PRODUCTION AND INDUSTRIAL ENGINEERING

SCHEME Semester II

Evaluation Scheme (Marks)

Hrs/Week Sessional Exam

(internal)

Sl.

No.

Course

Number

Subject

L

T

P

TA

CT

Sub

Total

ESE

(Theory /

Practical)

Total

Credits

++

2

PTL

1 MPIE 201

Advanced

Precision

Machining Process

3

2

0

25

25

50

100

150

4

2 MPIE 202

Flexible

Manufacturing

Systems

3

1

0

25

25

50

100

150

3.5

3 MPIE 203

Management

Information

System

3

1

0

25

25

50

100

150

3.5

4 MPIE 204 Supply Chain

Management 3 1 0 25 25 50 100 150 3.5

5 MPIE 205 Professional

Elective – III 3 1 0 25 25 50 100 150 3.5

6 MPIE 206 Professional

Elective – IV 3 1 0 25 25 50 100 150 3.5

7 MPIE 207 Team Exercise 0 0 2 50 0 50 0 50 1

8 MPIE 208 CAD/CAM

Laboratory

0

0

3

25

25

50

100

150

1.5

18 7 5 400 700 1100 24

MPIE 205 Professional Elective – III 205.1 Principles of Robotics and Applications.

205.2 Sensors for Intelligent, Manufacturing & Condition Monitoring.

205.3 Design for Manufacturing and Assembly.

205.4 Failure Prevention.

205.5 Machine Tool Dynamics.

205.6 Simulation of Manufacturing Systems.

MPIE 206 Professional Elective – IV

206.1 Neural Network & Fuzzy Logic.

206.2 Lean & Agile Manufacturing.

206.3 Treatment of Metals.

206.4 Product Development & Manufacturing.

206.5 Decision Models.

206.6 Finite Element Method.

206.7 Advanced Operations Research Applications

PRODUCTION and INDUSTRIAL ENGINEERING

COURSE SYLLABI

SECOND SEMESTER

MPIE 201 ADVANCED PRECISION MACHINING PROCESS

Prerequisites:

Basic understanding of manufacturing processes mechanical and physical

properties of materials, and physics.

Course objectives:

1. Describe and develop basic theory encountered in the discipline of non-

traditional, nano manufacturing processes.

2. Develop the ability to properly assess the capabilities, limitations, and potentials

of non-traditional, nano manufacturing processes and their competitive aspects.

3. Describe new developments in processes, materials, and computer integration of

both technological and managerial activities in manufacturing organisation.

Course description:

New, difficult-to-machine materials and increased part complexity have resulted

in the creation of new manufacturing processes, known as non-traditional manufacturing

processes. This course introduces students to fundamentals of non-traditional

manufacturing processes, such as laser cutting and welding, abrasive water jet machining,

ultrasonic machining, Electro-discharge machining, chemical and electrochemical

machining, hybrid machining (laser beam, plasma arc and water jet assisted machining).

Rapid prototyping and manufacturing (RPM) techniques will be included in the program

of this course as well. RPM is a new term coined to describe a group of "layer-by-layer"

manufacturing processes which are capable of building a free-form part directly from

CAD data. The course represents a good balance between theoretical problems and

practical considerations related to the non-traditional manufacturing processes.

Course outline by topical areas:

Module 1

Introduction to non-traditional, nano Manufacturing Processes

Module 2

1. Laser Beam Processing

- Fundamentals

- Materials processing (cutting, drilling, welding, surface modification, micro

machining, laser deposition of thin film)

- Equipment for Laser Beam Processing

2. Electron Beam Processing

- Fundamentals

- Materials Processing (machining, welding, lithography)

3. Ion-Beam Processing

- Ion Beam removal, deposition, surface treatment

Module 3

1. Electrical Discharge Machining

- Operating Principles

- EDM micro-hole drilling, grinding

- EDM wire cutting

2. Plasma Arc and Laser Beam Assisted Machining

Module 4

1. Abrasive Water jet Machining

- Operating Principles

- Applications

2. Ultrasonic Machining

Module 5

Chemical and Electrochemical Machining (principle, types, process

parameters, control, MRR, surface finish, application etc. – Electro chemical

grinding, lapping, honing; process principle & Ra etc, applications – EBM,

LBM, IBM, AJM, Abrasive water jet machining, LIGA process.

Reference: -

1. J.J. Beaman, J.W. Barlow, D.L. Bourell, R.H. Craford, H.L. Marcus and K.P.

McAlea, Solid Freeform Fabrication.

2. A New Direction in Manufacturing, Kluwer Academic Publishers,

Dordrecht/Boston/London, 1997

3. Kalpakjian, Manufacturing Engineering & Technology, Addison – Wesley, 4nd

edn.

4. Bhattacharyya A., -"Metal Cutting Theory & Practice", Central Book Publishers.

5. Debitson A.- Hand book of precision engineering.

6. J.A. McGeough, Advanced Methods of Machining, Chapman and Hall, London,

New York, 1988.

7. Momber A.W.; Kovacevic R.- Principles of Water Jet Machining, Springer –

Verlag.

8. Precision Engineering Manufacturing by R.L.Murthy., New age intrnational

9. Metcut research associates - Machinablity Data Center Vol. 3 - Metcut research

associates,Cincinnati, USA.

10. G. Chryssolouris, Laser Machining – Theory and Practice, Springer Verlag, New

York, 1991.

