Semester 1 08O101 calculus and its applications 3 2 0 4 basic concepts
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Total 42TEXT BOOKS: 1. Michael Grieves, “Product Life Cycle Management”, Tata McGraw Hill, 2006. 2. David S Linthicum, “B2B Application Integration”, Addison Wesley, England, 2001. 3. Faisal Hogue, “E-Enterprise Business Models Architecture and Components”, Cambridge University Press, United Kingdom, 2000. REFERENCES: 1. Alexis Leon, “Enterprise Resource Planning”, Tata McGraw Hill, New Delhi, 2002. 2. Danier Amor, “The E-Business Revolution”, Pearson Education Asia, New Delhi, PHI, 2000. 3. John W Gosnay and Christine M Mears, “Business Intelligence with Cold Fusion”, Prentice Hall India, New Jersey, 2000. 4. David Ferry and Larry Whipple, “Building an Intelligent e-business”, Prima Publishing, California, EEE Edition, 2000. 5. Terry Quatrain, “Visual Modelling with Rational Rose and UML”, Addison – Westey, England, 1998. 6. David Bedworth, Mark Hederson and Phillip Wolfe, “Computer Integrated Design and Manufacturing” McGraw Hill Inc., New York, 1991. 7. Windchill R5.0 Reference manuals. 08P013 CLEANER PRODUCTION 3 0 0 3 INTRODUCTION: Industrialzation and its impact on environment. Concept of cleaner production, global warming and related issues. International standards : BHARAT stage II,III and EURO standards, ISO 14001. (6) ENVIRONMENTAL PARAMETERS: Basic terminology, units, measurement techniques, significance (BOD, COD, TSS, TDS, Color) waste and energy audit methodologies, application of mass and energy balance. (6) Major industrial processes considering energy and environmental points of view: Identification of major unit processes associated with energy consumption and pollution generation. (6) Effective resource ustilization: Design for recycling - life cycle studies. Process optimization by integrating both energy and environmental aspects, energy management concepts and measures to improve energy efficiency. (8) ESTABLISHING A CLEANER PRODUCTION CENTER: Formulation of concept plan for the center, creating its basic design, planning to meet the financial requirements, establishment of the center (8) CLEANER PRODUCTION ASSESSMENT: Planning and organization, Pre-assessment, Assessment, feasibility analysis, implementation, monitoring. Case studies. (8) Total 42TEXT BOOKS: 1. Narayanan P, “Environmental Pollution: Principles, Analysis and Control”, CBS Publishers & Distributors, 2007. 2. “How to Establish and Operate Cleaner Production Centres”, Guidance Manual, UNEP/ UNIDO, 2003. 3. Rossiter A P, “Waste Minimization through Process Design”, McGraw Hill, New York, 1995. REFERENCES: 1. Anthony Clayton, “Policies for Cleaner Technology: A New Agenda for Government ad Industry”, Earthscan Publications Ltd., 2006. 2. James P Womack, Daniel T Jones, “Lean Thinking: Banish Waste and Create Wealth in your Corporation”, Simon & Schuster, 2003. 3. Modak P, Visvanathan C and Parasnis M, "Cleaner Production Audit", Review No: 32, ENSIC, AIT, 1997. 4. Mahumoud M Elhalwagi, “Pollution Prevention through Process Integration: Systematic Design Tools”, Academic Press, 1997. 08P014 TOTAL QUALITY MANAGEMENT 3 0 0 3 INTRODUCTION: Definition of TQM - Basic approach-Gurus of TQM - TQM Framework – Awareness - Defining Quality - Historical review – Obstacles - Benefits of TQM. (5) LEADERSHIP: Definitions - Characteristics of Quality Leaders - Leadership Concepts - The 7 Habits of Highly Effective People – Ethics -The Deming Philosophy - Role of TQM leaders - Implementation - Quality Council - Core Values, Concepts and Framework - Quality Statements - Strategic planning - Communications. (6) CONTINUOUS PROCESS IMPROVEMENT: The Juran Trilogy - Improvement strategies - Types of Problems - The PDSA cycle - Problem - Solving method, TRIZ - problem solving process, Kaizen, Quality Circles. (5) PERFORMANCE MEASURES: Basic concepts- Strategy - Performance measure presentation - Quality costs - Malcolm Baldrige National Quality