INSY 3800: Materials and Manufacturing Processes (Required for B.I.S.E.)

Department of Industrial & Systems Engineering

Fall 2009

Instructor: Dr. Lewis Payton

E-mail: payton@auburn.edu

Office: DML in Shop Building 2/Phone (334) 844-3315

Office Hours: Mon. & Fri. 1:00 - 2:00 pm

Prerequisites: (MATL 2100) Introduction to Materials Science

Credit Hours: 3

Course Website: Maintained on Blackboard.

Lectures: Mon. & Wed. 9:00 - 9:50 am Shelby Center 1126

Labs: Per Blackboard

2009 Catalog Description: The AU Bulletin description is “Materials, measurement and

quality assurance. Manufacturing processes (casting, forming, materials removal, joining).

Processes and techniques related to manufacturing.”

Required Material:

Text: “Materials and Processes in Manufacturing” 9th Edition, Degarmo et.al. ISBN 0-471-

03306-5.

Dress code: No hats, sunglasses, loose clothing, ties, or jewelry. Closed toe shoes and

slacks are required whenever you are in the lab or on a tour. Hair must be worn up in a high

ponytail or bun. Beards must be neatly trimmed to less than 0.5 inches.

Course Learning Outcomes: Upon completion of this course, the students will:

a) Be able to communicate the design and production process for a simple mechanical

product

b) Be familiar with all the materials used in manufacturing

c) Be familiar with the all the processes used in manufacturing

d) Be familiar with all non-destructive and destructive testing techniques used in

manufacturing

e) Be able to do 2D and 3D CAD drawings of wiring harnesses and other assemblies

f) Be able to do simple sheet metal drawings

g) Be familiar with the concepts of Computer Numerically Controlled machines

h) Be familiar with the FANUC CNC Control languages and MasterCAM

i) Understand the relationships between CAD/CAM/CIM

j) Be familiar with data acquisition methods such as LABVIEW

Grading Policy: The following is a description of how grades will be calculated:

Weighted grades on quizzes, homework assignments, exams, and labs will be based on the

following scale:

Short Quizzes, 10 (drop lowest grade) 300 Points

Homework Assignments 30-50 Points

Exams, 3 300 Points

Final Exam 150 Points

Labs, 12-14 150-200 Points

Total Points Possible 1000 Points

Final course grades will be determined based upon points obtained in course:

Student’s Total Points > 900 A

Student’s Total Points > 800 B

Student’s Total Points > 700 C

Student’s Total Points > 600 D

Student’s Total Points ≤ 600 F

Topics Covered:

Lecture Topics Labs

Safety and Material Safety

Metals and Alloys Mechanical Testing/Load Frame labs

Plastics and Powder Materials Metrology Labs

Composite Materials

Non-destructive testing procedures Part Modeling/Hand Tools

Process Capability/Fundamentals of CASTING SE Schematics/Casting Demos

Advanced Casting Processes/Powder Metallurgy Process Assemblies

Sheet Metal Processes/Forging Processes

Friction in Metal Working/Extrusion Processes Schematic Drawings

Fabrication of Plastics & Composites/Intro to Metal cutting Engineering Calculation Tools

Drilling, milling, broaching, lathes, Gear Production Molded Parts

Non-traditional Machining Methods, Abrasive Machining

Work holding/Rapid Prototyping

CNC Processes/Welding Processes Rendering CNC Operations

Welding Processes/Joining Processes CNC Operations

Electronic Circuit Boards/Golden Rules of Design

ABET Outcomes: Assessments:

(a) An ability to apply

knowledge of

mathematics, science,

and engineering

Students are tested on their understanding of Fundamentals of

Materials Science, including strength of materials and solids,

dislocation dynamics and work hardening as they apply to

modern manufacturing processes in the American Southeast.

Students must exhibit a working knowledge of the terminology

of metal cutting and deformation, plastic formation, composite

formation, powder metallurgy, forging, casting, and rapid

prototyping. Non-destructive testing is emphasized although all

destructive testing methods are also covered for each process.

(c) An ability to design a

system, component, or

process to meet desired

needs

Lab grades from a lab where the students design a manufacturing

cell (part of a manufacturing system)

Lab grades from a lab where the students design a NC process

plan to make a fatigue specimen

Lab grades from a lab where the students design a NC process

plan to make a three axis NC machine (a work holding device).