MPIE 202 FLEXIBLE MANUFACTURING SYSTEMS

Module 1

FMS – An Overview: Definition of an FMS – types and configurations concepts – types

of flexibility & performance measures. Functions of FMS host computer – FMS host and

area controller function distribution.

Module 2 Development and implementation of an FMS: Planning phases – integration – system

configuration – FMS layouts – simulation – FMS project development steps. Project

management – equipment development – host system development – planning –

hardware & software development.

Module 3

Automated material handling and storage: Function – types – analysis of material

handling equipments. Design of conveyor & AVG systems.

Automated storage: Storage system performance – AS/RS – carousel storage system –

WIP storage – interfacing handling storage with manufacturing.

Module 4

Concepts of distributed numerical control: DNC system – communication between

DNC computer & machine control unit – hierarchical processing of data in DNC system

– features of DNC system.

Programmable controllers: Control system architecture – elements of programmable

controllers: language, control system flowchart, comparison of programming methods.

Module 5

FMS Relationale: Economic and technological justification for FMS – as GT, JIT –

operation and evaluation – personnel and infra structural aspects – typical case studies –

future prospects.

Textbooks: -

1. Parrish D. J. “Flexible Manufacturing”. Butter Worth Heinemann Ltd. Oxford,

1993

2. Groover M. P, “Automation, Production Systems and Computer Integrated

Manufacturing” Prentice Hall India (P) Ltd., 1989.

3. Kusiak A “Intelligent Manufacturing Systems”, Prentice Hall, Englewood Clitts,

NJ, 1990.

Reference: -

1. Considine D. M, & Considine G.D, “Standard Handbook of Industrial

Automation”. Chapman and Hall, London, 1986.

2. Viswanadham N & Narahari Y, “Performance Modeling of Automated

Manufacturing Systems”. Prentice Hall, India (P) Ltd., 1992

3. Ranky P. G, “The Design and Operation of FMS”, IFS Pub, UK, 1998.

MPIE 203 MANAGEMENT INFORMATION SYSTEMS

Module 1

Introduction: Meaning and definition of Management Information (MIS) – System

Approach – role of MIS to face increased complexity of business and management –

system view of business – MIS organization within the company.

Module 2

Conceptual information system design: Defining the problems – Setting system

objectives – Establishing system constraints – Determining information needs –

Determining information sources – Developing alternate conceptual design and selecting

the most preferred one – Documenting the conceptual design – preparing the conceptual

design report.

Module 3

Detailed information system design: Informing and involving the organization – Project

Management of MIS – Detailed – Design – Identifying dominant and trade-off criteria –

subsystems – definitions – sources – sketching the details and information flows –

automation – Informing and involving the organization again – Inputs, outputs and

processing Early system testing – organization to operate the system – Documentation –

Revisiting the manager – user.

Module 4

Evolution of information systems: Basic information Systems – Financial information

systems – Production / Operations systems – Marketing information Systems – Personal

information systems.

Information systems and decision making: Decision making and MIS - Programmed

and non programmed decision – MIS for making programmed decisions – decision –

assisting information systems – components of decision support systems.

Module 5

Information technology and MIS: Comparison of manual and computer based

information systems – conversation of manual to computer – based systems – types of

computer based applications in MIS – conceptual design of computer integrated security

management Information system – application of multimedia, internet and intranet

technologies in MIS.

Textbooks: -

1. Murdick R.G., Ross J. E & Claggett. J. R., Information Systems for Modern

Management”. Prentice Hall of India Private Ltd., India, 3rd

edition, 1992.

References: -

1. Henry C Lucas Jr., “The Analysis, Design and Implementation of Information

Systems”. McGraw Hill Company, New York 4th

Edition 1992.

2. Burch J. E., Strater F. R & Grudnikski G., “Information Systems: Theory and

Practice”. John Wiley and Sons, New York, 1987.

MPIE 204 SUPPLY CHAIN MANAGEMENT

Module 1

Introduction to supply chain management: Information systems and Supply chain

management, Inventory across the SCM, Supply chain relations.

Module 2

Role of information technology in the SCM: Inter organizational information systems,

Information requirement determination for supply chain I. T applications for Supply

Chain Management.

Module 3

Materials flow management across the supply chain: Supply chain Basics – Internal

supply chain, External supply chain and Inter Organizational supply chain. Supply chain

performance measures.

Module 4

Re-engineering supply chain logistics: Definition of logistics, SCM and Logistics,

International Considerations, Re-engineering challenges and opportunities, Cycle time

reduction across the Supply chain, Measurement of performance measures.

Module 5

Supply chain relationships: Integrated supply chain model, Total Quality Management

and supply chain, developing relationships in the Supply Chain, Resolving conflicts in

Supply chain relationships.

References: -

1. Hand Field Robert B., Nichols Jr., Ernest L., “Introduction to supply chain

management”. Prentice Hall, New Jersey, 1999.

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

2001.

3. Roberta S. Russell, Bernard W. Taylor III, Operations Management, PHI, 2003.

MPIE 205 PROFESSIONAL ELECTIVE - III

MPIE 205.1 PRINCIPLES OF ROBOTICS AND APPLICATIONS

Course Description:

Physical mechanisms of robotics, issues of modelling, planning, control, and

programming. Principles underlying the design and analysis of robotic systems.

Topics

Module 1

Introduction: Definition, configurations, work envelopes, specifications, and other basic

parameters of robots.

Module 2

Kinematics Principles: Position and orientation, co-ordinate systems, Relative Frames,

Homogeneous Co-ordinates, Direct and inverse Kinematics, Differential motions and the

Jaconians.