Award. (5) QUALITY MANAGEMENT SYSTEMS: Benefits of ISO 9001 registration - ISO 9000 series of standards – Sector - specific standards - ISO 9001 requirements - Implementation - Documentation - Writing the documents - Internal audits – Registration - Closing comments. (6) CONVENTIONAL TOOLS AND TECHNIQUES: Pareto diagram - Process flow diagram - Cause and effect diagram – Checksheets - Histogram - Benchmarking process - Pitfalls and criticisms of Benchmarking, experimental design, One factor at a time, Orthogonal design, Two factors. (5) MANAGEMENT TOOLS: Why–Why Analysis - Force Field Analysis - Nominal Group Technique - Affinity diagram - Interrelationship diagram - Tree diagram - Matrix diagram - Prioritization matrices - Process Decision program chart - Activity network diagram. (5) INFORMATION TECHNOLOGY: Computers and the quality function - The internet and other electronic communication - Information quality issues - Technologies of the future. (5) Total 42 TEXTBOOKS:
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08P015 SURFACE ENGINEERING AND TRIBOLOGY 3 0 0 3 Surface engineering: Significance of surfaces, nature of surfaces contact, surface energy, surface topography, surface texture evaluation techniques, surface integrity, Instruments and techniques for surface analysis, scanning electron microscopy and atomic forces microscopy, surface zone layers, structure of superficial layers, characteristics of superficial layer obtained by manufacturing processes, strength properties, tribological properties. (9) Surface coatings: Structure of coatings, classification of coatings, need for technical and technological coatings, techniques for producing surface layers, thermal spraying, electron beam technology, laser based technology, ion implantation techniques, CVD methods and PVD techniques. (9) Surface hardening: Surface hardening by flame and induction, laser and electron beam hardening, selection and applications, surface diffusion process, carbonitriding, aluminizing, siliconizing, chromizing, sursulf, selection of diffusion process. (6) Tribology: Scope of Tribology, Tribology in metal working, surface effects on tribology, liquid lubricants and lubrication, lubrication by solids, mechanism and effects of lubrication, film parameter, selection criteria for lubricants, basics of hydrodynamic, elasto-hydrodynamic, boundary and extreme pressure lubrication, tribological components, bearings, gears and piston rings. (9) Friction AND WEAR: Laws of dry friction, mechanism of friction, sliding friction of metals and polymers, stick slips in machine tool slides, frictional heating and contact temperature, wear mechanisms, abrasive, erosive and cavitation wear, effects of adhesion between wearing surfaces, seizure and scuffing, corrosive wear and fatigue wear, wear analysis and measurement. (9) Total 42 TEXT BOOKS:
REFERENCES: 1. Basu S K, Sengupta S N and Ahuja D B, “Fundamentals of Tribology”, Prentice Hall of India, 2005. 2. Sharma and Rajan, “Heat Treatment Principals and Techniques”, Prentice Hall of India, 2004. 3. Bharat Bhushan, “Modern Tribology Hand Book”, John Wiley and Sons, 2002. 4. Biran Griffiths, “Manufacturing Surface Technology, Surface Integrity and Functional Performance”, Elsevier, 2001. 5. ASM Metals Handbook, Vol. 5, “Surface Engineering”, 2000. 6. Gwidon W S and Andrew W Batchelor, “Engineering Tribology”, Butterworth Heinemann, 2000. 7. Kenneth C Ludema, “Friction, Wear, Lubrication: A Textbook in Tribology”, CRC Press, 1996. 8. Ernest Rabinowicz, “Friction and Wear of Materials” John Wiley and Sons, 1995.
1. Philip F Ostwald and Jairo Munuz, “Manufacturing Processes and Systems”, John Wiley and Sons, New York, 1998. 2. Heldt P M, “High Speed Combustion Engines”, Oxford IBH publishing Co., Calcutta, 1996.
1. Degarmo E P, “Materials and Process in Manufacturing”, Macmillan Publishing Co., 1997. 2. Kalpakjian, “Manufacturing and Engineering and Technology”, Addison Wesloy, Publishing Company, 1995.
