRP system

3. Describe construction and working of CNC machines.

4. Understand networking of computers

5. Understand concepts of CAM,CIM and FMS

6. Study applications of robots in automation



FF No. : 654

IP477TLP::MANUFACTURING AUTOMATION

Credits: 04 Teaching Scheme: 3. Hours / Week

Unit I Introduction to Mechatronics Introduction to Mechatronics – Conventional and Mechatronics approach in designing

products - Mechatronics design process - Mechatronics in Manufacturing – Adoptive and

distributed control systems – Modeling and simulation of mechatronics systems.

Unit II Sensors

Overview of sensors and transducers – Microsensors - Signal conditioning – Operational

amplifiers – Protection – Filtering - Analog and Digital converters.

Unit III Actuators

Electro – pneumatics and Electro – hydraulics - Solenoids – Direct Current motors –

Servomotors – Stepper motors - Micro actuators; Drives selection and application.

Unit IV Microprocessor based Controllers

Architecture of microprocessor and microcontroller – System interfacing for a sensor,

keyboard, display and motors - Application cases for temperature control, warning and

process control systems.

Unit V Programmable Logic Controllers Architecture of Programmable Logic Controllers – Input/Output modules – programming

methods – Timers and counters – Master control – Branching – Data handling – Analog

input/output

Unit VI Intelligent Mechatronics and Case Studies

Fuzzy logic control and Artificial Neural Networks in mechatronics – Algorithms –

Computer – based instrumentation - Real-time Data Acquisition and Control – Software

integration - Man- Machine interface -Vision system – Mechatronics system case studies.

Practicals/projects: 1. Design a coin counter machine that accepts handful of coins of 50 paise,1 rs and 5 rs.

2. Strain gauge /LVDT based weighing machine

Text Books: 1. Bolton .W, (2008), Mechatronics, 4

th Edition, Pearson Education.

References:

1. Devdas Shetty, Richard A. Kolk (2011), Mechatronics System Design, PWS Publishing

Company

2. Dan Necsulescu, (2002), Mechatronics, 3rd Edition, Pearson Education

3. Michael B. Histand and David G. Alciatore (2005), Introduction to Mechatronics and

Measurement systems, McGraw-Hill.

4. B.P. Singh (2002), Advanced Microprocessor and Microcontrollers, New Age

International Publisher.



Outcomes:

Student will be able to

1. Identify the elements of mechatronics system.

2. Select suitable sensors to meet specific requirements

3. Select actuators to meet specific requirements

4. Select controllers to meet specific requirements

5. Understand PLC and applications.

6. Demonstrate intelligent mechatronics system for engineering applications.



FF No. : 654

IP479TH::LOGISTICS & SUPPLY CHAIN MANAGEMENT

Credits: 04 Teaching Scheme: - Theory 3 Hrs/Week & Lab 2Hrs/Week

Unit I (7 Hrs)

Logistics Management

Definition, Logistics Function: Transportation – Significance, Modes of Transportation,

Warehousing – Objectives, Warehousing Functions, Types of Warehouses, Inventory

Management, Order Processing – Role of IT, Material Handling, Transportation: Modes of

Transportation – Rail, Road, Pipelines, Water Air – Advantages & Disadvantages, Concept

of TL, LTL, FTL. Modes of Transportation – Rail, Road, Pipelines, Water Air –

Advantages & Disadvantages, Selections of Appropriate Modes of Transportation

Unit II (7 Hrs)

Warehouse Management

Concept of SKUs, Warehousing Principles & Best Practices in Receiving, Shipping, Order

Picking, Storage & Put away, Warehouse Activity Profiling, Warehouse Layout Planning.

Stores Management: Functions of Stores, Stores Procedure – Documentation. Need of

physical stock taking, method of stock taking like annual, continuous, reorder point stock

taking, Inventory records. Surplus and Obsolescent stocks: Introduction, Genesis of surplus

materials. Disposal of surplus and obsolete materials, Stores Documentation – Bin Cards,

Stores Ledger. WMS Systems in Practice

Unit III (7 Hrs)

Concept of SCM

Supply Chain: Concept, Objective. Decision Phases in Supply Chain. Process View of

Supply Chain – Cycle View, Push/pull view, Supply Chain Performance – Achieving

Strategic Fit. Types of Supply Chain – Responsive, Efficient, Achieving Strategic Fit.