Module 3

Introduction to Dynamics. Types of Motions: Slew, joint-interpolated, Straight line

interpolated motions. Planning of manipulator Trajectories and control. Drives Basic

Electrical, Hydraulic, and pneumatic drives – basics and relative merits.

Module 4

Components: Harmonic reduction Units, servo valves, and grippers.

Module 5

Sensors: Basic types including vision, Force – torque wrist sensors. Programming

various methods levels typical languages like VAL. Industrial Applications. Robot cell

formation. Case studies.

Textbooks: -

1. Richard D.Klafter, Thomas A.Chmielwski, Michael Negin, “Robotics

Engineering, An Integrated approach”, Prentice Hall of Indi. 1989

2. Fu.K.S.Gomalez, R.C, LeeC.S.G., “Robotics: Control, Sension, Vision and

Intelligence”, McGraw Hill, 1980.

3. Mikell.P.Grooveretal, “Industrial Robots – Technology, Programming and

application”, McGraw Hill, 1980.

Reference: -

1. Shiman.Y.nof.”Handbook of Industrail Robotics”, John Wiley & sons, 1985

2. Deh.S.R.,”Robotics Technology and Flexible Automation”, Tata McGraw Hill,

1994.

3. Craig, J.J., Robotics: Mechanics and Control, Addison Wesley, 1989.

4. Groover, M.P., Fundamentals of Modern Manufacturing: Materials, Processes,

and Systems, Prentice Hall, 1996.

5. Craig, J., Adaptive Control of Mechanical Manipulators, Addison Wesley, 1988.

6. Snyder, W.E., Industrial Robots: Computer Interfacing and Control, Prentice-

Hall, 1985.

7. Song, S.M., and Waldron, K.J., Machines That Walk, MIT Press, 1988

8. IEEE Journal of Robotics and Automation

9. International Journal of Robotics Research

10. IEEE Transactions on Man, System, and Cybernetics

MPIE 205.2 SENSORS FOR INTELLIGENT MANUFACTURING AND

CONDITION MONITORING

Module 1

Introduction – role of sensors in manufacturing automation – operation principles of

different sensors – electrical, optical, acoustic, pneumatic, magnetic, Electro optical and

vision sensors.

Module 2

Condition monitoring of manufacturing systems – principles – sensors for monitoring

force, vibration and noise, selection of sensors and monitoring techniques.

Module 3

Acoustic emission – principles and applications – concepts of pattern recognition.

Sensors for CNC machine tools – linear and angular position and velocity sensors.

Module 4

Automatic identification techniques for shop floor control – bar code scanners, radio

frequency systems – optical character and machine vision sensors.

Module 5

Smart / intelligent sensors – integrated sensors.

Adaptive control of machine tools.

Reference: -

1. Sensors: Hand Book by Sabrie Soloman ; McGraw Hill

2. Thermal Sensors: Vo. IV, Sensors: A Comprehensive Survey by Jorg Scholz

(Editor), John wiley & Sons

3. Mechanical Sensors: Vo. VII, Sensors: A Comprehensive Survey by H.H. Bau

(Editor), John wiley & Sons

4. Sensor Technology & Devices by Ljubisa Ristia (Editor), Artech House

Publishers.

MPIE 205.3 DESIGN FOR MANUFACTURE AND ASSEMBLY

EFFECT OF MATERIALS AND MANUFACTURING PROCESS ON DESIGN : Major

phase of design. Effect of material properties on design. Effect of manufacturing process

on design. The material selection process – cost per unit property, weight properties and

limits on properties methods.

TOLERANCE ANALYSIS: Process capability, mean variance, skewness, kurtosis, process

capability metrics Cp., Cpk cost aspects, feature tolerances, geometric tolerances, surface

finish, review of relationship between attainable tolerance grades and different machining

process, cumulative effect tolerances, sure fit, law normal law and truncated normal law.

SELECTIVE ASSEMBLY: Interchangeable and selective assembly, deciding the number

of groups – Model-I group tolerances of mating parts equal; Model – II: total and group

tolerances of shaft, control of axial play – introducing secondary machining operations,

laminated shims, examples.

DATUM SYSTEMS: Degrees of freedom, grouped datum systems – different types, two

and three mutually perpendicular grouped datum planes, grouped datum system with

spigot and recess, pin and hole, grouped datum system with spigot and recess pair and

tongue – slot pair – computation of transitional and rotational accuracy, geometric

analysis and applications.

TRUE POSITION THEORY: Comparison between co-ordinate and convention method of

feature location, tolerancing and true position tolerancing, virtual size concept, floating

and fixed fasteners, projected tolerance zone, assembly with gasket, zero true position

tolerance, functional gauges, paper layout gauging, compound assembly, examples.

FORM DESIGN OF CASTINGS AND WELDMENTS: Redesign of casting based on

parting line considerations, minimising core requirements, redesigning cast members

using weldments, use of welding symbols.

TOLERANCE CHARTING TECHNIQUE: Operation sequence for typical shaft type of

components, preparation of process drawings for different operations, tolerance

worksheets and centrality analysis, examples, design features to facilitate machining,

datum features – functional and manufacturing, component design – machining

considerations, redesign for manufacture, examples.

CASE STUDIES: Redesign to suit manufacture of typical assemblies, tolerances design

of typical drive – system, example, design of experiment, value analysis and design rules

to minimize cost of a product. Computer aided DFMA, poke yoka principles.