1. Ebeling Charles E, “An Introduction to Reliability and Maintainability Engineering”, Tata McGraw Hill Publishing Company, New Delhi, 2000. 2. Stephen B Vardeman and Marcur Jobe J, “Statistical Quality Assurance Methods for Engineers”, John Wiley & Sons, 2000. REFERENCES: 1. Guangbin Yang, “Life Cycle Reliability Engineering”, John Wiley and sons, 2007. 2. Amit Mitra, “Fundamentals of Quality Control and Improvement”, Prentice Hall of India, 2007. 3. Montgomery Douglas C, “Introduction to Statistical Quality Control”, John Wiley and Sons, New Delhi, 2007. 4. Patrick D T o'connor, “Practical Reliability Engineering”, John-Wiley and Sons Inc, 2002. 5. David J Smith, “Reliability, Maintainability and Risk: Practical Methods for Engineers”, Butterworth, 2002. 6. E E Lewis, “Introduction to Reliability Engineering, John Wiley, 2000. 7. Layth C Alwan, “Statistical Process Analysis”, McGraw Hill, 2000. 8. William J Kolarik, “Creating Quality Process Design for Results”, McGraw Hill, 1999. 9. Sharma S C, “Inspection Quality Control and Reliability”, Ghanna Publishers, 1998. 08P018 SIMULATION OF MANUFACTURING SYSTEMS 3 0 0 3 INTRODUCTION TO SIMULATION: Areas of application, systems and system environment, components of a system, discrete and continuous systems, model of a system, types of models, discrete-event system simulation, steps in a simulation study. (6) RANDOM NUMBER GENERATION: Properties of random numbers, generation of pseudo-random numbers, techniques for generating random numbers, tests for random numbers. (6) RANDOM VARIATE GENERATION: Inverse transform technique, exponential, uniform, weibull, triangular, empirical, continuous, discrete distribution, direct transformation for the normal distribution, acceptance, rejection technique, poisson, gamma. (6) INPUT MODELLING: Data collection, identifying the distribution with data, parameter estimation, goodness-of-fit tests, selecting input models without data. (6) DESIGN AND EVALUATION OF SIMULATION EXPERIMENTS: Length of simulation runs, variance reduction techniques, experimental layout, validation. (6) MANUFACTURING SYSTEMS EXAMPLES: Simulation of single machine job shop, two machine job shop, simulation of inventory system and simulation of projects networks. (6) Introduction to SIMULATION SOFTWARE: Programming for discrete event systems, Case studies. (6) Total 42 Text Books: 1. Jerry Banks and John S Carson, "Discrete Event System Simulation", Prentice Hall of India, New Delhi, 2003. 2. Gordon G, "Systems Simulation", Prentice Hall of India Ltd., New Delhi, 2003. 3. Narsingh Deo, "System Simulation with Digital Computer", Prentice Hall of India, New Delhi, 2001. ReferenceS:
08P019 SUPPLY CHAIN MANAGEMENT (Also common with 08M027) 3 0 0 3 INTRODUCTION to SUPPLY CHAIN MANAGEMENT: Definition, global optimization, Key issues in SCM. Logistics networks - data collection, data aggregation, transportation rates, mileage estimation, warehouse costs, warehouse capacities, potential warehouse locations, service level requirements, future demand, model and data validation, solution techniques. (7) INVENTORY MANAGEMENT: Introduction, a single warehouse, Inventory example, economic lot size model, effect of demand uncertainty. Risk pooling, centralized and decentralized system, managing inventory in the supply chain, practical issues, forecasting. (7) VALUE OF INFORMATION: Bullwhip effect, information and supply chain trade-offs, supply chain integration - push, pull and push-pull system. Demand driven strategies, impact of internet on SCM, distribution strategies. (7) STRATEGIC ALLIANCES: Framework for strategic alliance, third party logistics, retailer, supplies partnerships, distributor - integration, procurement and outsourcing strategies. (7) INTERNATIONAL ISSUES IN SCM: Introduction, risks and advantages, issues, design for logistics, supplier integration into new product development, mass customization. The dimensions of customer value. (7) INFORMATION TECHNOLOGY FOR SCM: Goals, standardization, infrastructure, integrating supply chain information technology. (7) Total 42 TEXT BOOK: 1. Simchi – Levi Davi, Kaminsky Philip and Simchi-Levi Edith, “Designing and Managing the Supply Chain”, Tata McGraw Hill Publishing Company Ltd, New Delhi, 2003. REFERENCES: 1. Jorg Thomas Dickersbach, “SCM with APO : Structures Modelling Approaches”, Springer Verlag, New York, 2004. 2. Gerhard Knolmayer and Peter Merte NS, “SCM Based SAP Systems”, Springer Verlag, New York, 2004. 3. Robert B Hand Field and Ernest Nichols,” Supply Chain Management”, Prentice Hall, New Jersey, 1999. 4. Hartmud Stadler and Christoph Kilger, “Supply Chain Management and Advanced Planning : Concepts Models, Software”, Springer Verlag, New York, 2000.