Supply Chain Drivers – Facilities, Inventory, Transportation, Information. Importance of

Supply Chain, Examples of Supply Chain

Unit IV (7 Hrs)

Network Design in Supply Chain

Factors Influencing Distribution Network Design – Response time, Product variety,

Product availability, Customer experience, Order visibility, Return ability.

Logistics Modeling: Location – Allocation Models Multiple Facility Location Models:

Baumol Wolf Method, Add & Construction Heuristic,

Allocation Models: Transportation Model: Variants, Special Cases, Solution - Vogel’s

Approximation Method, Optimality Methods – UV Method, Stepping Stone Method,

Transshipment problems. Traveling Salesman Problem, Vehicle Routing Problem

Unit V (6 Hrs)

Planning Demand, Supply and Inventories in a Supply Chain



Managing Supply: Different strategies of managing Capacity and Inventory, Managing

Demand: Variable pricing, Forward buying,

Managing Economies of Scale: Cycle Inventory- Role in SC - Lot sizing for single product,

multiple products or customers, Aggregating multiple products in single order

Managing Uncertainty: Safety Inventory – Role in SC – Determine appropriate level of

safety inventory.

Collaborative Planning Forecasting & Replenishment, Demand Forecasting & Aggregate

Planning in Supply Chain.

Unit VI (6 Hrs)

Co-ordination & Technology in the Supply Chains Co-ordination in Supply Chain: Lack of SC Coordination & Bullwhip Effect. Effect on

Performance. Obstacles to SC Coordination. Manager Levers to Achieve Coordination.

Information Technology and Supply Chain: Role of IT in SC Supply Chain IT Framework.

E-business & Supply Chain, Building Strategic Partnerships and Trust within a Supply

Chain. Future of IT in Supply Chain. Cases on E-business and supply chains

List of Practicals:

Assignments

1. Detailed Study of Supply Chain of any one company in an Industry of your choice

2. Study of Industry Based on ETIG SCM CD

3. Numerical & Cases on Facility Location Models- Single and Multiple Facility

4. Location & Location - Allocation Models

5. Numericals & Caselet on Demand Forecasting

6. Case let on Aggregate Planning

7. Case let on Inventory Management

8. Numerical and Cases on Travelling Salesman Problem

9. Numerical and Cases on Vehicle Routing Problem

10. Comprehensive Case Study or Research paper study on SCM

11. Computerized Simulation Game or Case Study on Logistics Modeling

12. Industrial Visit

Text Books 1. Sunil Chopra & Peter Meindl, Supply Chain Management - Strategy, Planning &

Operation –, Pearson Education, Sixth edition (17 June 2016)

Reference Books 1. Bowersox, Logistical Management - The Integrated Supply Chain Process

2. Martin Christopher, Logistics & Supply Chain Management, Fifth Edition, Pearson,

2011

3. G Raghuram, Logistics & Supply Chain Management, McMillan Publications

4. Ronald Ballou, Business Logistics / Supply Chain Management, Peason Education.

Course Outcomes:


1. Analyze and select the appropriate modes of transportation

2. Analyze, design and optimize warehousing processes for manufacturing organizations

3. Identify the key elements and processes in a supply chain and their interaction

4. Analyze, design and optimize supply chain networks for manufacturing organizations

5. Identify the techniques used in management of critical components of supply chain

6. Explain the likely future development of logistics and supply chain management



FF No. : 654

IP476THP MATERIALS AND OPERATIONS MANAGEMENT


Unit 1: Functions of Materials Management (06 Hours)

Introduction, Classification and Costs of Inventories: Types, Objective of holding

inventories, Costs Associated with Inventory - Carrying cost, Procurement cost &

Ordering Cost. Different types of Inventories, EOQ - Concept, Assumptions of EOQ

Model, EMQ Model -Carrying cost, Set up cost, Shortage Cost. Inventory. Practical

Constraints vs Theoretical EOQ Value, Numerical Analysis, Quantity Discounts method.