Text Books: -

1. Harry Peck, “Designing for Manufacture”, Pitman Publications, 1983.

2. Matousek, “Engineering Design – A systematic Approach” Blackie & Son Ltd.,

London 1974.

Reference: -

1. Spotts, M.F., “dimensioning and tolerance for Quantity Production”, Prentice Hall

Inc., 1983

2. Oliver R.Wade, “Tolerance Control in Design and Manufacturing”, Industrial

Press Inc., New York, 1967

3. James G.Bralla, “ Hand Book of Product Design and Manufacturing”, McGraw

Hill Pubilications, 1983.

4. Trucks, H.E., “ Design for Economic Production”, Society of Manufacturing

Engineers, Michigan, 2nd

Edition, 1987.

5. Poka – Yoke, “Improving Product Quality by Preventing Defects”, Productivity

Press, 1992

6. Creveling, C.M., “ Tolerance Design – A Hand Book for Developing Optimal

Specifications”, Addison Wesley Longman, Inc, 1997

7. Pahl, G. and Beitz W. “Engineering Design – Systematic Approach”, Springer

Verlag Pub., 1996.

8. Mahmoud M.Farag, “Material Selection for Engineering Design”, Prentice Hall,

1997.

MPIE 205.4 FAILURE PREVENTION

Modes of mechanical failure, strength and deformation of metals, theories of

failure, fatigue and fracture, life prediction, statistics, fretting, wear, and corrosion.

Goals: The course is designed to introduce the students to the wide variety of failure

modes of mechanical systems. They will investigate current models to predict

structuralfailure, and they will use the available methodologies to design structures to

prevent these failures.

Topics:

1. Introduction to Mechanical Failure

2. Deformation Response of Metals

3. Fracture Mechanics

4. High-Cycle Fatigue

5. Cumulative Damage and Life Prediction

6. Low-Cycle Fatigue

7. Neuber Analysis

9. Fatigue Crack Growth

10. Statistics in Fatigue Analysis

11. Weibull Analysis

12. Fretting, Wear and Corrosion

Course Outcomes:

1. Students will be able to identify a wide variety of failure modes of mechanical

systems.

2. Students will be able to design mechanical structures to prevent failures from

deformation, brittle fracture, fatigue, and corrosion.

3. Students will be able to analyze data using appropriate statistical tools.

4. Students will be able to generate a computer code to predict the fatigue life of a

structure.

Text Book: -

1. Ewalds H. L. & Wanhill R.J.H., Fracture Mechanics, Edward Arnold Edition

Reference: -

1. Broek D., Elementary Engineering Fracture Mechanics, Sijthoff & Noordhoff

International Publishers

2. Kare Hellan, Introduction to Fracture Mechanics, McGraw Hill Book Company

3. Prashant Kumar, Elements of Fracture Mechanics, Wheeler Publishing

4. ISBN; 81 7371 259 X Fracture Mechanics for Modern Engineering design by

Simha, K.R.Y. University Press

MPIE 205.5 MACHINE TOOL DYNAMICS

Machine tools as a closed loop.

Machine tool frames-static deflection models.

Thermal distortion.

Dynamic behaviour, longitudinal, laternal and torsional vibrations.

Dynamics of cutting forces.

Tool chatter.

Slide ways, hydrodynamic bearing, air and gas bearings.

Instability

Hydraulic servomechanisms.

Vibration dampers

Practical design considerations

Measurement of dynamic forces and vibrations

Reference: -

1. Theory of Machines - Thomas Bevan

2. Theory of Machines - P.L. Ballaney

3. Mechanical Vibrations, V edition - G.K. Groover

4. Theory of Vibrations with

applications, III Edn - W.T. Thomson

5. Mechanical Vibrations - S. Graham Kelly,

Schaum’s outlines

6. Fundamentals of Vibrations - Leonard Meirovitch, MacGraw

7. A text book of sound - L.P. Sharma & H.C. Saxena

8. Engineering Noise Control - D.A. Bies & C.H. Hausen.

9. Noise & Vibration Control - Leo N. Beraneck

MPIE 205.6 SIMULATION OF MANUFACTURING SYSTEMS

Module 1

Principle of computer modelling and simulation: Monte Carlo simulation. Nature of

computer modelling and simulation. Limitations of simulation, areas of application.

Module 2

System and environment: Components of a system – discrete and continuous systems.

Models of a system – a variety of modelling approaches.

Random number generation: Techniques for generating random numbers – Midsquare

method – The midproduct method – Constant multiplier technique – Additive

congruential method – Linear congruential method – Test for random numbers – The

Kolmogorov –Smirnov test – the Chi-square test.

Module 3

Random variable generation: Inverse transform technique – exponential distribution –

uniform distribution – Weibull distribution Emprical continuous distribution – generating

approximate normal variants – Erlang distribution.

Module 4

Emprical discrete distribution: Discrete uniform distribution – poisson distribution –

geometric distribution – acceptance – rejection technique for Possion distribution –

gamma distribution.

Module 5

Design and evaluation of simulation experiments: Variance reduction techniques –

antithetic variables – verification and validation of simulation models.

Discrete event simulation: Concepts in discrete-event simulation, manual simulation

using event scheduling, single channel queue – two server queue, simulation of inventory

problem.

Textbooks: -

1. Jerry Banks & John S. Carson II, “Discrete Event System Simulation” Prentice

Hall Inc., 1984.