REFERENCES: 1. James L Pappas and Eugene F Brigham, “Managerial Economics”, Holt, Rinehaut and Winston Ltd., 1983. 2. Srinath L S, “PERT and CPM – Principles and Applications”, EWP, New Delhi, 1982. 3. Norman N Barish, “Economic Analysis for Engineering”, McGraw Hill Book Company, New York, 1978. 08P021 COMPUTATIONAL FLUID DYNAMICS (Also common with 08M017/ 08A019) 3 0 0 3 INTRODUCTION: Basic concepts of fluid flow-derivation of the governing equations, conservation of mass, momentum and energy. Mathematical classification of flow - hyperbolic, parabolic, elliptic and mixed flow types. (7) DISCRETISATION: Finite difference method - forward, backward and central difference schemes, explicit and implicit methods. Properties of numerical solution methods - stability analysis, error estimation, difference between the FDM and FVM methods. (9) INTRODUCTION TO GRID GENERATION: Choice of grid, grid oriented velocity components, cartesian velocity components, staggered and collocated arrangements, adaptive grids. (6) CFD TECHNIQUES: Lax - Wendroff technique – MacCormack’s technique, relaxation technique. Artificial viscosity, ADI technique, Pressure correction technique - SIMPLE algorithm, Upwind schemes - flux vector splitting. (9) TURBULENCE MODELING: Turbulence energy equation- one-equation model, the k-ω model, the k- ε model. (6) CASE STUDIES: Solving industrial problems using CFD packages. (5) Total 42 TEXT BOOKS:
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08P022 APPLIED HEAT TRANSFER IN MANUFACTURING 3 0 0 3 INTRODUCTION: Modes of heat transfer – conduction, convection, radiation – examples in engineering and manufacturing. (3)
CONDUCTIVE TRANSFER: Governing equations of heat conduction, boundary conditions and their physical meaning - Steady and unsteady state heat conduction, applications in metal casting, welding, metal cutting and metal forming. (9) CONVECTIVE TRANSFER: Convection – Governing equations, Boundary conditions - Free and forced convection, definition of heat transfer coefficient, Nusselt and Reynolds number. Thermal and velocity boundary layers, applications in heat treatment, moving work pieces and tools as in metal forming and metal cutting. (9) RADIATIVE TRANSFER: Governing equations, view factor, grey body, black body situations. Application to furnaces and laser assisted materials processing. (9) CASE STUDIES: Modelling and simulation of temperature field during heat treatment, freezing of a casting in a mold, temperature field in a weldment, heat transfer in Laser Assisted Material Processing (LAMP), temperature distribution in cutting tools during metal cutting and temperature distribution in an Injection molded component. (12) Total 42 TEXT BOOKS:
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08P023 PRODUCTION PLANNING AND CONTROL 3 0 0 3 INTRODUCTION: Manufacturing as competitive advantage – manufacturing for competitive advantage framework – corporate strategy and manufacturing strategy. (3) FORECASTING: Common time series forecasting models – monitoring the forecasting system – controlling the forecasting system – focus forecasting – pyramid forecasting – the forecasting process. (5) AGGREGATE PLANNING: The nature of the aggregate planning decisions – aggregate planning defined – the value of decision rules – costs – aggregate planning strategies – aggregate planning methods – the master production schedule: bill of material types – structuring the bill of material – modular bills of material – disaggregation techniques – managing the master schedule – maintenance of the MPS. (8) THE PLANNING OF MATERIAL REQUIREMENTS: MRP and MRP II – implementation of MRP and MRP II – the parts requirements problem – the mechanics of MRP – MRP concepts and advantages – lot sizing – uncertainty and change in MRP systems – net change versus regenerative MRP systems – system nervousness, firm planned orders and time fences. (7) CAPACITY PLANNING AND CONTROL: Long-range capacity planning – medium-range capacity planning and control – short-term capacity planning and control – High-volume production activity control and just-tin-time systems: the production environment – controlling continuous production – sequencing and line balancing methodologies – relationship to aggregate planning – batch processing techniques – process industry scheduling – Just-in-time. (8) JOB