Deterministic Inventory Model- Calculation of EOQ considering Investment, Space

Availability.

Unit 2: Lead Time (07 Hours) Components of Lead Time - Internal and External. Variability in demand and lead time.

Probabilistic Replenishment System. Replenishment Systems: Introduction, Concept of

lead time and its effects on Safety Stock & Reserve Stock Evaluation. Ways to minimize

lead time, Different types of replenishment systems like Fixed order quantity system,

Fixed order interval system, Combination of fixed order interval and quantity system,

Two Bin System, Symptoms of Poor Inventory management, Selective Inventory Control:

Concept of ABC analysis, Selective Inventory Control - VED analysis, HML analysis,

SDE analysis, SOS analysis, FSN analysis, GOLF analysis

Unit 3: Procurement Management (07 Hours) Responsibilities of Purchase Department. Procurement Procedure, Documents in

Procurement, Methods of Buying, Legal Aspects of Buying, Vendor Development,

Vendor Selection methods like Vendor Rating Method, Analytical Hierarchy Process

(AHP), Saaty rating Scale used In AHP , Categorical Method. Import-Export Procedure –

Imports & Exports, Documentation – Bin Cards, Stores Ledger, Goods Receipt Note,

Material Requisition, Purchase Order – Format, Terms & Conditions. Documentation in

Imports

Unit 4: Inventory Management & Selective Inventory Control (07 Hours)

EOQ & Quantity Discounts, Probabilistic Replenishment System (Inventory Models).

Selective Inventory Control Techniques. ABC analysis VED analysis, HML analysis,

SDE analysis, SOS analysis, FSN analysis, GOLF analysis. EMQ Model - Carrying cost,

Set up cost. EOQ Special Considerations – Spares, Bought-outs, etc. Symptoms of Poor

Inventory management, Measuring Effectiveness of Inventory Function (Inventory

Turnover Ratio, Average Inventory, etc.)

Unit 5: Material Requirement Planning (MRP ) (07 Hours)

Operations Planning & Control – PPC – Functions, Operations Planning & Control

Framework. Material Requirement Planning (MRP I): Inputs to MRP – MPS, BOM –

Types of BOM, BOM Explosion, Inventory Transaction Files, MRP Processing (Logic) –

Time Phased Operation Plan, Numerical on BOM Explosion Netting Requirements,

Outputs of MRP.



Unit 6: Manufacturing Resource Planning (MRP II) (06 Hours) Operations Control – Gantt Charts. Planning & Scheduling Techniques: Scheduling v/s

Loading, Scheduling Types – Forward Scheduling & Backward Scheduling Scheduling

Techniques – Dispatching Rules – SPT, LPT, Johnson’s method – Johnson’s rule for 2,3

and M machines problem, Slack per operations Critical Ratio, EDD, etc. –Evaluate

lateness, tardiness.

List of Practicals:

1. Assignment on Costs of Inventories, Assignment on EOQ

2. Assignment on EOQ – Practical Constraints – Quantity Discounts, Shelf Life,

Packing

3. Constraints

4. Assignment on Replenishment Systems – Deterministic Model

5. Assignment on Replenishment Systems – Probabilistic Model

6. Numerical Assignment based on Vendor Rating

7. Numerical Assignment based on AHP Method used for – Vendor Selection

8. Numerical Assignment based on transportation costs like Terminal Handling Cost

9. Assignment on Selective Inventory Control

10. Case – Purchase Management

11. Case – Vendor Selection, Vendor Rating

Projects:

1. MRP Model for any Organization

2. Calculation of EOQ & comparison with actual process

3. Assessment of Vendor selection process

Text Books: 1. L.C. Jhamb Inventory

management

2nd Edition Everest

Publishing

House

2009

2. Panneerselvam, Production &

Operations

Management

Revised Edition McGraw Hill

Publications

Year.

2007

Reference Books:

1. Dobler Burt Material

Management

2nd Edition McGraw

Hill

1971

2. John Willey and

sons

Inventory

Control and

Management

2nd Edition Silver and

Peterson

2003


1. Understand need of various functions in production planning and control for better

management of manufacturing and/or service systems.

