A University established under Section 3 of the UGC Act, 1956

SASTRA UNIVERSITY

School of Mechanical Engineering M.Tech -Advanced Manufacturing - In collaboration With M/s Lucas-TVS, Chennai
Code No. Course Periods per week L T P 4 4 4 4 4 4 0 4 4 4 4 4 4 0 4 4 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 3 0 0 0

C 3 3 3 3 3 3 1 3 3 3 3 3 3 1 3 3 3 4 12 63

Semester I MAMGL101 MAMGL102 MAMGL103 MAMGL104 MAMGL105 MAMGL106 MAMGL107 Semester II MAMGL201 MAMGL202 MAMGL203 MAMGL204 MAMGL205 MAMGL206 MAMGL207 Semester III MAMGL301 MAMGL302 MAMGL303 MAMGL304 Semester IV MAMGL401 L - Lecture

Statistical Methods Mechanics of Metal cutting Metal Forming Technology Automation & Computer Integrated Manufacturing Logistics & Supply Chain Management Elective I CAD/CAM / CIM Lab Total Quality Management Optimization Techniques Precision Manufacturing Lean Manufacturing Systems Elective II Elective III Mechatronics & Automation Lab Elective IV Elective V Elective VI Project Phase I (Mini Project) Project Phase II

Total Number of Credits = T - Tutorial P - Practical C - Credits

List of Electives
MAMGLE0 1 MAMGLE0 2 MAMGLE0 3 MAMGLE0 4 MAMGLE0 5 MAMGLE0 6 MAMGLE0 7 MAMGLE0 8 MAMGLE0 9 MAMGLE1 0 MAMGLE1 1 MAMGLE1 2 MAMGLE1 3 MAMGLE1 4 MAMGLE1 5 MAMGLE1 6 MAMGLE1 7 Industrial Robotics Mechatronics Systems Reliability & Maintenance Engineering Design for Manufacturing Flexible Manufacturing Systems Non-Destructive Testing Tolerance Technology Computer Aided Metrology and Inspection System Simulation CNC and Adoptive Control Computer Aided Process Planning Industrial Safety Engineering Enterprise Resource Planning Accounting Concepts and Financial management Operations Strategy for Industry Industrial Engineering & Costing Human Resource Management

MAMGLE1 8 MAMGLE1 9

Cellular Manufacturing System Project Management

MAMGL101: STATISTICAL METHODS UNIT I (15)

Introduction to probability theory Random variable Probability density and distribution functions Standard distributions: Geometric, Hypergeometric, Binomial, Poisson, Normal, Log-Normal, Exponential, Gamma, Beta and Weibull distributions Applications Bayes Theorem Chebysev's Theorem. UNIT II Sampling distributions of statistical parameters Standard error central limit theorem t, F and Chi-square distributions - Estimation Point estimation - Interval estimation for population means, standard deviation, proportion, difference in mean, ratio of standard deviations, proportions - Maximum likelihood estimation, least square estimation and bayesian estimation. UNIT III TESTING OF HYPOTHESIS: Probability density function and applications of t, F, Chi square distributions - Large sample tests for means, variances, and proportions - Small sample tests for means, variances, and attributes.

Non-parametric test run test, sign test, U-test, H-test and kolmogorov-Smirnov (k-s) test spearman rank correlation coefficient test. UNIT IV Experimental designs completely randomised blocks Latin square Analysis of variance Methods for one, two factor models, concepts of factorial design, fractional factorial design, response surface methods and central composite designs. References: 1. Irwin Miller & John Freund. E, Probability and Statistics for Engineers, , PHI, 1987. 2. Montgomery D.C & Runger G.C., Applied Statistics and Probability for Engineers, John Wiley and Sons, USA, 1994. 3. Johnson R.A., Probability and Statistics for Engineers, Prentice Hall of India, 2003, 6th Edition. MAMGL 102: MECHANICS OF METAL CUTTING UNIT I Mechanics of Metal Cutting Introduction-Terms and Definitions-Chip formation-Types of chip-Forces acting on the cutting tool and their measurement-Specific Cutting Energy-Apparent mean shear strength of the work material-Chip thickness-Theory of Ernst and Merchant-Theory of Lee and Shaffer-Experimental Evidence of above theories-Friction in metal cutting Temperatures in Metal Cutting Heat generation in metal cutting-Heat transfer in a moving material-Temperature distribution in metal cutting-Temperatures in the Primary Deformation ZoneTemperatures in the Secondary Deformation Zone-Effect of cutting speed on temperatures-Measurement of cutting temperatures UNIT II Tool Life and Tool Wear Progressive tool wear-Crater Wear-Flank Wear-Tool Life Criteria-Effect of Built up Edge and tool angles on tool wear-Effect of Speed and Feed on cratering and Built up edge formation-Tool materials-Tool Wear and Machinability Testing-Factors affecting the machinability of metals Cutting Fluids and Surface Roughness Cutting fluids-Action of coolants-Boundary Lubrication-Lubrication in metal cuttingCharacteristics of an efficient lubricant in Metal Cutting-Surface Roughness-Ideal Surface Roughness-Natural Surface Roughness UNIT III Economics of Metal Cutting Operations

Introduction-Choice of feed-Choice of cutting speed-Tool life for minimum cost and minimum production time-Estimation of factors needed to determine optimum conditions Machining at maximum efficiency Nomenclature of Cutting Tools Introduction-Systems of cutting tool nomenclature-British Maximum Rake SystemAmerican Standards Association System-German System-New International StandardSetting System UNIT IV Machine Tool Vibrations Introduction-Forced vibrations-Self induced vibrations-Dynamics of metal cutting-Effect of undeformed chip thickness variations-Effect of Rake and Clearance angle variationsStability of the Cutting operation-Regenerative Chatter. Design for Machining Introduction-Standardization-Choice of work material-Shape of work material-Shape of component-Assembly of components-Accuracy and surface finish. References: 1. Boothroyd.G And Knight.W.A Fundamentals of Machining and Machine tools, Marcel Decker, New York, 1989 2. Shaw.M.C., Metal cutting Principles, Oxford clarendon Press,1984. 3. Bhattacharya, Metal cutting Theory and Practice, New central Book Agency(p) Ltd., Calcutta, 1984 4. V.Arshinov, G.Alekseev, Metal Cutting Theory and Cutting Tool Design, Mir publishers, Moscow,1976 5. Kuppusamy.G., Principles of metal cutting, Universities Press(India)Ltd., 1996 MAMGL103: METAL FORMING TECHNOLOGY UNIT I Theory of Plastic Flow of Metals Flow curve - Yield criteria - Principle of Normality - Flow rule - yield surface - Introduction to Slip line field theory - Introductory treatment of upper bound and lower bound analysis - plasticity of powder materials. UNIT II Forming of Metals I Different forming processes - slab method of analysis of metal working - flow stress determination - strain rate - friction - formability, forming limit diagram; Forging types - analysis of open and closed - die forging - defects - powder forging ; Rolling Classification - analysis - hot and cold rolling force analysis in Rollers- defects. UNIT II