SHOP PRODUCTION ACTIVITY PLANNING: Database information requirements – scheduling – shop loading – sequencing – priority rules for dispatching jobs – mathematical programming, heuristics and simulation – worker scheduling in service operations. (4) JOB SHOP PRODUCTION ACTIVITY CONTROL: dispatching – corrections to short-term capacity – production reporting and status control – factors affecting the completion time of jobs – techniques for aligning completion times and due dates – scheduling in flexible manufacturing system. (4) THEORY OF CONSTRAINTS AND SYNCHRONOUS MANUFACTURING: Theory of constraints – the goal and performance measures – capacity – synchronous manufacturing – marketing and production. (3) Total 42 TEXT BOOKS:
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08P024 STRATEGIC QUALITY MANAGEMENT 3 0 0 3 INTRODUCTION: The strategic quality management era -Total quality management- Strategy, quality and customer value - The continuous improvement philosophy - The total view of quality - Beyond total quality management - The nature of paradigm shift. (5) STRATEGIC MANAGEMENT AND THE EMERGING PARADIGM: Introduction - The growing role of strategic management - Defining strategy - Participants of strategic management - The emerging paradigm and strategic management - Strategic management of customer value - Defining the business - Writing a mission statement - Vision statement - Using market opportunity analysis to define the business - stakeholder analysis - Corporate values/Philosophy/Principles - External analyses - Remote environment analysis - Industry analysis - Competitor analysis- Forecasting and prioritising the opportunities and threats - Internal analysis - Performance analysis - Function, activity and process analyses - Portfolio analysis. (7) STRATEGIC QUALITY MANAGEMENT: Elements of Strategic Quality Management - Integrating quality into Strategic Management - Quality and the management cycle - Quality policies - Quality goals - Resources for quality activities - Training for quality – Implementing total quality - Obstacles to achieving. Strategic Quality Management. (5) DEFINING KEY PROBLEMS AND STRATEGIC ISSUES: Root problems versus symptoms - Strategic alternatives - Goals and Objectives - Long-term strategies - Competitive strategy versus cooperative strategy – Evaluating strategic alternatives - Strategic choice and strategy implementation - Annual goals and objectives - Action plans and policies - Leadership and Management - Systems and Structure - Organisational culture - Human resource Management. (6) STRATEGIC LINKAGE OF OPERATIONS THROUGH EMPLOYEE INVOLVEMENT: Introduction - Definition of employee involvement - Establishing employee involvement within a strategic context - Establishing the context: Utilizing the MAT framework - Improving Operational Proficiency - A “pull” model of employee involvement - The organisational forms of employee involvement - Mistakes to be avoided when implementing employee involvement - Human resource implications of employee involvement, Deming award. (6) CULTURAL CHANGE AND ORGANISATIONAL LEARNING: Introduction - TQM at advanced computer technology: journey into cultural change - Change and organisational culture - The difficulty of triggering change - Cultural change as a paradigm shift - Causing a transformational change - The Baldrige award as a trigger for change - The critical path of change – Frame -Breaking change - Leverage points for driving transformational change - The importance of sensitivity to cultural impediments to transformational change - Assessing organisational culture - Responsibility to do the cultural analysis - Data gathering- Organisational learning and transformational change - Espoused theory and theory in use - Double loop versus single loop learning - Continuous improvement requires continuous learning. (7) TECHNIQUES FOR MEASURING CUSTOMER VALUE: Techniques for measuring customer value - Techniques for measuring commercial customer value - Principles of measurement - Avoiding value measurement errors - Using customer value measures - Translating learning into strategy and systems - Methods for improving system performance - Customer Relationship Management - Improvement of systems and processes - Satisfaction and Dissatisfaction Measurement - Measures of customer satisfaction - The dynamics of values and implications for measurement - Refining satisfaction and dissatisfaction measurement - Implications for strategy. (6) Total 42 TEXTBOOKS:
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3. Logothetis N, “Managing for Total Quality – From Deming to Taguchi and SPC”, Prentice Hall of India Private Limited, New Delhi, 1997. 08P025 VALUE ENGINEERING 3 0 0 3 INTRODUCTION: Meaning of Value - Improving Value - Definitions of Value Engineering - Overview on the Value Engineering Job Plan. (3) VE PROGRAMME METHODOLOGY: Exposure to Value Engineering - In depth training - Selection of VE Projects - Formation of Teams - The VE Job plan - Implementation of VE Team’s recommendations - Rewarding VE efforts - Perpetuation of VE programme - VE Coordinators - Organisation for Value Engineering - VE Calendar - The Value Engineering Job plan. (6) ORIENTATION PHASE: Launching Value Engineering project work - Objectives and Targets - VE Project work: a time-bound programme - Projects and Teams - Time Schedule - Co-ordination - Consultant. (4) INFORMATION PHASE: Technical data - Marketing related information - Competition profile - Cost data - Materials Management related information - Quality related information - Manufacturing data. (4) FUNCTION ANALYSIS PHASE: Objectives - Function definition - Classification of functions - Higher level functions – Function –Cost – Function – Worth - Value Gap - Value index - How to carry out Function Analysis? – Fast Diagraming - Cost Modelling. (6)
CREATIVE PHASE: Creativity - How to improve creativity of an individual? – How to promote creativity in the organisation? - Obstacles to Creativity - Mental road blocks - Creativity killer phrases. Positive thinking - Ideas stimulators - Creativity techniques - Brainstorming. (4) EVALUATION PHASE: Paired comparison and Evaluation Matrix techniques - Criteria for selection of VE solutions. (4) INVESTIGATION PHASE: Design – Materials – Quality – Marketing – Manufacturing - Preview session. (4) RECOMMENDATION PHASE: The report - presentation. (3) IMPLEMENTATION PHASE: Design department - Materials department - Production Planning & Control - Quality Control – Manufacturing – Marketing - Need for co-ordinated teams - The Action Plan. (4) Total 42 TEXT BOOK:
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08P026 LEAN MANUFACTURING 3 0 0 3 INTRODUCTION: Holistic view of Lean Manufacturing - Definition and brief description of the five primary elements of lean manufacturing - Lean Manufacturing approach- Roadmap - Implementation methodology - Lean Manufacturing principles - Expected benefits. (6) ORGANISATION ELEMENT: Introduction - Communication planning - Product focussed responsibility - Leadership development - Operational roles and responsibilities - Workforce preparation. (6) METRICS ELEMENT: Introduction - DuPont Model (A company view) - Output-based measures (a cell team’s results) - Process-driven measures (infinite continuous improvement) – Goal alignment through policy deployment - Measurement definition and understanding (power to the people). (6) LOGISTICS ELEMENT: Planning/control function- priority panning (forward plan) - Capacity planning (workload) - Capacity control (input/output control) - Priority control (dispatch list) - A,B,C material handling - Service cells - Customer /supplier alignment - Just-in-time (JIT) Kanban demand signals - Cell tem work plan - Level loading - Mix-model manufacturing - Workable work. (6) MANUFACTURING FLOW ELEMENT: Introduction - Product/Quantity Analysis (Product Grouping) - Process Mapping - Routing Analysis (Process, Work content, Volume matrices) – Takt time - Workload balancing and One-Piece flow - Cell Design Criteria - Cell Layout - Kanban Sizing. (6) PROCESS CONTROL ELEMENT: Single-Minute exchange of dies - Total Productive Maintenance - Poka-Yoke (Fail Safe) - 5S (Housekeeping) – Visual controls - Graphic work instructions. (6) IMPLEMENTATION OF LEAN MANUFACTURING PROGRAMME: Setting the stage - Beginning- game plan - Project charter - Milestone plan - lean assessment - Current state gap- Future state design – Deployment - Evaluation of results. (6) Total 42 TEXT BOOK: 1. Field W M, “Lean Manufacturing: Tools, Techniques, and How to Use Them”, St.Lucie Press, London, 2001. REFERENCES:
08P027 RESOURCE MANAGEMENT TECHNIQUES 3 0 0 3 ADVANCED ALGORITHMS FOR LINEAR PROGRAMMING: Revised simplex method - dual simplex method – parametric linear programming – the upper bound technique – an interior-point algorithm. (6) NETWORK OPTIMIZATION MODELS: Terminology of networks – the shortest-path problem – the minimum spanning tree problem – the maximum flow problem – the minimum cost flow problem – the network simplex method. (6) DYNAMIC PROGRAMMING: Characteristics of dynamic programming problems – deterministic dynamic programming – probabilistic dynamic programming – introduction to integer and nonlinear programming. (8) METAHEURISTICS: Nature – Tabu search – simulated annealing – genetic algorithms. (6) GAME THEORY: The formulation of two-person, zero-sum games – solving simple games – games with mixed strategies – graphical solution procedure – solving by linear programming – extensions. (4) MARKOV DECISION PROCESSES: A model for Markov decision processes – linear programming and optimal policies – policy improvement algorithm for finding optimal policies – discounted cost criterion. (6) SIMULATION: The essence of simulation – some common types of applications of simulation – generation of random numbers – generation of random observations from a probability distribution – outline of a major simulation study – performing simulations on spreadsheets. (6) Total 42 TEXT BOOKS: 1. Frederick S Hillier and Gerald J Liberman, “Introduction to Operations Research”, Tata McGraw Hill Publishing Company Ltd., New Delhi, 2006. 2. Gupta P K and Hira D S, “Operations Research”, S. Chand & Co., New Delhi, 2006. REFERENCES:
DETAILED SYLLABI FOR INDUSTRIAL TRAINING 08P100 INDUSTRIAL TRAINING I (MANUFACTURING ORGANIZATION - STRUCTURE AND OPERATIONS) 0 15 0 4 Industry organization structure, safety and environmental needs, plant layout - list of machine tools – specifications - operation done on each machine tool - constructional arrangements of machine tools, various work holding and tool holding methods, types of cutting tools used – hand tools - type of component and material of the component, organizational structures - industrial safety – sales and marketing – maintenance – power distribution. Total 210 08P200 INDUSTRIAL TRAINING II (COMPONENT MANUFACTURING TECHNOLOGIES) 0 15 0 8 Study of components used in lathes, pumps, motors along with needed machine tools, gauges- functions – materials and their importance - study of component drawings – sequence of operations – cutting parameters – cutting tools – geometry of cutting tools – hand tools - gauges and instruments and their applications – jigs and fixtures – job setting procedures – assembling procedures – sequence of assembling for pumps, motors and Lathes. Total 210 08P300 INDUSTRIAL TRAINING III (PROCESS ENGINEERING AND ASSEMBLY TECHNOLOGIES) 0 15 0 12 Machining, assembly and process engineering - preparation of process sheets for spur gear - helical gear - sprockets - worm - worm wheel and rack - sequence of operations – machine tools used - speed and feed in each type of machine tool - setting time - operating time - cutting tools - study of assembly methods for conventional lathe, pre assembly, sub-assembly and final assembly -study of assembly drawings - preparation of ration of loading sheets - assembly flow chart - assembly time - fits and tolerance between components - inspection methods – material flow diagrams. Total 210 08P400 INDUSTRIAL TRAINING IV(INSPECTION AND TESTING OF MECHANICAL ASSEMBLIES) 0 15 0 8 Inspection and testing of lathes, pumps and motors - BIS specification for motors and pump sets - list of testing instrument - functions - foot mounting motor dimensions as per IS: 1231 - importance of name plate and identification of name plate details - trouble shooting of induction motors - type of routine test of induction motor as per IS : 7538 (Performance Calculations) 1) Measurement of stator resistance 2) High voltage test 3) Measurement of insulation resistance 4) Reduced voltage test 5) No load test 6) Full load test 7) Locked rotor test 8) Starting torque and starting current 9) Pull up torque 10) Pull out torque 11) Momentary over load test 12) Temperature rise test - Final inspection and testing for conventional lathes - Test charts - Inspection of the machine tool for BIS and IMTMA standard - Cutting test - Method of inspection testing - Gauges and