2. Apply various methods to reduce lead time in manufacturing and services organizations

3. Analyze, assess and develop vendor selection and rating systems for manufacturing

organizations for effective procurement of materials.

4. Design inventory replenishment systems for manufacturing and services organizations to

optimize the inventory levels for organizations.



5. Develop master production schedule, and material requirements plans for manufacturing

and service organizations.

6. Develop complete schedule of organization as a part of resource requirement planning.



FF No. : 654

IP480THP::OPERATIONS RESEARCH


Unit 1: INTRODUCTION & FORMULATION OF LP MODEL (10 Hours)

OR methodology, Definition of OR, Application of OR to engineering and Managerial

problems, Features of OR models, Limitation of OR, formulation LPP Models. Definition,

mathematical formulation, standard form, solution space, solution – feasible, basic feasible,

optimal, infeasible, multiple, optimal, Redundancy, Degeneracy. Graphical and simplex

methods. Variants of simplex algorithm – Artificial basis techniques, Big M Method

Unit 2: QUEUING THEORY - (06 Hours)

Queuing Theory: Introduction, terminology, Customer Behaviors, Different Queuing Models,

( M /M /1): (GD/∞/∞) Model, , ( M /M /1): (GD/N/∞) Model, ( M /M /1): (GD/ N / N)

Model, ( M /M /C): (GD/∞/∞) Model ( M /M /C): (GD/N/∞) Model, ( M /M /C): (GD/ N / N)

Model, Tandem queuing concept- M/Ek/1 Model.

Unit 3: SIMULATION MODELLING (06 Hours) Simulation: Definition, Introduction to Monte Carlo Simulation., Application, Different

Problems solved using Monte Carlo Simulation, Using Applications of Simulation,

Generation of Random Numbers. Simulation software, Building Model on Simulation

Software, Running the simulation, Understanding the results

Unit 4: GAME THEORY & REPLACEMENT ANALYSIS (06 Hours) Introduction, two -person zero sum game, minimax and maximin principle, saddle point,

methods for solving game problems with mixed strategies, Graphical and iterative methods,

solving game by LP Method. 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. Individual Replacement,

Group Replacement Policies, Problems

Unit 5: INTEGER AND DYNAMIC PROGRAMMING (06 Hours) Integer Programming: Branch & bound, cutting plane method. Dynamic

Programming: Introduction, application, capital budgeting, different problems solved by

dynamic programming

Unit 6: GOAL PROGRAMMING & DECISION MAKING TOOL (06 Hours) Goal Programming & Decision Making Tools: Goal Programming-Definition, Introduction,

Problems, Analytical Hierarchy Process, Decision Tree – Logic. Decision making under risk

(EMV criteria) and Decision making under uncertainty



List of Practicals: 1 Assignment on Sensitivity Analysis in Linear Programming Problems

2. Assignment based on any two Models of queuing theory & Multi stage queuing Model

3. Assignment based on replacement models & Game theory problems.

4. Assignment on Integer programming & on Dynamic programming

5. Assignment on Goal programming and on decision making tools.

6. Health Care System for outpatient treatment of any Multi specialty hospital.

7. Simulation on Multiple stage Queuing application.

Project work based on designing of a simulation model using any available simulation

software like Promodel, Simio-3D

Text Books:

1. Panneerselvam, Production & Operations Management,3rd

Edition, McGraw Hill

Publications,

Reference Books:

1. Chary, Production & Operations Management –1st Edition, McGraw Hill Publications

2. Tony Arnold, Materials & Operations Management –1st Edition, Pearson Publications

Course Outcomes:


1. Understanding of Functions of Materials Management and its usefulness.

2. Understanding of Components of Lead Time

3. Understanding different purchasing systems used

4. Understanding different transportation techniques & modes used

5. Understanding warehouses and SKU used in Production system

6. Understanding of logistics Outsourcing & customer service



FF No. : 654

IP481THP PROJECT MANAGEMENT


Unit 1: Introduction: (6 Hours) Definition & Characteristics of Project, Performance Parameters: Time, Cost & Quality.