Forming of Metals II Extrusion - analysis - hydrostatic extrusion - tube extrusion, computer aided extrusion defects.; Sheet metal forming - different processes - analysis of forces in sheet metal forming- forming limit - defects.; Drawing - analysis of wire and tube drawing - defects.; Metal spinning and analysis. UNIT IV Advanced Forming Techniques High Energy rate forming-High velocity forming-dynapac- explosive forming - electro magnetic - electrohydraulic forming - powder forming techniques - metal injection moulding, super plastic forming and applications. References: George E. Dieter, Mechanical Metallurgy, Mc Graw Hill Book Company, 1988. Metal Hand Book - Volume 5 - Forging and Casting - A. S. M. - 1970. Avitzur B.,Hand Book of Metal Forging Processes , John Wiley & Sons, NY, 1983. Hosford W. F. and Caddell R. M, Metal Forming : Mechanics and Metallurgy , Prentice Hall Inc., N. J., 1983. 5. Dr. R. Narayanasamy and Dr. R. Ponnalagusamy, Theory of Engineering Plasticity, Ahuja Book Company Pvt. Ltd., 2000. 1. 2. 3. 4.

MAMGL104: AUTOMATION & COMPUTER INTEGRATED MANUFACTURING UNIT-I Introduction to automation: Basic elements of an automated system, automation functions, levels of automation, process versus discrete manufacturing industries, continuous versus discrete control, computer process control, forms of computer process control Controlsystemcomponents- sensor, actuators, analog-to-digital and digital-to-analog conversion, Input/output devices UNIT-II Automated Manufacturing Systems: Components, Classification and Overview of Manufacturing Systems, GT and Cellular Manufacturing Part Families, Parts Classification and Coding, Production Flow Analysis, Cellular Manufacturing, Application Consideration in GT Flexible manufacturing systems Introduction, Elements of FMS, Classification and Types of FMS, FMS work stations, Lay out configurations, Petrinets , modeling with Pertinets. FMS FMS Components-workstations, material handling and storage systems, computer control system. FMS Application and Benefits FMS Planning and Implementation issues.

UNIT-III Computer integrated Manufacturing systems Introduction, Modern manufacturing, Sequence of functions in CIM, Elements of CIM system,CIM data base management system, CIM related standards, , Guide lines for CIM development Benefits of CIM. UNIT-IV Input/output system and Programmable logic controllers: Interfacing, I/O ports, Interface requirements, peripheral interface adapters, communication interfaces. Programmable logic controller- basic structure/o processing, programming-ladder logic, mnemonics, Timers internal relays and counters, shift register, master and jump controls,data handling,analogue input/output, selection of PLC.

REFERENCES: 1. Computer control of manufacturing systems - Yorem Koren, Tata McGraw-Hill edition, 2005 2. Automation Production Systems and CIM - Mikell P Groover,Pearson Education, Asia 2006 3. Principles and Applications of PLC - Webb John, Mcmillan 2004 4. Mechatronics-W.Bolton, Pearson education asia second edition 2001

MAMGL105: LOGISTICS & SUPPLY CHAIN MANAGEMENT

Unit I: Introduction Importance Of Supply Chain Management In Business Operations - Logistics As A Strategic Tools For Business Planning - Logistical Competency Logistical Mission Logistical Renaissance Development Profile -Work Of Logistics Integrated Logistics Operating Objectives Barriers To Internal Integration Performance cycles Unit II: Customer Focus Customer Service - Customer Focused Marketing - Basic Service Capability Increasing Customer Expectations Value Based Services Customer Satisfaction and Success Integration Logistical Performance Cycles Managing Operational Uncertainty.

Unit III: Channels Channel Structure Economics Of Distribution Channel Relationship Logistical Service Alliances Marketing Channel Structure. Unit IV: Global Logistics Logistics In A Global Economy Views Of Global Logistics Global Operating Levels Interlinked Global Economy - Global Supply Chain Issues Related To Foreign Trade Regulatory Aspects Of Foreign Trade.

References: 1. Donald J Bowersox, David J Closs Logistical Management The Integrated Supply Chain Process The Mcgraw Hill Companies, Inc, 1996 Edition. 2. Philip Kotler Marketing Management Analysis, Planning, Implementation And Control, PHI , Ninth Edition 1998 3. Sahay.B.S, Supply Chain Management Macmillan, New Delhi. 1999

MAMGL107: CAD CAM CIM LAB Geometric modeling using MDT & CATIA V5 Creation of solid modeling from Orthographic two-dimensional outlines and primitives. Modifying an existing model Creation of two dimensional drawings from 3dimensional models Creation of surface modeling Analysis (Using FEA package) Simple stress and strain analysis of structural members Object modeling and meshing using 2 D elements. Object modeling and meshing using 3 D elements

Kinematic analysis of simple mechanism Programming using G-code and M-code 1. 2. 3. 4. 5. Turning and facing operations Radius and taper turning operations Thread cutting and grooving operations Turning, thread cutting and grooving using canned cycles. Milling Operations

Exercises on 3D CAM software 1. Turning operations 2. Drilling, threading and boring operations. 3. Milling operations 4. Wirecut EDM operations Exercises on Robo Programming, PLC based automation systems, work cell software simulation.