instruments required - Accuracy requirements - Deviation observed - Study of inspection methods and preparation of inspection format for lathe bed - Head stock body - Tail stock body - Apron body - Threading and feed box - Gear box - Head stock spindle - Tail stock spindle - Gear - Lead screw - Feed shaft - Spine shaft – Exposure to metrological aspects of components used for lathes, pumps and motors. Total 210 08P500 INDUSTRIAL TRAINING V(PRODUCT DEVELOPMENT AND QUALITY SYSTEMS) 0 15 0 8 Activities involved in PD, market survey, concept development, product tear down, innovation reverse engineering, rapid prototyping, product reliability, a case study. Report preparation, presentation and evaluation - Awareness of TQM, ISO9000, ISO14000 and other standards etc. - Process capability studies – Rejection analysis – Six sigma applications – Calibration needs – Calibration authorities – Records – Charts – Applications – Form error understanding and verification- Case studies in quality systems.Total 210 08P600 INDUSTRIAL TRAINING VI(DESIGN AND PRODUCTION OF CASTINGS) 0 15 0 12 Foundry practice, design knowledge of patterns, Moulds, Cores (Mini Project – II), Layout, Pattern shop - Sand plant - Machine moulding - Core shop - Heavy moulding – furnaces - melting-knock-out and shot blasting - fettling - Study of various casting designs - Metallurgy – Inspection - Semi Automation processes -Sand reclamations - Preservations - Rough Machining - Various allowances - Method Engineering - Computational applications - Planning & Scheduling -Costing - Cleanliness - Orderliness - Environmental requirements - Safety needs - Energy Conservations - Bio Mass Power Generators - DISA Machine operations - Material Handling techniques - Case studies for a few selected castings to understand steps to design plan right from pattern to finish casting. Inspection of casting, casting defects and remedies, cause and effects diagram, Rejection analysis. Total 210 08P700 INDUSTRIAL TRAINING VII(MANAGERIAL SKILLS, CREATIVITY, SOFT SKILLS, HRM) 0 15 0 8 Managerial skills, soft skills and HRM, Generation of creative and innovative ideas, SWOT analysis Executive Skills-Group Discussions - Communication Skills - Project Report preparation methods - Focus on customer needs - Visual Management - Scheduling systems - Maintenance Management - Vendor Developments - Model Preparations - Production, Planning & Controls - Storage & Inventory Management - Supply Chain Management - Lean Methods - Wastage Identifications - Equipment Up Time - Kaizen & Lean Practices, human Resource Management Skills - Innovation & Adaptation Skills - Creative Skills - Patent Right knowledge - Competitive Skills - Interview focusing skills - Product Development Skills - Reverse Engineering Skills - Concurrent Engineering Skills - Prototyping Skills - Costing Skills - Analyzing Skills - Marketability Analysis Skills.Total 210 08P800 INDUSTRIAL TRAINING VIII(INDUSTRIAL VISITS AND COLLOQUIUM I) 0 15 0 4 Industrial profile - Product range - Catalogue - Infrastructure - Turn over - Quality system - Labor force - Industrial structure - Location - Layout - ISO 9000 and other standards - Material handling system - R&D - Product development - Manufacturing system - Advanced quality systems - Types of industry 1) Automobile 2) Foundry 3) Steel 4) Cement 5) Machining 6) Forging 7) Fabrication 8) Electrical - Industry Lecture – Seminars - Quiz programmes. Training at external industries. Total 210 08P900 INDUSTRIAL TRAINING IX(INDUSTRIAL VISIT AND COLLOQUIUM II) 0 15 0 4 Visiting external industries and acquiring knowledge about the following productivity enhancement techniques: Focus on customer – Visual management – Scheduling system – Maintenance management – Model preparation – Vendor development – Production planning and control – Storage and inventory management - Supply chain management, Kanban systems – Layout and material handling system – Orderliness – Safety and environment – Equipment uptime- Study and application of KAIZEN, Lean practices, Value Stream Mapping, Value engineering, Zero defects, Wastage identification, Productivity improvement, Continuous Productivity improvement – Reverse engineering – Poka-Yoke, ISO system needs, Knowledge on TQM, TPM and applications. (Training partially at PSG II and partly at other external industries). Total 210 |