Difference with respect to Standard Routine Production. Classification of Projects: Sector

based, Investment based, Technology based, Causation based, Need based (BMERD) -

Balancing, Modernization, Replacement, Expansion & Diversification Project Life Cycle

Phases – Concept/Initiation Phase: Parameters Involved in Project Identification. Sources

of New Project Ideas,

Governmental Framework for Identification of Opportunities, Incentives from state &

central govt.; Import-substitution projects.

Unit 2: Project Conceptualization & Feasibility Analysis (8 Hours) Project Definition Phase: Project Formulation & Feasibility. Types of Feasibility Studies –

Pre-feasibility, Support/Functional, Feasibility Study. Preparation of Project Feasibility

Report & Specification; Aspects of Project Feasibility Managerial/Organization: Promoters

Background, Criteria of Evaluation, Marketing/Commercial: Demand & Supply,

Competition, Market Survery, Porter’s 5 Forces, Operational/Technical: Process,

Technology, Location, Capacity, Labour, Raw Material & Utility Availability. Financial:

Cost of Project, Means of Finance, Financial Projections – Profit & Loss Account, Balance

Sheet, Funds Flow Statement, Cash Flow Statement, Schedule of Fixed Assets, Schedule of

Term Loans.

Socio-Economic: Socio-Cost Benefit Analysis. Effective Rate of Protection, Domestic

Resource Cost

Unit 3: Project Planning, Implementation & Control (8 Hours)

Planning & Organization Phase: Project Planning, Scheduling & Monitoring, Statement of

Works, Project Specifications, Work Breakdown Structure, Network Analysis & Duration

Estimating Network Diagrams – PERT/CPM, Estimate Activity Times, Milestone

Scheduling. Resource Leveling, Resource Smoothening, Project Crashing. Implementation

Phase: Activities Involved: Erection & Commissioning, Installation, Trial Runs &

Commencement of Commercial Production. Cleanup/Shutdown Phase: Handover to Client,

Settlement of Accounts

Unit 4: Project Cost Management (8 Hours) Project Cost Estimation: Need, Causes of Cost & Time Overruns. Nature of Cost

Estimates, Types of Project Cost Estimates, Estimation of Manpower & Utilities. Project

Budgeting & Control, Earned Value Management System: Concept of AC, PV, EV,

Variances etc.

Unit 5: Project Risk and Contract Management (6 Hours) Contract Management: Responsibility Sharing Matrix, Types of Contract Payments, Risk

Factors in Contracts – Contractor & Owner. Critical Chain Project Management.

Project Management Information System and Control, Management Pitfalls



Unit 6: Computer Applications in Project Planning & Control (8 Hours) Introduction to MS Projects – Understanding the MS Project screen & different views,

Defining the project, Working with calendar, Outline the project, Create dependencies

between tasks, Creating WBS, Format task list and Gantt chart, Resource planning,

leveling and preparing resource graph, Working with baseline, tracking the project.

Home Assignment on Exercise with MS Projects Software.

List of Practicals:

1. Preparation of Project Feasibility Report

a. Project Identification, Definition

b. Project Feasibility – Managerial/Organizational Perspective

c. Project Feasibility – Marketing, Exit Plan

d. Project Feasibility – Operational

e. Project Feasibility – Financial, Financial Projections

2. Assignment on Capital Budgeting – PBP, Discounted PBP, NPV, IRR, Annual Worth

3. Numerical on PERT/CPM – Calculation of Floats, Determination of Critical Path &

Project Duration

4. Case let - Project Crashing

5. Case let - Resource Leveling & Resource Smoothening

6. Project Planning & Scheduling (Using MS Projects) 1 – Preparation of Statement of

Works, WBS

7. Project Planning & Scheduling (Using MS Projects) 2 – Network Diagram, Gantt

Charts, Project Monitoring

Text Books: 1. Narendra Singh Project Management & Control Himalaya Publishing

House, Mumbai.