MAMGL201: TOTAL QUALITY MANAGEMENT UNIT: 1 Quality Concepts :Introduction - quality function, quality costs, quality in production, design & marketing, quality system, quality control and quality assurance. System audit objective of system audit, types of quality audit, product Vs system audit, internal quality audit & management review - Causes of variations chance and assignable Quality circle functions, structure and Implementation.

Tools and techniques - Taguchi & Poka-Yoke technique, Kaizen, PDCA cycle, Flow diagram, 5 S compaign, 7 QC tools, 7 Management tools and FMEA. UNIT: 2 Control Charts: Theory of control chart, control chart for variables - Control charts for mean and range mean and standard deviation. Control chart for attributes - Control charts for fractions non-conforming (p-charts), number of non-conforming items (npchart), number of non-conformities (c-charts), and number of non-conformities per unit (u-chart), Process capability analysis - Problems using SQC tables. UNIT: 3 Sampling Techniques: Acceptance sampling fundamental concepts and terms, Operating characteristic curves (OC Curves), AQL, LTPD, AOQL - Sampling plan single, double, multiple & Sequential sampling plan. Dodge Rooming sampling plans, lot by lot acceptance sampling by attributes, AQL system for Lot by Lot sampling, Acceptance sampling by variables. UNIT: 4 TQM: Introduction, principles, Essentials of TQM, Organizing for TQM Organizing for quality implementation, TQM organization structure, employee involvement JIT: JIT Production system, KANBAN, JIT techniques such as waste & its implementation. Total productive maintenance (TPM), push versus pull systems. ISO clauses, Importance References: 1. John.S.Oakland "Total Quality Management", Text with Cases 3/e ButterworthHeineman An Imprint of Elsevier Publications 2008 2. Statistical Quality Control by L. Grant Tata Mc Graw Hill 2008 3. Jerry Banks, Principles of Quality control, John Wiley & Sons.2007 4. John.S.Oakland, Total Quality Management ELSEVIER Publications,. 2009 5. K. C. Jain & A. K. Chitale, Quality Assurance & TQM", Khanna Publishers, 2005 6. S. M. Sundare Raju, "Total Quality Management", Tata McGraw Hill Publishing Co. Pvt. Ltd., 2007 MAMGL202: OPTIMIZATION TECHNIQUES UNIT I Dynamic Programming Basic Concepts - Multi Stage decision problems, formulation of dynamic programming model - Bell man's Principle of Optimality recursion equation approach, Forward and backward computations, continuous and discrete type problem.

UNIT II Non - Linear Programming Unconstrained Non-Linear Programming: - Direct Search Methods Random Search Methods- Random Walk Method, Random Jumbing Method- Powell Methods- Simplex Method, Reflection, Expansion and Contraction. Indirect Search Method- Steepest descent method- Newton's Method- Conjugate gradient method.

UNIT III Scheduling Production scheduling: Single machine scheduling Flow shop scheduling Johnsons Algorithm for n jobs and two machines n jobs and three machines Two jobs through m machines. Branch and bound method for n jobs and m machines Flow shop scheduling job shop scheduling Applications. Simulation Random Number Generation Monte Carlo Simulation Advantages and Limitations of Simulation Simulation Applications.

UNIT IV Non - Traditional Optimization Techniques Genetic algorithm - Reproduction - crossover - Mutation - Fitness Function - Simulated Annealing - Objective Function - Numerical illustration - Termination Criteria - Parameter setting criteria- Introduction to Particle Swarm Optimization and Ant Colony Algorithm.

References Books 1. 2. 3. 4. S. S. Rao , Optimization Theory and Application, Willey Eastern Ltd. , New Delhi,2000.. Hamady A. Taha, Operations Research, Printice Hall of India Private Limited, 1998 R. Panneer Selvam, Operations Research, Printice Hall of India Private Limited, 1999 Kalyanmoy Deb, Optimization for Engineering Design Algorithms and Examples, Prentice Hall of India Pvt Ltd, New Delhi, 2000 5. Gold Berg D.E., Genetic Algorithms in Search, optimization and Machine Learning, Addison and Wesley, New Delhi, 1999 MAMGL 203: PRECISION MANUFACTURING UNIT I Non-Traditional Machining Processes Operating principles, equipment, process parameter & limitations of

Mechanical Processes: Ultrasonic machining, AJM & Water jet machining - Electrical processes: ECM & ECG - Thermal Processes: IBM, LBM, EDM, EDWC & Plasma arc machining - Chemical Processes: Chemical milling, Chemical blanking & Chemical engraving. UNIT II Lithography Photolithography, Extreme UV lithography, Electron lithography, Ion lithography. Steps in IC fabrication. UNIT III Rapid Prototyping Fundamentals of RP technology-Classification-liquid based-solid based-powder based. Steps, Materials, Application and limitations. UNIT IV MEMS & Nanotechnology MEMS: Introduction, Technique in MEMS, Actuator and Sensors, Microsystem Technology & Applications. Nanotechnology: Introduction, Molecular Engineering, Top down and Bottom up approach, Nano-fabrication technologies and applications. References: 1. Wellar, J. and Mathew Haavisto, Non traditional Machining Process, SME Michigan, 1984. 2. Marc J. Madou, Fundamentals of Microfabrication Science of Miniaturization, 1999 3. Mikell P. Groover, Fundamentals of Modern Manufacturing Materials, Processes & Systems. Willey Text Books, 2001 4. Kalpakjian, Manufacturing Engineering & Technology, New Age International, 2002. beam lithography, X-ray