Syllabus Prepared by: Dr. Lewis Payton

Date: 8-17-09

INSY 3800 – Manufacturing Systems I

Spring 2012

1 of 3

Course Title: INSY 3800 Manufacturing Systems I Department: Industrial and Systems Engineering Credit Hours: 3 hours (2 hours lecture, 1 hour lab) Designation: Required Prerequisites: None Web site: Blackboard Instructor: John L. Evans

3308 Shelby Transportation jevans@eng.auburn.edu 844-1418

Office Hours: M 1:00 – 2:30 PM W 10:00 to 11:30 AM

G.T.A.: TBD

Course Time and Location: Lecture: Tuesdays/Thursdays, 12:30 PM – 1:45 AM, Shelby 1122; Lab: Wednesdays 3:30-6:00 PM, Shelby Basement Lab Course Text: Mikell P. Groover, Automation, Production Systems, and Computer-IntegratedManufacturing, 3rd Edition, 2007, Prentice Hall, Upper Saddle River, NJ References: Askin, Ronald G., J.B. Goldberg, Design and Analysis of Lean Production Systems, 2001, 1st Edition, John Wiley & Sons, New York, NY; Goldratt, E. M., The Goal, 1992, 2nd Revised Edition, North River Press, Great Barrington, MA. Course Description: Introduction to the design, analysis, and operation of manufacturing systems, the first course in a required two-course sequence including Manufacturing Systems II. Course Objectives: Through class instruction and discussion, homework assignments, exercises and team case studies, students will develop a general understanding of the basic concepts and practical models in manufacturing systems analysis and design, and be able to apply these concepts and models in the design and evaluation of basic manufacturing systems. Course Requirements and Evaluation: Students will be evaluated based on the following assignments and exams: Description Date Weight Exam 1 Week 6 – in class 25% Exam 2 Week 10 – in class 25% Final Exam per AU schedule 35% Team Homework/ Case Studies 15%

Class Policy Statements: Exams will be closed book & closed notes. Grades will be based on minimum of 10 point systems (The instructor may scale grades if appropriate). Students must maintain a weighted average of 55% on the three exams (including final) to be eligible to pass the class with a D average or better. The University academic honesty policies will be strictly enforced. Please refer to the Tiger Cub for details about these policies and procedures. Students with Disabilities: Any student with a disability needing special accommodation should notify the instructor and contact Dr. Kelly Haynes, Director of the Program for Students with Disabilities, located in 1244 Haley Center, Auburn University.

INSY 3800 – Manufacturing Systems I

Spring 2012

2 of 3

Course Topic Outline:

Date Topic Chapter/Reference Lab

1/10 Introduction to Manufacturing Systems Chapter 1

1/12 Manufacturing Operations Chapter 2

1/17 Manufacturing Models (with LP) Chapter 3 Lab #1 - LP

1/19 Manufacturing Models (with LP) Chapter 3 Lab #2 - Automation

1/24 Introduction to Automation Chapter 4

1/26 Industrial Control Systems Chapter 5 Lab #3 – Industrial Hardware

1/31 Hardware Components for Automation Chapter 6

2/7 Computer Numerical Control Chapter 7 Lab #4 - CNC

2/9 Computer Numerical Control Chapter 7

2/14 Industrial Robotics Chapter 8 Lab #5 - Robotics

2/16 Test #1 – Manufacturing Models and Operations

Homework

2/21 Casting Lab #6 - Casting

2/23 Metal Forming Methods Extra Material

2/28 Metal Forming Methods Extra Material Lab #7 – Metal

Forming

3/1 Plastic Molding Operations Extra Material

3/6 Joining and Welding Extra Material Lab #8 – Joining /

Welding 3/8 Joining and Welding Extra Material

3/13 Machining Extra Material

3/15 Machining Extra Material

Lab #9 – Machining

3/27 Test #2 – Manufacturing Processes Chapter 15

3/29 Material Handling & Identification Technologies

Chapter 10

4/3 AS/RS Systems Chapter 11 Lab #10 – AS/RS

INSY 3800 – Manufacturing Systems I

Spring 2012

3 of 3

4/5 RFID Chapter 12

4/10 Manufacturing Systems Chapter 13 Lab #11- RFID

4/12 Single Station Manufacturing Cells Chapter 14

4/17 Manual Assembly Lines Chapter 15 Lab #12- Manual

Stations

4/19 Automated Production Lines Chapter 16 Homework

Team Case 5

4/24 Automated Assembly Lines Chapter 17 Lab #13-

Automated Assembly

4/26 Cellular Manufacturing Chapter 18

5/1 Flexible Manufacturing Systems Chapter 19

TBD Final Exam All Class Material

Contribution to Meeting the Professional Component Manufacturing systems engineering offers the student a comprehensive understanding of the tools and techniques needed to meet the challenging manufacturing environment. Specific focus is placed on the ability of the student to apply his or her knowledge to an actual manufacturing problem. The goal is to ensure the student is ready to meet the need of the manufacturing industry upon completion of this course. Relationship to Program Outcomes While this course relates to several of the department’s stated ABET outcomes, the two outcomes for which assessments are taken are: c) an ability to design a system, component, or process to meet desired needs and g) an ability to communicate effectively. The first outcome (c) is defined in three areas (facility layout, automated storage capacity, and station sequencing) and is intended to show an ability to design specific manufacturing needs based on facility or throughput requirements. The second outcome (g) is intended to evaluate the student’s capability to understand a complex manufacturing engineering problem, formulate a solution and present this solution to the class in a comprehensive manner.