2. Gordon G, “ System Simulation”, Prentice Hall Ltd. 1991.

Reference: -

1. Narsingh Deo, “System Simulation with Digital Computer” Prentice Hall, 1979

2. Francis Neelamkovil, “ Computer Simulation and Modeling”, John Wiley &

Sons, 1987.

3. Ruth M. Davis & Robert M.O’Keefe, “Simulation Modeling with Pascal”,

Prentice Hall Inc., 1989.

MPIE 206 PROFESSIONAL ELECTIVE – IV

MPIE.206.1 NEURAL NETWORKS AND FUZZY SYSTEMS

Course Description: Discussion of neural networks, architectures, algorithms and applications, including

Hebbian, Hoffield, Competitive Learning, ART and Back propagation neural nets.

INTRODUCTION TO NEURAL NETWORKS: Difference between Biological and

Artificial Neural Networks Typical Architecture, Common Activation function,

McCulloch – Pits Neuron, Simple Neural Nets for Pattern Classification, Linear

Seperability – Hebb Net, Perceptron, Adaline, Madaline – Architecture, Algorithm, and

Simple applications.

PATTERN ASSOCIATION: Training Algorithms for pattern association – Hebb rule and

Delta rule, Heteroassociative, Autoassociative and lterative Autoassociative Net,

Bidirectional Associative Net, Bidirectional Addociative Memory – Architecture,

Algorithm, and Simple applications.

NEURAL NETWORKS BASED ON COMPETITION: Fixed Weight Competitive Nets –

Maxnet, Mexican Hat and Hamming Net, Kohenen Self organizing Maps, Learning

Vector Quantization, Counterpropagtion – Architecture, Algorithm, and Simple

applications.

ADAPTIVE RESONANCE AND BACKPROPAGATION NEURAL NETWORKS: ART1

and ART2 – Basic Operation and Algorithm, Standard Backpropagation Architecture

Derivation of learning rules, Multi layer Neural Nets as Universal Apporximators,

Boltzman Machine Learning and Neocognitron - Architecture, Algorithm, and Simple

applications.

CLASSICAL AND FUZZY SETS AND RELATIONS: Properties and operations on

Classical and Fuzzy sets, Crisp and Fuzzy relations – Cardinality, Properties and

operations, Composition, Tolerance and Equivalence relations, Value Assignments –

Cosine Amplitude, Max-min Method, Simple problems.

MEMBERSHIP FUNCTIONS: Features of membership function, standard forms and

boundaries, fuzzification, membership value assignment, fuzzy to crisp conversions,

lambda cuts of fuzzy sets and relations. DeFuzzification methods.

FUZZY ARITHMETIC: Extension principle – Fuzzy numbers, Fuzzy vectors, Classical

predicate logic, fuzzy logic approximate reasoning, fuzzy tautologies, fuzzy rule based

system-natural language, linguistic hedges, graphical techniques of inference.

FUZZY APPLICATIONS: Neonlinear simulations, fuzzy associated memories, fuzzy

decision making – Evaluation ordering, multiobjective decision making, fuzzy

classification – cluster analysis, cluster validity, c-Means clustering, fuzzy pattern

recognition, fuzzy control applications in industry, fuzzy logic controllers.

Reference: -

1. Neural Computing Theory & Practice - Philip D. Wasserman.

2. Simon Haykins, "Neural Network a - Comprehensive Foundation", Macmillan

College, Proc, Con, Inc

3. Zurada J.M., "Introduction to Artificial Neural Systems, Jaico publishers

4. Driankov D., Hellendoorn H. & Reinfrank M., "An Introduction to Fuzzy

Control", Norosa Publishing House

5. Thimothy J. Ross, "Fuzzy Logic with Engineering Applications", McGraw Hill

6. Bart Kosko. "Neural Network and Fuzzy Systems", Prentice Hall, Inc.,

Englewood Cliffs

7. David E. Goldberg, "Genetic Algorithms in Search Optimisation and Machine

Learning", Addison Wesley

8. Suran Goonatilake & Sukhdev Khebbal (Eds.), "Intelligent Hybrid Systems",

John Wiley & Sons

9. Adaptive Pattern Recognition & Neural Networks - Pay Y.H.

10. An Introduction to neural computing - Chapman & Hall

11. Artificial Neural Networks - Robert J. Schalkoff, McGraw Hill

12. Artificial Neural Networks - B.Yegnanarayana, PHI

13. Architectures, Algorithms and Application, Laurene Fausett, Prentice-Hall, 1994.

14. Simon Haykin,Neural Networks: A Comprehensive Foundation, MacMillan

Publishing, 1994.

15. Bart Kosko, Neural Network and Fuzzy Systems: A Dynamic System Approach

to Machine Intelligence, Prentice-Hall, 1992

16. David E. Rumelhart and James L. McClleland, Parallel Distributed Processing

Vol. I Foundations, MIT Press, 1986.

17. James L. McClleland and David E. Rumelhart, Explorations in Parallel

18. Charles Koelbel, et. al., Fundamental of Neural Networks: Distributed Processing:

A Handbook of Models, Programs and Exercises, MIT Press, 1986.

19. LiMin Fu, Neural Networks in Computer Science, McGraw-Hill, 1994.

MPIE 206.2 LEAN AND AGILE MANUFACTURING

INTRODUCTION TO LEAN MANUFACTURING: Meaning of lean – prerequisites of

becoming lean in manufacturing systems – ford Production System (FPS) – phases of

change – education and training – new measurable in FPS – managing change in a large

corporation.