MAMGL204: LEAN MANUFACTURING SYSTEMS UNIT I

INTRODUCTION TO LEAN MANUFACTURING: Objectives of lean manufacturing-key principles and implications of lean manufacturing- traditional Vs lean manufacturing. LEAN MANUFACTURING CONCEPTS: Value creation and waste elimination- main kinds of waste- pull production-different models of pull production-continuous flow-continuous improvement / Kaizen- Worker involvement - cellular layout- administrative lean. UNIT II LEAN MANUFACTURING TOOLS & METHODOLOGIES: Standard work -communication of standard work to employees -standard work and flexibility -visual controls-quality at the source- 5S principles -preventative maintenance-total quality management-total productive maintenance -changeover/setup time -batch size reduction -production leveling. VALUE STREAM MAPPING: The as-is diagram-the future state map-application to the factory simulation scenario-line balancing -poke yoka-Kanban overall equipment effectiveness. UNIT III MANUFACTURING STRATEGY AND SUPPLY CHAIN: Forecasting systems Dimensions of manufacturing strategy Supply chain management concepts Aggregate planning Single stage inventory control DECENTRALIZED PULL SYSTEMS: Kanban systems Constant work in process pull alternative MULTI STAGE PRODUCTION SYSTEMS: Materials requirement planning Capacity planning Managing change UNIT IV COST CONCEPTS: Cost structure labour, material, overhead cost nature of overhead cost overhead absorption methods direct labour, direct material, number of pieces, labour hour rate, machine hour rate methods cost control labour, material, overhead variance analysis. ACTIVITY BASED COSTING: Concept objectives comparison with conventional costing activity cost drivers resource mapping resource driver activity cost shifting costs to activities designing the optimal ABC system. ACTIVITY BASED MANAGEMENT: Concept value added analysis tree value added activity , strategic activity, support activity value added analysis in manufacturing. TARGET COSTING AND TOTAL COST MANAGEMENT: Concept different approaches price based, cost based, value based target costing- strategies for achieving target cost value analysis, vendor development, outsourcing, core competence. References: 1. Askin R G and Goldberg J B, Design and Analysis of Lean Production Systems, John Wiley and Sons Inc., 2003. 2. Michael L George, David T Rowlands, Bill Kastle, What is Lean Six Sigma, McGraw-Hill, New York, 2004. 3 Ronald G Askin, Design and Analysis of Lean Production system, John Wiley & Sons, 2002

4 Bedworth D D, "Integrated Production Control Systems Management, Analysis, Design", John Wiley and Sons, 5 Blocher chen and Lin, Cost Management ? A Strategic Emphasis, McGraw Hill Irwin, 2002. 6 Micheal Breamer, Brain Mckibben, Thomas Mccarting, Six Sigma Financial Tracking and Reporting McGraw Hill, 2006. MAMGL207: MECHATRONICS & AUTOMATION LAB 1. Design a simple pneumatic circuit to open and close the bus door. operated valve to open a main gate of a factory. 3. Design a pneumatic circuit using a double acting cylinder to draw a liquid metal from a smelting crucible by a casting ladle and cast in moulds. The raising and lowering of the ladle should be controlled by push buttons. 4. Using OR gate design a pneumatic circuit. 5. Using AND gate design a pneumatic circuit. 6. Design a pneumatic circuit using a time delay valve with AND and OR gate. 7. Design a pneumatic circuit using a double acting cylinder, roller operated valve, 3\2 push button and 5\2 single pilot valve to control the cylinder position. 8. Design a circuit controlling double acting cylinder using double pilot valve. The double pilot valve has to be controlled by only one push button. ElectroPneumatics 9. Washers for injection pump are to be cleaned in a cleaning bath. The double acting cylinder is used to dip washers in and out of the cleaning bath. W rite a program to count the 100 strokes of the cylinder and stop the cycle. 10. Using a electro pneumatic circuit, control the A.C. Non servo motor clockwise and anti-

2. Design a pneumatic circuit using a double acting cylinder and 5/2 Hand

clockwise with time delay. 11. Exercises on linear slideways and conveyors with sensors.

MAMGLE01:INDUSTRIAL ROBOTICS UNIT I Introduction to Robotics components of an Industrial Robot classification mechanics and control of manipulators. Spatial descriptions and Transformations - operations and mapping. UNIT II Manipulator kinematics Denevit-Hartenberg representation - direct and inverse kinematics - examples. Introduction to dynamics. UNIT III Jacbians in velocity and force domain. Singularity and static forces. Trajectory planning joint space and task space schemes - collision-free path planning. UNIT IV Robot programming concepts Lead through and textual programming LISP Speech/ voice programming. Robotic applications in manufacturing material handling processing assembly.

References: 1. John J. Creig, Introduction to Robotics, Mechanics and control, Pearson Education (Singapore) Pte. Ltd., 2002. 2. Fu, Gonzalez and Lee, Robotics: control, sensing, vision and intelligence, McGraw Hill International edition, 1987. 3. Mikel P. Groover, Mitchell Weiss, Roger N. Nagel and Nicholas G. Odrey, Industrial Robotics: Technology, Programming and applications, McGraw Hill International Edition, 1986.

MAMGL E02: UNIT I Introduction

MECHATRONIC SYSTEMS

Definition of Mechatronics, Mechatronics in Products - Measurement Systems - Control Systems - Traditional design and Mechatronics Design system and design Mechatronics approach integrated product design Modeling, Analysis and Simulation Man Machine interface. UNIT II Sensors and Transducers Introduction - Performance Terminology - Displacement, Position and Proximity Velocity and Motion Fluid pressure - Temperature sensors - Light sensors - Selection of sensors - Signal processing - Servo systems. UNIT III Drives and Actuators Hydraulic and pneumatic drives electrical actuators such as Servo Motor and Stepper Motor drive Circuits, Open loop & Closed loop control Peizo electrical and magneto strictive actuators materials, static and dynamic characteristics. Illustrative examples for positioning vibration isolation. UNIT IV Programmable Logic Controllers

Introduction - Basic structure Input / Output processing - Programming -Mnemonics Timers, Internal relays and counters - Data handling - Analog input / output - Selection of PLC. Case studies: Mechatronics design of a coin counter Robotic walking machine Car engine management

References: 1. Michael B.Histand and David g. Alciatore, Introduction to Mechatronics and Measurement Systems, McGraw-Hill International editions, 1999.