2. Prasanna

Chandra Project: Preparation, Appraisal, Budgeting

& Implementation

3. Pinto Project Management – Achieving

Competitive Advantage & MS Projects

Pearson Education

Reference Books:

1. Maylor Project Management Pearson Education

2. Gopal &

Ramamurthy

Project Management

Handbook

Macmilan

3. PMI Project Management Body of

Knowledge

3,4,5 PMI

4. Ghatak & Sandra Practical Project Management

Pearson Education (Singapore) Pte. Ltd

2001

5. SARDA Handbook on Project

Appraisal & Follow-up

Govind Prakashan 2001

Course Outcomes:


1. Learn the basic concepts of project and project management

2. Ascertain the feasibility of small and medium projects with respect to managerial,

marketing, operational, financial and socio-economic perspectives

3. Plan and schedule small and medium projects to achieve the triple constraint of time, cost

and quality using software package



4. Understand the concept of earned value management system and critical chain in

managing projects

5. Evaluate and apply the concepts of risk management and contract managment in

managing projects

6. Monitor the progress of projects to determine variances and recommend corrective

actions using software package



FF No. : 654

IP482THP::WORLD CLASS MANUFACTURING

Credits: 04 Teaching Scheme: Theory 3 Hrs/Week

Lab/Project 2Hrs/Week

Unit 1: WCM & Lean Manufacturing (7 Hours) Introduction To World Class Manufacturing. Lean Manufacturing – Definition & Concept.

Characteristics of Lean Manufacturing. Lean Mfg Tools & Techniques, Hall’s, Schonberger,s

framework of World Class Manufacturing, Various models of world class manufacturing,

Concept of MUDA, MURA & MURI. Value Stream Mapping – VSM Symbols, Current

State v.s Future State, Kaizen Bursts.

Unit 2: Lean Manufacturing Tools & Techniques - 1 (6 Hours)

Design of JIT-Pull System, Kanban – Types, Calculations of Kanban, Set-up Time

Reduction: SMED Methodology for Set-up reduction, Set-up Reduction Projects, Quick

Attachment Devices, Jidoka – Autonomation, Andon Principles, Problem Solving Approach,

Toyota 14 Principles of Management.

Unit 3: Lean Manufacturing Tools & Techniques - 2 (6 Hours)

Concept of Standard Work – Standardization, Standard Operating Procedures,

Group Technology Approaches, Characteristics Of A Group/ Cell Families Of Parts,

Production Flow Analysis And Choice Of Family, Benefits And Applications Of Group

Technology. Cellular Manufacturing: Work cell concepts and applications, Work cell design,

work cell staffing and equipment issues, Group Technology – Codification & Classification

Systems.

Unit 4: Total Productive Maintenance (7 Hours)

Maintenance – Breakdown, Preventive, Predictive. TPM: Concept & Origin, Outline of TPM

– 8 Pillars, TPM Performance Measures – PQCDSM & OEE, Introduction to Autonomous

Maintenance (Jishu Hozen) activities, Small-Group activities of TPM. Introduction to 5S:

Steps in 5S Methodology, Concept of 1S(Seiri), 2S(Seiton), 3S (Seiso), 4S (Shiketsu), 5S,

(Shitsuke). Implementation of 1S & 2S, MBNQA, EFQM Award, RBNQA Award, JIPM

TPM Award, Losses & Abnormalities in TPM.

Unit 5: Business Process Reengineering (7 Hours)

BPR Concepts, Practices & Philosophy, Key features and guiding principles of

Reengineering, Changes required on Behavioral Side in a BPR Project, Concepts of Business

and Core Processes in BPR, Process Mapping, SIPOC, BOLO (Be On Look Out)

Methodology , Tools in BPR

Unit 6: Theory of Constraints (7 Hours)

Introduction to TOC, Concept, Constraints – Types, Concept of Throughput, Inventory &

Operating Expenses, Throughput Accounting, TOC Methodology, Numerical & Cases in

TOC. Application of TOC in industry , Drum-Buffer-Rope Approach, Numerical & Case in

TOC Applications.