LEAN MANUFACTURING PRACTICES: System model of lean manufacturing – lean

supplier to system sub model – core production system sun model – Interaction between

production worker influence and production strategies – performance impacts of the lean

manufacturing system, - relationship between lean manufacturing practices and

performance measures.

IMPLEMENTING LEAN MANUFACTURIENG: Lean manufacturing program – defining

lean manufacturing principles – lean flow – two paths of implementing lean

manufacturing – pitfalls in implementing lean manufacturing.

SUCCESFUL IMPLEMENTATION OF LEAN MANUFACTURING: Meaning and

definition of agility – forces pulling towards agility – three consequences of converging

physical products, information and services – empowerment – enterprise integration –

concurrent operations.

NTRODUCTION TO AGILE MANUFACTURING: Meaning and definition of agility –

forces pulling towards agility – three consequences of converging physical products,

information and services – empowerment – enterprise integration – concurrent

operations.

CUSTOMIZING AGILE BUSINESS STRATEGIES: Model for agile relationships –

products, services and enrichment of each customer – enrichment chain – moving from

one time product to providing customer – enrichment – steps in customising the agile

business strategies – analysis of company – overall opportunity analysis – comparison

with current products – initial plan of market presence – refining the plan – analysing the

barriers to change – planning the internal realignment of the company – role of strategic

planning departments.

BARRIERS TO ASSIMILATING AGILITY: Generally accepted accounting principles –

activity based costing – time based costing fully utilised balanced line fallacy – budgeting

procedures – dysfunctional organisation and information systems – betrayal of trust – not

sharing information – external barriers.

INTRASTRUCTURE AND ENABLING SYSTEMS FOR AGILITY: Infrastructure for

agility – enterprise elements – customer dialogue and support – communication and

information – co-operation and teeming – continuous improvement and change –

enterprises wide concurrency – environmental enhancement – flexible and rapidly

responding operations – people support – supplier support – enabling subsystems –

continuous education and training – customer interactive systems – lean organisation and

methods – modular re configurable process components – performance metrics and

evaluation – waste management and elimination.

Text Books: -

1. Liker, J.K. (ed.), 1997, “Becoming Lean”, Productivity Press, Oregan.

2. Goldman, S.L., Nagal, R.N. and Preiss, K. 1995, Agile competitors and Virtual

organizations, Van Nostrand Reinhold, New York.

Reference: -

1. Montgomery, J.C. and Levine, L.O., 1995. “The transition to agile

manufacturing” – Staying flexible for competitive advantage, ASQC Quality

Press, Wisconsin.

MPIE 206.3 TREATMENT OF MATERIALS

Functional characteristics of engineering surfaces

Material treatments

Significance of material treatments on function

Material treatment techniques

Case hardening

Phosphating

Aluminising

Plating

Ion treatment

Metal spraying

Micro alloy materials characteristics and their functional behaviour

Case study

Reference: -

1. Stan Grainger, Editor; Engineering Coating Design and applications

2. Chapman.B. Glow Discharge Process, John Wiley.

3. G. Dearnaley - Ion Implantaion North Holland Publishing Co. amsterdam.

4. Bunshah, R.f.; et.al. Deposition Technologies for films and Coatings. Park Ridge,

NJ. Noyes Publications, 1982.

5. Ballard W.E. Mtal Spraying and the Flame Deposition of Ceramics and Plastics.

6. Rabinowicz, Friction and Wear of Materials, John Wiley and Sons.

MPIE 206.4 PRODUCT DEVELOPMENT AND MANUFACTURE

PRODUCT ANALYSIS: Consumer – Industrial products, demand and quality of

production, life cycle, cost, quality and service aspects. Component classification makes

or buys decision. Group technology, introduction to concurrent engineering.

LATEST TRENDS IN PRODCUT DEVELOPMENT: Internet, collaborative product

commerce, and concept, functionality and implementation software for CPC, use of

software for CPC – Use of software in CPC.

ENGINEERING MATERIALS: Use of standard sections and components, review of

different materials and its properties like Machinablity, hardenability, weldability,

formability, use of standard assembly (sub modular assembly).

ASSEMBLY AND FINISHING TECHNIQUES: Types of fasteners, types of joints.

Assembling methods – site assembly (shipbuilding), group assembly and line assembly.

MANUFACTURING OF PRISMATIC COMPONENTS: Methods of loading, holding,

sequence of operations, inspection of gear box body, headstock, gear pump body,

application in milling machines, special purpose machines, transfer lines and machining

centres.

MANUFACTURING OF COMPONENTS BY FORMING Need for forming process, die

casting, injection moulding, extrusion and cold heading with examples of components.

Manufacturing of sheet metal components. Selection of press, selection of material for

blanking and piercing dies, manufacturing of components like circlip, cups, control panel

and cabinets.

PRODUCTION OF HEAVY COMPONENTS: Casting (pit moulding) and fabrication of

components like machine tool parts pressure vessels, scooter frame and press frames.

Text Books: -

1. Product design and manufacture. A.K.Chitale, R.C.Gupta – Prentice Hall India,

1997

2. Design and manufacture – An integrated approach. Rod Black – Macmillan

Publishing Company, 1996.

Reference: -

1. Automation, Production system and Computer Integrated Manufacturing,

Michael, P.Groover – Prentice Hall, 1980.

2. Purchasing and Materials Management Donald, W.Dobler, Lamer Lee Jr and

David N burt, 1989.