2. Bolton w, Mechatronics, Thomas press Ltd., 1999. 3. HMT limited, Mechatronics, McGraw-Hill publishing company Ltd., New Delhi, 2001

MAMGLE03: RELIABILITY &MAINTENANCE ENGINEERING UNIT I Reliability Analysis Reliability- Definition and its importance, Reliability functions, Bathtub curve, Failure &Causes of Failure, Hazard Models- Constant, linearly increasing and weibull Models, System Reliability-Series, Parallel and mixed configurations, Reliability improvement techniques- important concepts, redundancy, element redundancy, unit redundancy and standby redundancy

UNIT II Maintenance Systems and Economics of Reliability Maintainability and Availability concepts- MTTF, MTTR, MTBF and MDT, Maintainability and Availability functions and their mathematical expressions, Economics of ReliabilityEconomic issue, Manufacturers cost, Customers cost, reliability achievement and utility cost models, depreciation cost models, availability cost model for parallel systems UNIT III Maintenance and Spares Management Maintenance and Spares Management- preventive replacement-individual breakdown replacement policy- individual preventive replacement policy- preventive

group replacement- preventive versus breakdown maintenance- Queuing theory applications in maintenance planning Control of spare parts-regular spares-insurance spares-capital spares- - maintenance policy

UNIT IV Condition Monitoring and Analysis Condition based maintenance- advantages and disadvantages-vibration monitoringvibration parameters- vibration measurements- vibration instruments-data representation- data interpretation-signature analysis- contaminant analysisspectrometric oil analysis procedure- ferrography- magnetic chip detectors- computer aided maintenanc REFERENCES: 1.Srinath.L.S., Reliabilty Engineering, Affliated East West Press Pvt.Ltd., 1991 2.Collact, Mechanical Fault Diagnosis & Condition Monitoring,1977 3.Balagurusamy E., Reliabilty Engineering, Tata Mcgraw Hill Publishing Company, New 4.V.N.A. Naikan, Reliabilty Engineering & Life Testing,PHI Learning Pvt. Ltd. 2009

MAMGL04: DESIGN FOR MANUFACTURING

UNIT I

DESIGN PROCESS

Methodologies and tools, design for assembly and evaluation, minimum part assessment, Taguchi method, robustness assessment, manufacturing process rules, failure mode analysis, Value Analysis. Design for minimum number of parts, development of modular design, minimizing part variations, design of parts to be multifunctional, multi-use, ease of fabrication, Poka Yoka principles.

UNIT II MATERIAL SELECTION Factors determining choice of materials, performance characteristics of materials, material selection process. Evaluation methods for material selection. Principal materials used in manufacturing.

UNIT III DESIGN FOR FABRICATION Design for machining. Design for castings. Design for forgings. Design for sheet metal forming. Design for welding. Design for powder metallurgy. Design for assembly.

UNIT IV

GEOMETRIC ANALYSIS

Process capability, feature tolerance, geometric tolerance, surface finish, review of relationship between attainable tolerance grades and difference in machining processes. Analysis of tappers, screw threads, applying probability of tolerances. Geometric analysis and applications.

References: 1. Harry Peck, Designing for Manufacture, Pitman Publications, 1983 2. Sports M.F., Dimensioning and Tolerance for Quantity Production, Prentice Hall Inc. 1983. 3. Oliver R. Wade, Tolerance Control in Design and Manufacturing , Industrial Press Inc. New York Publications, 1967. 4. Engineering Design,Georage .E.Dieter, McGraw Hill 1st edition,1987

MAMGL E05: FLEXIBLE MANUFACTURING SYSTEMS UNIT I Introduction to FMS FMS concepts components of FMS, Economic justification, FMS project management planning, scheduling & control. DNC DNC system, communication between DNC computer and machine control unit, Features of DNC system. UNIT II Database of FMS Introduction to DBMS Distributed system in FMS computer network architectures in FMS, Computer networks protocol & distributed database management system. Distributed tool database & part programming style in FMS.

UNIT III Group Technology Part families Classification and coding production flow analysis machine cell design benefits. UNIT IV Material Handling Systems Automatic storage and retrieval system AGV Fixed path and free range vehicle application of AGV Systems Industrial Robotics Programming Cell Design Material Handling and Assembly application - Robots and machine interface and work cell controller. References: 1. Paul Ranky, The Design and Operation of FMS, IFS Publication, 1983. 2. David J. Parish, Flexible Manufacturing, Butterworth, 1990. 3. Mikell P. Groover, Automation, Production system & Computer Integrated Manufacturing, Prentice Hall, 1987. 4. Roser Bonetto, FMS in practice, North Oxford academic council, 1988.

MAMGLE06: NON-DESTRUCTIVE TESTING UNIT I Surface Non-destructive Testing Visual Inspection: Basic of visual aids Borescopes- Fiber optic borescopes Rigid borescopes Construction Machine vision technology Image sensors Liquid Penetrant Testing: Principles Types of Penetrants & /developers Penetrant testing processes Magnetic Particle Testing: Principles electrically induced magnetism Magnetic particle testing systems Demagnetization procedure UNIT II Ultrasonic Testing Principle Typical transducer characteristics Types of ultrasonic wave propagation types of transducers Construction of probes Ultrasonic testing of methods

Inspection procedures Ultrasonic system display Selection and use of coupling media UNIT III Radiographic Testing Principle X-ray and Gamma ray generation X-ray tube construction Geometric principle in radiography Absorption and scattering Radiographic screen Penetrameter Gamma ray source Handling equipment Film handling and storage

UNIT IV Modern NDT Techniques Eddy current testing Principle - application Acoustic emission testing Principle application Leak testing Pressure test and types Halogen detectors Helium leak testing Thermography Principle Detectors Equipment Techniques - Applications References: 1. ASM- Hand Book , Vollume XVII, 2000 2. ASNDT, Non-Destructive Testing Handbook, Section X, 2000

MAMGLE07: TOLERANCE TECHNOLOGY UNIT I Geometric Dimensioning and Tolerancing Limits, Fits Tolerance IT grades, Hole basis system Shaft basis system, Basic terms and concepts of GD and tolerancing, Modifiers and symbols

UNIT II Surface Texture, Form Tolerance Single Features Surface texture Definition Symbols for indicating surface texture, Interpretation, Inspection and application of flatness control, Straightness, circularity, cylindricity, profile of line and surface UNIT III Form, Orientation and Position Tolerance of Related Features Introduction to datum system and datum target Interpretation, Inspection and application of parallism, perpendicularity, angularity circular total run out, concentricity and symmetry control UNIT IV Tolerance Stack Tolerance stack - Virtual condition concepts Definition part stack and assembly using coordinate Dimensioning and geometry dimensioning and tolerancing