List of Practical: (Minimum Five)

Assignments on the following:

1. Case – Design of JIT / Kanban System

2. Case – Cellular Manufacturing

3. Case – Setup Time Reduction (SMED Philosophy)

4. Exercise – Design of Single Piece Flow

5. Assignment on TPM Performance Measures & OEE

6. Case on BPR

7. Case Study & Numerical on Application of TOC

Projects: Minimum Two

Project-1: Based on identification of 3M, Kaizen and Value Stream Mapping

Project-2: Based on any one or many Lean Tools and Techniques

Project-3: Based on Total Productive Maintenance

Project-4: Based on Theory of Constraints or Process Reengineering

Text Books: 1. Richard Chase, Nicholas Aquilano, Nitin Agarwal, F. Robert Jacobs; Operations

Management for Competitive Advantage; 11/e; TATA McGRAW HILL Publication.

2. Mooref; Making Common Sense Common Practice

Reference Books:

1. Narayanan; Managing Technology & Innovation for Competitive Advantage

2. M.G.Korgaonkar ; Just In Time Manufacturing

3. B.S.Sahay ; World Class Manufacturing

4. Schonberger ; World Class Manufacturing

Course Outcomes:


1. Identify, eliminate and reduce the non-value added activities (wastes) in manufacturing

organization.

2. Apply the tools and techniques of lean manufacturing to improve productivity in

manufacturing and service organizations.

3. Understand the concept, tools and techniques in TPM philosophy.

4. Analyze, map and improve business processes for achieving improvements.

5. Apply the tools and techniques of constraint management to improve productivity in

manufacturing and service organizations.



FF No. : 654

IP483THP :: INDUSTRIAL ROBOTICS

Credits: 04 Teaching Scheme: 4. Hours / Week

Unit 1: Basic Concepts in Robotics (…8.. Hours)

Automation and robotics, robot anatomy, robot specifications, Development of industrial

Robots and manipulators, basic structure of robots, resolution, accuracy and repeatability.

Classification, Configuration of robots, arm and body motions, wrist motions,

Mechanical, hydraulic and pneumatic Manipulators

Unit 2: Robot Arm Kinematics (….7 Hours)

The direct kinematics problem, the inverse kinematic solution, Homogeneous

transformations, Denavit - Hartenberg's representations, Global & Local Coordinates for

analysis

Unit 3: Static and dynamic analysis of manipulator arm (….7. Hours) Statics of planer arm robot, Mass and inertia of links, Lagrangian formulation for equations

of motion for serial manipulators

Unit 4: Robot Grippers (….6. Hours) Classification, types, Design consideration, Materials for hostile operation. Cylindrical

Cam type; Grippers using pneumatic, , Vacuum Grippers, ultrasonic grippers

Unit 5: Sensors in Robotics (….6. Hours) Sensors - functioning, types, analysis and fields of applications – position, velocity and

acceleration sensors, Tactile sensors, temperature sensors, Variable Pressure Light

Converting Sensor, High Resolution Compliance, Range & Proximity Sensors, Electro-

optical Sensors. Pneumatic tactile Sensor, Slip type Sensors

Vision system: Median filtering, thresholding, discretization, Smoothening of binary image.

Recognition Procedure. CCD Camera.

Unit 6: Robot Drives, Control and Robot Programming (….6. Hours) DC servo motors, basic control systems concepts and models, control system analysis,

robot activation and feed back components. Positional and velocity actuators. Methods of

Programming the robot, Languages, Robographics, Introduction to Artificial Intelligence,

Hydraulic systems, Power transmission systems, robot joint control design.

List of Practicals:

1 problems on accuracy, precision and repeatability, resolution

2 problem on forward kinematics-Cartesion

3 problem on forward kinematics-cylindrical

4 problem on forward kinematics-polar

5 problem on forward kinematics-jointed arm.

.

And



List of Project areas: 1. Project 1- Algorithm for pick and place operation

2. Project 2- Programme for pick and place operation.

Text Books:

1. Deb S.R., Robotics, Tata McGraw Hill Publications, New Delhi.

2. Yoram Koren, Robotics for Engineers, McGraw Hill Book Co.

3. Groover M.P., Weiss M., Nagel R.N., Odrey N.G., Industrial Robotics Technology -

Programming and Applications, McGraw Hill Book Co.

4. Fu K.S., Gonzalex R.C., Lee C.S.G., Robotics Control Sensing, Vision and

intelligence, McGraw Hill Book Co

Reference Books:

1. Hartenberg and Denavit, Kinematics and Synthesis of Linkages, McGraw Hill Book

Co.