MPIE 206.5 DECISION MODELS

Goals:

Focus on quantitative and qualitative decision models and techniques for technical

and managerial problems. Emphasis on application and interpretation of results.

The goal of this course is to provide the student with an understanding of how

various business situations can be modelled effectively as mathematical models using

optimisation and stochastic modelling techniques. We will learn, through examples and

cases, how such techniques provide framework for decision making when information

from several sources need to be integrated and we will understand the benefits of an

aggregate approach over “linear” decision process. We will learn how to incorporate

multiple decision criterion and uncertainty in the decision process. We will learn

modelling techniques that are suitable for taking decisions with partial information, and

situations that are naturally modelled as a network of queues using simulation. The skills

learned in the course should enhance student’s ability to think methodically while making

important decisions.

This course should be of primary interest to people aspiring to a career in general

management or leading the engineering function in an enterprise. It should be of interest

to people who may manage and participate in the decision process in operations and other

business functions such as marketing, finance, accounting and human resources.

Topic outline

Module 1

Decision trees,

Influence diagrams

Module 2

Weighting methods.

Value of information.

Module 3

Analytical hierarchy process.

Bayes theorem.

Module 4

Monte Carlo simulation.

Utility theory.

Module 5

Risk analysis.

Group decision-making.

Reference: -

1. Management Science and Decision Technology; Jeffrey D. Camm and James R.

Evans South-Western Thomson Leaning, 2000, ISBN # 0-324-00715-9

2. Data, Models, and Decisions: The fundamentals of Management Science, by

Dimitris Bertsimas and Robert M. Freund, South-Western Thomson Learning,

2000 Additional Topics: Statistical Sampling, More advanced coverage of

regression models, non-linear and discrete optimisation. Comments: Material at

slightly more advanced level, more advanced examples

3. Quantitative Methods for Business, 8th

Ed, by Anderson, Sweeney and Williams,

South-western Thomson Learning Additional Topics: Markov Decision Process

Comments: Material at more introductory level, but nicely organised.

4. Introductory Management Science, by Eppen, Gould, Schmidt, Moore and

Weatherford, Prentice Hall, 1998 Additional Topics: Extensive discussion on

basic spreadsheet modelling, and linear programming modelling in Excel, LP

graphical analysis, Non-linear optimisation. Comments: Lots of very nice ill-

structured cases. Interesting discussion on proper consideration of sunk and

variable costs

5. Applied Management Science, by Lawrence and Pasternack, John-Wiley, 1998

Additional Topics: Most topics are covered in the books mentioned above.

Comments: The discussion in this book is very readable. The cases are more

structured and may be viewed as large well-defined problems.

6. Practical Management Science, by Winston and Albright, Duxbury, 2001

Additional Topics: Decision-Making under Uncertainty Comments: The book is

spread sheet based and tied very closely to @Risk and spread sheet solvers. Lots

of very nice examples, and cases, particularly those on financial topics.

7. Managerial Spreadsheet Modelling and Analysis, by Hesse, 1997 Additional

Topics: More extensive discussion on Routing Models, Integer Programming

Models Comments: A well-organised book with readable examples and cases.

8. AMPL A Modelling Language for Mathematical Programming, by Fourer, Gay

and Kernighan, The Scientific Press, 1993 Comments: This book serves as a

reference for a very popular modelling language: AMPL. Other similar languages

are GAMS and the modelling language that comes with LINDO. One can write

AMPL models and submit them over www to a server at the optimisation

technology centre, and get solutions to the model on line. Highly recommend this

if you want to learn the use of mathematical modeling beyond the use within

spreadsheets.

9. Simulation with Arena, by Kelton, Sadowski and Sadowski. McGraw Hill 1997.

Comments: Arena is one of the most popular user-friendly simulation software,

which has been used extensive to model queuing system. This book has a good

introduction to discrete event simulation. The book is shipped with an academic

version of Arena software.

MPIE 206.6 FINITE ELEMENT ANALYSIS

Introduction to FEM: Engineering design analysis – meaning and purpose-steady state,

propagation and transient problems-basic concepts of FEM – applicability of FEM to

structural analysis, heat transfer and fluid flow problems-advantages and limitations of

FEM, commercial finite element packages – organization – advantages & limitations.

Static analysis: General procedure of FEM – skeletal and continuum structures –

Discretization of domain-basic types of elements – concept of stiffness analysis – Direct

– approach – Formal approach using Shape Functions – Reyleigh – Ritz method-

formulation of elements – stiffness matrices – truss, beam, triangular, quadrilateral and

brick elements – Isoparametric elements – Axisymmetric elements.

Dynamic analysis: equations of motion for dynamic problems – consistent and lumped

mass matrices – formulation of element mass matrices – tree vibration and forced

vibration problem formulation.

Solution methods for finite element equations: Handling of simultaneous equations –

Gaussian elimination method – Choleski method solving of eigen value problems –

Jacobi & subspace iteration methods – direct integration and mode superposition method

– Interpolation techniques.

Heat transfer and fluid flow analysis: basic equations of heat transfer & fluid flow

problems – Galerkin method – finite element formulation – one – dimensional heat and

fluid flow problems.

Mechanism analysis: Introduction to analysis of mechanisms – creation of kinematics

models – imposement of constraints and forces – inertial data – static and dynamic

analysis of kinematics system – analysis of output data – animation – displacement,

velocity and acceleration functions.

MPIE 206. 7 ADVANCED OPERATIONS RESEARCH APPLICATIONS

Goals:

The course is designed to develop an understanding of operation research with

Particular attention to linear programming, network analysis, dynamic programming, and

Integer programming.