Reference Books 1. ASME Study manual on Tolerance stacks Volume I second edition 1994 2. ASME Self study work book on GD & T second edition 1994 3. Spotts, Dimensioning and tolerancing of mass production Prentice Hall Inc. New Jercy, 1983 4. Harry S Peck, Design for manufacture CH.III Pitman, 1973

MAMGLE08: COMPUTER AIDED METROLOGY AND INSPECTION UNIT I Laser Metrology

LASER interferometer LASER alignment telescope LASER micrometer on-line and inprocess measurements of diameter and surface roughness using LASER Micro holes and surface topography measurements Straightness and flatness measurement. UNIT II Co-Ordinate Measuring Machines Evolution of measurement coordinate measuring machines Non Cartesian CMMS Accessory elements Application software Performance evaluations Temperature fundamentals Environmental Control Accuracy enhancement Applications Measurement integration. UNIT III Opto-Electronic Measuring Systems Opto electronic devices contact and non-contact types Applications in on-line and in-process monitoring systems Tool wear measurement Manufacturing metrology 3D surface roughness. UNIT IV Image Processing and its Application in Metrology Shape identification Edge detection techniques Normalization Grey scale correlation Template techniques Surface roughness using vision system Interfacing robot and image processing system Measurement of length and diameters.

Reference Books 1.Watson.J., Optoelectronic, Van Nostrand Reinhold (UK) Co Ltd., 1988. 2.Robert.G. Seippel, Optoelectronic for technology and Engineering, Prentice Hall New Jersey, 1989. 3.Ulrich-Rembold, Armbruster and Ulzmann, Interface technology for computer controlled manufacturing processes, Marcel Dekker, Pub New York, 1993. 4.International Journals on CIRP. 5.Thomas G.G. Engineering Metrology, Butterworh Pub. 1974.

MAMGLE09: SYSTEM SIMULATION

UNIT I Introduction Basics concepts of systems, General systems, Elements of systems, theory, concept of simulation simulation as a decision-making tool types of simulation system modeling and types of modeling desk and bench mark simulation. UNIT II Random Number Probability and statistical concepts of simulation pseudo random numbers Methods of generating random variables discrete and continuous distribution testing of random numbers sampling - simple random and simulated. UNIT III Design of Simulation Experiments Problem formulation data collection and reduction time flow mechanism key variables logic flowchart starting condition run size experimental design consideration output analysis and interpretation, Validation application of simulation in industries, engineering and scientific organizations. UNIT IV Simulation Language Development of simulation models using the simulation language studied for systems like: Queuing systems production systems inventory systems - maintenance and replacement systems investment analysis and network. References: 1. 2. 3. 4. Jerry Banks And John S Carson, Discrete event system simulation, Prentice Hall, 1984. R.E.Shannon, Systems simulation the art and science, Prentice Hall, 1975. Jeo H Mize and J Grady Cox, Essentials of simulation, Prentice Hall, 1968. Jeffrey L Whitten, Lonnie D Bentley & Victor M Brace, System analysis and design methods, Calgotia Publications pvt ltd., 1991. 5. Thomas J Schriber, Simulation using GPSS, John Wiley 1974.

MAMGLE10: CNC AND ADAPTIVE CONTROL

UNIT I Introduction to CNC Machine Fundamentals of NC Classification of CNC system Design consideration for CNC machine tool methods for improving machine accuracy MCU Function CNC controllers Interpolators UNIT II System Drives and Control Drives: Hydraulics systems DC motors AC motors Stepping motors Servomotors Transmission systems recirculating ball screw, LM guideways, air bearings. Feed back devices: Encoders Resolvers Inductosyn tachometer & laser inferometer UNIT III CNC Part Programming NC words-Manual Programming, Computer Aided Part Programming, APT Part programming, Parametric programming and post processors. Programming for Fanuc and Sinumeric control system. UNIT IV Adaptive Control System Introduction, Adaptive control with Optimization, Adaptive control with constrains, Adaptive control for turning, milling and grinding process & practical problems with adaptive control. References: 1. Yoram Koren, Numerical Control of Machine Tools, Khanna Pub., New Delhi, 1988. 2. Radhakrishnan, P., Computer Numerical Control Machines, New Central Book Agency, Calcutta, 1992. 3. Kundra, T. K., Rao, P.N. & Diwari., Numerical Control and Computer aided manufacturing, Tata McGraw Hill, New Delhi, 1985.

MAMGLE11: COMPUTER AIDED PROCESS PLANNING UNIT I Introduction The Place of Process Planning in the Manufacturing cycle - Process Planning and Production Planning Process Planning and Concurrent Engineering, CAPP, Group Technology. UNIT II Part Design Representation Design Drafting - Dimensioning - Conventional tolerance - Geometric tolerance CAD topology - Geometric transformation - Perspective transformation - Data structure Geometric modeling for process planning - GT coding - The optiz system - The MICLASS system. UNIT III Process Engineering and CAPP Process planning: Experienced, based planning - Decision table and decision trees Process capability analysis - Process Planning - Variant process planning - Generative approach - Forward and Backward planning, Input format, Al. CAPP: Logical Design of a Process Planning - Implementation considerations manufacturing system components, Production Volume, No. of production families UNIT IV Integrated Process Planning Systems Totally integrated process planning systems - An Overview - Modulus structure - Data Structure, operation - Report Generation, Expert process planning. References: 1. Gideon Halevi and Roland D. Weill, Principles of Process Planning A logical approach, Chapman & Hall, 1995. 2. Tien-Chien Chang, Richard A.Wysk, An Introduction to automated process planning systems, Prentice Hall, 1985. 3. Chang, T.C., An Expert Process Planning System, Prentice Hall, 1985. 4. Nanua Singh, Systems Approach to Computer Integrated Design and Manufacturing, John Wiley & Sons, 1996.