2. Hall A.S.,Kinematics and Linkage Design, Prentice Hall.

3. Hirchhorn J., Kinematics and Dynamics of Machinery, McGraw Hill Book Co.

4. Todd D.J., Fundamentals of Robot Technology, Wiley Publications

5. Paul R., Robots - Manipulators, Mathematics, Programming and Control, MIT Press.

6. Janakiraman P.A., Robotics and Image Processing, Tata McGraw Hill 1995.


1. Understand robot system and Select type of robot for industrial applications

2. Solve direct and inverse kinematic problem for Cartesian, polar, cylindrical and

articulated arm robot.

3.Understand concept of static and dynamics of manipulator arm

4.Understand various types of end effectors used in industrial robots.

5. Understand concepts and applications of sensors used in industrial robots.

6. Study and Select appropriate drives and robot programming for industrial robots



FF No. : 654

IP480PRJ :: PROJECT

Credits: 05 Teaching Scheme: - Practical 2 Hr/Week

The project work could be of the following nature:

1. Manufacturing /Fabrication of a prototype machine' including selection, concept,

design, material, manufacturing the components, assembly of components, testing and

performance evaluation.

2. Improvement of existing machine / equipment / process.

3. Design and fabrication of Jigs and Fixtures, dies, tools, special purpose equipment,

inspection gauges, measuring instruments for machine tools.

4. Computer aided design, analysis of components such as stress analysis.

5. Problems related to Productivity improvements.

6. Problems related to value engineering.

7. Problems relating to material handling system.

8. Energy Audit of organization, Industrial evaluation of machine devices.

9. Design of a test rig for performance evaluation of machine devices.

10. Product design and development.

11. Analysis, evaluation and experimental verification of any engineering problem

encountered.

12. Quality systems and management. Total Quality Management.

13. Quality improvements, In-process Inspection, Online gauging.

14. Low cost automation, Computer Aided Automation in Manufacturing.

15. Time and Motion study, Job evaluation.

16. Ergonomics and safety aspects under industrial environment

17. Management Information System.

18. Market Analysis in conjunction with Production Planning and Control.

OR

Fabrication of models, machines, prototypes based on new ideas, robots and machine

based on hitech systems and automation, experimental set-up, fabrication of testing

equipment, renovation of machines, etc. Computer based design / analysis or modeling /

simulation of product(s), mechanism(s) or system (s) and its validation or comparison

with available benchmarks / results. Modelling/simulation of product(s), mechanism(s) or

system(s) and its validation or comparison with available bench marks / results.

Design/development and Fabrication of models, machines, and prototypes based on new

ideas, robotic and automation systems, Experimental set ups, test rigs/ equipments.

The project work shall be taken up individually or in a group consisting of not more than 4

students.

A report containing maximum 30 pages shall be submitted based on the background, need

and scope of the project, project specifications, activities involved in the project and

activity plan, study of literature and basic theory, and work completed (if any).



Guidelines:

• Report shall be typed or printed.

• Figures and tables shall be on separate pages and attached at respective positions.

• Project title and approval sheets shall be attached at the beginning of the report

followed by index and synopsis of the project.

• References shall be mentioned at the end followed by appendices (if any).

• When a group of students is doing a project, names of all the students shall be

included on every certified report copy.

Each group of students shall submit two copies of reports to the institute and one copy

shall be prepared for each individual student.

Course Outcomes :


1. Survey literature for problem identification

2. Cultivate the habit of working in a team, communicate effectively and attempt a

problem solution in a right approach

3. Correlate the theoretical and experimental/simulations results and draw the proper

inferences.

4. Apply engineering knowledge in carrying out project starting from design, drafting,

process planning, project management, costing, manufacturing, QC and inspection,

down to assembly, testing and evaluation.

5. To practice data collection and analysis using different measurement equipment’s and

software packages.

6. Prepare project report as per guideline and present it effectively

Bansilal Ramnath Agarwal Charitable Trust’s Vishwakarma ... · Project 1:-Development of process...

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