Topics:

Module 1

Linear Programming a. Problem formulation

b. Graphical solution

c. Interpretations

d. Simplex method

e. Duality theory

f. Sensitivity analysis

Module 2

Network Analysis a. Shortest route problem

b. Minimal spanning tree problem

c. Maximum flow problem

Module 3

Integer Programming

a. Graphical method

b. The branch and bound technique

c. Gomary’s cutting plane method

d. Transportation problem

Module 4

Goal Programming

a. Goal programming formulation

b. Goal programming algorithms

a. Weighting Method

b. Preemptive Method

Module 5

Dynamic Programming a. Prototype example

b. Characteristic of Dynamic Programming

c. Deterministic Dynamic Programming

Course Outcomes:

1. Students will have a working knowledge of operation research techniques such as

linear programming, Integer Programming, Goal Programming and Dynamic

Programming.

2. Students will have the ability to analyse and perform sensitivity analysis on

different Optimum solutions generated.

3. Students will have the ability to tackle real life optimisation problems.

Reference Books:

1. Hamda & Taha, Operations Research - 7th

edn; Pearson

2. Ravindran, Phillips, Solberg: Operations Research Principles and Practice, Willey

& Sons 1987.

3. Ronald L.Rardin, Optimisation in Operation Research, Pearson Education

4. Verma A.P., Operation Research, S.K.Katharia & Sons

5. Winston W. L.: Operations Research: Applications and Algorithms (3rd ed.),

PWS-Kent Pub, (1994).

6. Gnedenko B., Kovalenko I.: Introduction to Queuing Theory, Birkhauser, 1987.

7. Kon-Popovska M.: Mre`no planirawe, analiza na tro{oci, analiza na resursi,

Matemati~ka {kola, 1979.)

MPIE 207 A TEAM EXERCISES

The student will take part in a primarily design-based group/team exercise, giving

him experience in managing a long-term project. The student will be encouraged to work

within his team in competition with the other teams, planning and carrying out the work

within a set time frame

MPIE 208 CAD/CAM LABORATORY

Review: Study of chip formation in turning process;

Study of operation of tool & cutter grinder, Twist drill grinder, centreless grinder;

Determination of cutting forces in turning;

Inspection of parts using toolmakers microscope, roughness and form tester;

Studies on PLC programming.

Condition monitoring in machining processes using acoustic emission.

Determination of cutting forces in drilling and broaching;

Experiments in cylindrical grinding process.

Objective:

At the end of this laboratory course you must be able to Create and Edit solid

models and working drawings Perform Static and Dynamic analysis using FEM Program

and Simulate CNC machine tool operations Program an industrial robot for simple

material handling tasks Demonstrate the capabilities of a CMM for quality control

1. Exercises on solid modeling Introduction to computer graphics - viewing transformations, curves and surfaces

generation, curve fitting and curve fairing techniques - 2D, wire frame, 3D shading -

familiarity with Boolean operations - sweep, revolve, loft, extrude, filleting, chamfer,

splines etc. - windowing, view point, clipping, scaling and rotation transformations using

commercial solid modeling packages

2. Exercises on finite element analysis

Introduction to FEM - 1D, 2D and 3D elements - shape functions - preprocessing

- boundary conditions, structured and free mesh generation - analysis - linear and non

linear analysis - static and dynamic analysis - post processing - display, animation,

extraction of nodal data - exercises on heat conduction and elasticity may be given using

commercial FEM packages

3. Assembly and mechanism design Assembling of various parts and tolerance analysis - synthesis and design of

mechanisms - animations - exercises on various mechanisms like four bar linkages and its

variations - cam and follower - two and four stroke engines

4. Computer aided manufacturing

Part programming fundamentals - manual part programming and computer aided

part programming - hands on training in computer controlled turning and milling

operations - familiarity with windows based software packages - tool path generation and

simulation - exercises on CNC lathe and machining centre /milling machines

5. Programming of industrial robots

Introduction to robotics - structure, workspace analysis and various components -

actuators - sensors - encoders - end effectors - applications - hands on training on

industrial robots - manual and programmed path planning

6. Computer aided inspection and quality control

Introduction to CMM - classification - structure - components - familiarity with

measurement software packages and its modules - demonstration of the capability of

coordinate measuring machine using a sample component e.g. - engine block - concepts

of reverse engineering and rapid prototyping technology

Reference: -

1. Rogers D.F. & Adams J.A., "Mathematical Elements for Computer Graphics",

McGraw Hill, 2nd Edition.

2. Rogers David F., "Procedural Elements for Computer Graphics", McGraw Hill

3. Cook, Robert Davis et al., "Concepts and Applications of Finite Element

Analysis", John Wiley & Sons.

4. Koren Yoram, "Computer Control of Manufacturing Systems", McGraw Hill.

5. Kundra Rao & Tewari, "Numerical Control and Computer Aided Manufacturing",

Tata McGraw Hill.

2. Ramamurthy V., "Computer Aided Mechanical Design", Tata McGraw Hill

3. Fu K.S., Gonzalez R.C. & Lee C.S.G., "Robotics: Control, Sensing, Vision and

Intelligence", McGraw Hill.

4. Koren Yoram, "Robotics for Engineers", McGraw Hill.

5. John A. Bosch, "Coordinate Measuring Machines and Systems", Marcel Decker

Inc.

6. Learning Computer Numerical Control, By Michael Janke, Delmar Publishers

Inc.