6. Rao, Computer Aided Manufacturing , Tata McGraw Hill Publishing Co., 2000. MAMGLE12: INDUSTRIAL SAFETY ENGINEERING UNIT I Accident Prevention Accident: Injury-unsafe act-unsafe condition-Dangerous occurrence-Reportable accidents & Need for Safety. Safety education and training: Importance-various training methods-development of various training programs-Safety publicity by various means. Communication: Purpose-barrier to effective communication-Guidelines for good communication. Involvement in Safety: Role of management-supervisors-workersunions-Government and voluntary agencies. UNIT II Safety in use of machine Safe use of various types of hand tools for metal cutting. Cold forming of metals: Safety in use of power presses-Hand and foot operation presses-Hydraulic Presses-shearing press and rolling mills-safety in wire drawing operation. Hot forming of metals: Safety in foundry-forging-hot pressing and hot rolling operation. Other Operations: Safety in welding and cutting-Safety in soldering, brazing and grinding operation-Safety in electro-plating and heat treatment operation-painting. UNIT III Fire Safety Fire Triangle-various classes of fire stages in fire-Basics modes of fire-fire prevention-fire extinguisher-portable, water, foam, DCP & CO2. Fixed fire fighting systems-sprinklerhydrant-CO2-foam.

UNIT IV Personnel Safety Principles of ergonomics-human behaviors-motivation. Personnel protection equipmenthead protection-eye protection-ear protection-Naval protection-Face protection-Hand protection-Leg and foot protection References: 1. Heinrich, H.W, Industrial accident Prevention, Mcgraw Hill Company, Newyork, 1980. 2. John Ridhey, Safety at work, Bullerworth and company Ltd, London, 1983. 3. Accident Prevention Manual for Industrial Operation, NSC, 1982.

4. Gupta, R.S., Handbook of Fire Technology, Orient Longman, Bombay, 1997.

MAMGLE13: UNIT I Introduction

ENTERPRISE RESOURCE PLANNING

Evolution of ERP types of Engg. Enterprises and supply structures study of MRP & MRP II systems deficiency of MRP systems need for integration of MRP with other business systems ERP products and markets UNIT II ERP Packages Market leaders in ERP packages SAP BAAN ORACLE People SOFT, J.D Edwards modules in ERP work force management materials management inter- site logistics operation demand and capacity planning modules system. UNIT III Systems Approach to Supply Chain Management. Development of supply chain modules use of forecasting inputs in chain models systems approach to integrating supply chain manufacturing- management with financial systems identifying opportunities for ERP implementation. UNIT IV Re-Engineering & ERP Implementation Periods Identifying ERP benefits team formation consultant intervention selection of ERP process of ERP implementation managing change in it organization preparing its infrastructure need for re-engineering before ERP implementation- measuring benefits of ERP. References: 1. 2. 3. 4. Michael Hammer & James Chamby, Reengineering The Corporation,1997 Sahay, Enterprise Resource Planning , Macmillan, New Delhi, 1999 Crant Norris,E-Business & ERP : Transforming The Enterprise,2000 Robert B Manelfield, Ernest, L Jr Nicholas, Introduction To Supply Chain Management, 1999

MAMGLE14: ACCOUNTING CONCEPTS AND FINANCIAL MANAGEMENT Unit I Introduction to Accounting & financial management: Introduction to book keeping, Dual entry process, Special and adjusting entries, Trial Balance, Preparation of Balance Sheet & Income Statement, Need for financial management Responsibilities of financial manager - Organization ownership Goals of an organization Shareholder wealth Analysis of financial statements Ratio analysis, common size analysis, percentage change analysis, financial environment Markets, Institutions, Interest rates and Tax system, published accounts. Risk and Returns: Stand-alone risk and portfolio risk Risk-return theory Capital Asset Pricing Model Unit II Time value of money: Present and Future value Present Value of different types of cash streams - Discounted cash flow analysis - Project Cash Flow Analysis - Identifying relevant cash flow items, constructing cash flows, special cases of cash flow analysis Cost of Capital: Components of Capital Debt, Preferred Stock, Common stock Cost of debt, common stock and preferred stock Different Approaches Weighted Average Cost of Capital (WACC), activity based costing. Capital Budgeting: Project ideas and cash flow estimation Project selection NPV, IRR, MIRR, PI methods Comparisons Optimum capital budget Capital rationing, budgetary controls and techniques. Unit III Financing Decisions & Planning: Introduction to business finance, Strategic Planning Forecasting financial statements Capital Structure Significance of capital structure, Optimum Capital Structure. Short-term financing : Introduction to working capital Current Asset Management Inventory Management, Receivables Management, Cash Management Sources of short-term capital Commercial papers, bank loans, payables

Unit IV Management Accounting: Types of costs, cost-volume relationship, Importance of budgeting, Variance analysis. Financial model for a business, impact on business and operational activities, interpreting financial ratios to internal and external accounting, planning and evaluation of capital and revenue expenditure. References: Fundamentals of Corporate Finance Ross, Westerfield & Jordan, Tata McGraw Hill.

MAMGLE15: OPERATION STRATEGY FOR INDUSTRIES Unit I Introduction to operations strategy and its importance in an industrial business, strategic management, business environment, strategy design. Operations strategy, formulation, case studies, strategy design, analysis of strategy, implementation, impact of operations strategy at different levels of organization. Unit II Strategic decisions in operations, products and innovation, quality management, process planning, capacity management, supply chain. Outsourcing strategy. Integration of operations strategy with companys, strategies, business strategy, measuring the performance of operations strategies, areas of measurements, implementation of operations strategy, issues. Unit III Operations strategy decisions, tools, implementation of operations strategy, practices, tools and techniques, case studies-application of tools learnt. Examples of strategy formulations. Unit IV World class manufacturing, evolution of manufacturing and the journey to World Class, international manufacturing operations, global sourcing, global manufacturing, global distribution, case studies. References: a. Operations Strategy, Donald waters, Thomson Learning Co., U.K. b. Operations Strategy, Nigel Slack & Michael Lewis, Prentice Hall. 2002. c. Operations Management, Lee J.Krajewaki & Larry P.Ritzman, Adisson Wesley, 1990. d. Operations, Strategy & technology, Robert H. Hayes, Gary P. Pisano, David M. Upton, Steven C. Wheelwright, Wiley, 2004.

e. Manufacturing and operations strategy, Danny Samson, Prentice Hall, 1991

MAMGLE16: INDUSTRIAL ENGINEERING AND COSTING

UNIT 1 Industrial Engineering - Definition, Contributions, Techniques, Function of Industrial Engineer. Work study-Introduction, Importance, Concept of Work content, Method studydefinition, objectives, procedure, tools and techniques- motion economy principles, work measurement-purpose-use-procedure-tools and techniques- standard time. UNIT 2 Plant location, Plant layout-definition, objectives, principles, factors influencing layout, types of layout-tools and techniques. Materials handling-principles -types and selection of materials handling equipments- Value analysis and engineering-techniques.

UNIT 3 Job evaluation- Objectives-Procedure-Methods-Ranking method, Classification method, Factor comparison method, Point method. Merit Rating- Objectives- Methods- Wage Payment Plans- Introduction- Types of Wage Incentive Plans- Group incentive Plans UNIT 4 Raw Material Cost - Labour Cost Energy and consumables cost - Expenses - Cost of Product (Ladder of cost) - Analysis of overhead expenses - Factory expenses-

Administrative expenses - Selling and Distributing expenses - Allocation of overhead expenses. Depreciation - Causes of depreciation - Methods of depreciation, Profit Loss account, Sources of finance, Contract costing -Activity based costing. References: 1. Martand Telsang- Industrial Engineering and Production Management, S.Chand &Company Ltd., 2002. 2.Charles T. Horngren, George Fostel and Srikant M.Datar Cost Accounting: A Managerial Emphasis, Prentice Hall, USA, 1997 3. Dr. R. Shanker, Industrial Engineering and Management, Galgotia Publications pvt. Ltd. 4. M. Mahajan, " Industrial engineering and Production Management ", Dhanpat Rai & sons.

MAMGLE17: HUMAN RESOURCE TECHNIQUES

UNIT I Introduction Perception, Process,Obstacles in accurate perception,Overcoming ObstaclesPersonality, Determinants, Personality Traits ,Dimensions Attitude, Formation, Change and Actions related case study UNIT II Interpersonal Behaviour Learning Process, Classical Conditioning, Operant conditioning, Reinforcement, Reinforcement Schedules, Extinction , Punishment Motivation, Process, Enhancing Employees motivation, Performance through reward system Goal setting Expectations related case study UNIT III Distinguishing Obedience, Power & Influence, Social influence,Conformity,Compliance &

Propaganda,Brain Washing (Thought Control) Decision Making, Personal Vs Organisational decisions, Programmed Vs Non Programmed decisions, Improvement Techniques, Ethics in Decision Making Creativity, Characteristics of creative individuals, Measuring Creativity, Methods of enhancing Creativity, Establishing a climate for Creativity Manging Conflict and its sources Causes of job related stress and coping with it. Periods UNIT IV Job Analysis,selection devices, Types and methods of training, Career Development. Purposes of Performance Evaluation(PE), PE&Motivation, Methods of PE, Suggestions for improving PE, Providing performance feedback. The Union, Management Interface, Negotiation, Nature, Characteristics of a negotiation or bargaining situation Interdependence, Mutual adjustment, Interdependence & Perceptions, Ethics References: 1. Stephen P.Robbins, Organisational Behaviour, 10th Edition, Prentice Hall of India,2004 2. M.Gangadhar Rao,V.S.P. Rao and P.S. Narayana, Organisational Behaviour, Konark Publishing Ltd., Reprint 2000 3. Jerald Greenberg & Robert A.Baron, Behaviour in Organisations, Pearson Education, Reprint 2004 4. Udai Pareek, Understanding Organisational Behaviour, Oxford University Press, 2004 MAMGLE18: CELLULAR MANUFACTURING SYSTEM Unit I Traditional manufacturing systems, limitations, group technology, design and characteristics of GT, benefits of GT, types of GT. Unit II Cellular manufacturing system, design strategies, CMS models, traditional and nontraditional approaches to design of CMS. Unit III Cell layout-inter and intra, implementation of GT and CMS, CMS models-cost and noncost based, team approach, batch sequencing and sizing. 15

Unit IV Performance analysis, parametric analysis of CMS, cell loading, materials resource planning, economic aspects of CMS.

References: 1. Irani, Hand Book of Cellular Manufacturing Systems, Wiley, 1999. 2.Askin R.G. and Vakharia A.J, G.T Planning and Operation in the Automated Factory, Hand Book, of Technology and Management, TAB Books, NY, 1991. 3.Burbridge J.L., Group Technology in Engineering Industry, Mechanical Engineering Pub., London. 4.Nallan C. Suresh and John M Kay, Group Technology and Cellular Manufacturing, Springer, 1998.

MAMGLE19: PROJECT MANAGEMENT Unit I Definition of project-identification, formulation, classification, objectives factors determining the project influencing the project. Project life cycle-selection-feasibility report techno-economic study and its appraisal detailed project report and forecast on returns. Unit II Cost of project funding methods-securing funds-cost benefit analysis-risk analysis-types of funds for projects-funding institutions-approach of funding institution to project, their requirements and methods of analysis of feasibility report and detailed project reports.

Unit III Execution of projects commencement of projects-scheduling of projects-use of PERT/CPM-their merits and limitations-placement of order for materials and the worksthe constraints-planning at macro and micro levels-monitoring-co-ordination and documenting the project execution-progress review-cost/time overrun. Unit IV Personnel and industrial relations to projects-intra and inter-personnel processorganisation behavior-job satisfaction-attitudes-motivation-morale-leadership-group dynamics-communication-welfare measures-social security. References: 1. Rao, Project management, S. Chand & Co., New Delhi, 2000. 2.Jack Gido, An Introduction to Project Planning, Industrial Press, 2002. 3.Prasanna Chandra, Project preparation appraisal, Budgetry and Implementation, Tata McGraw Hill, 2000. 4.Project management, Gary Heerkens, McGraw-Hill Professional, 2001