ME LM Syllabus

7/27/2019 ME LM Syllabus

1/5

84

09ML01 STATISTICS AND RELIABILITY ENGINEERINGvide Computer Integrated Manufacturing 09MC23

09ML02 DESIGN OF LEAN PRODUCTION SYSTEM3 0 0 3

INTRODUCTION: Functional areas of firm product design, manufacture, delivery principles of production system role of

inventory and informationtypes of wastelean tools. (4)

LAYOUT: Types of layout - process layoutproduct layoutcell layoutperformance measure of layouts. (6)

VALUE STREAM MAPPING:The current state diagram - the future state map - application to the factory simulation scenario - linebalancing - poke yokeoverall equipment effectiveness. (7)

JUST IN TIME: Improving the production environmentquality engineeringimproving product flowthe transition to lean. (6)

MANUFACTURING STRATEGY AND SUPPLY CHAIN: Forecasting systems supply chain management concepts aggregateplanningmaster production schedule. (7)

DECENTRALIZED PULL SYSTEMS:Kanban systemsconstant work in process pull alternative. (6)

MULTI STAGE PRODUCTION SYSTEMS: Material requirements planningmanufacturing resource planningcapacity planningmanaging change. (6)

Total 42

REFERENCES:1. Ronald G Askin, Design and Analysis of Lean Production system, John Wiley and Sons, New York, 2003.2. Bedworth D D, "Integrated Production Control Systems Management, Analysis, Design, John Wiley and Sons, New York,

1987.3. Vollman T E, "Manufacturing Planning and Control Systems", Galgotia Publication (P) Ltd., New Delhi,2004.4. Dennis P Hobbs, Lean Manufacturing Implementation: A complete Execution Manual for any Size Manufacturing, J Rose

Publishing Inc, 2004.5. Taiichi Ohno, Toyoto Production System: Beyond Large Scale Production Productivity Press, New York, 1988.

09ML03/09MM03 LEAN TOOLS AND MANAGEMENT SYSTEMS3 0 0 3

INTRODUCTION TO LEAN MANUFACTURING: Objectives of lean manufacturing-key principles and implications of lean

manufacturing- traditional Vs lean manufacturing. (5)

LEAN MANUFACTURING CONCEPTS: Value creation and waste elimination- main kinds of waste- pull production-different modelsof pull production-continuous flow-continuous improvement / Kaizen- worker involvement -cellular layout- administrative lean.

(7)

LEAN MANUFACTURING TOOLS AND METHODOLOGIES: Standard work -communication of standard work to employees -standard work and flexibility -visual controls-quality at the source- 5S principles -preventative maintenance-total qualitymanagement-total productive maintenance -changeover/setup time -batch size reduction -production leveling. (7)

VALUE STREAM MAPPING:The as-is diagram-the future state map-application to the factory simulation scenario-line balancing -Poke Yoke -Kanbanoverall equipment effectiveness. (6)

JUST IN TIME MANUFACTURING: Introduction - elements of JIT - uniform production rate - pull versus push method- Kanbansystem - small lot size - quick, inexpensive set-up - continuous improvement. Optimised production technology. (6)

ONE-PIECE FLOW: Process razing techniquescells for assembly linecase studies. (4)

IMPLEMENTING LEAN: Road map-senior management Involvement-best practices. (4)

RECONCILING LEAN WITH OTHER SYSTEMS: Toyota production system-lean six sigma-lean and ERP-lean with ISO9001:2000.(3)

Total 42REFERENCES: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, McGrawHill, New York, 2004.3. Micheal Wader, Lean Tools: A Pocket Guide to Implementing Lean Practices, Productivity and QualityPublishing Pvt Ltd,

2002.4. Kenichi Sekine, One-Piece Flow, Productivity Press, Portland, Oregon, 1992.5. Alan Robinson Continuous Improvement in Operations, Productivity Press, Portland, Oregon, 1991.6. Joseph A De Feo, William W Bearnard , Juran Institutes Six Sigma Break Through and Beyond, Tata McGrawHill Edition,

New Delhi, 2004.

7. Richard B ChaseF Robert Jacobs and Nicholas J Aquilano,Operations Management for Competitive Advantage, McGrawHill/Irwin; Tenth Edition, 2003.

8. Poke - Yoke, "Improving Product Quality by Preventing Defects", Productivity Press, 1992.
http://www.amazon.com/exec/obidos/search-handle-url/index=books&field-author-exact=Richard%20B%20Chase/103-6646084-7639032http://www.amazon.com/exec/obidos/search-handle-url/index=books&field-author-exact=F.%20Robert%20%20Jacobs/103-6646084-7639032http://www.amazon.com/exec/obidos/search-handle-url/index=books&field-author-exact=Nicholas%20J%20Aquilano/103-6646084-7639032http://www.amazon.com/exec/obidos/search-handle-url/index=books&field-author-exact=Nicholas%20J%20Aquilano/103-6646084-7639032http://www.amazon.com/exec/obidos/search-handle-url/index=books&field-author-exact=Nicholas%20J%20Aquilano/103-6646084-7639032http://www.amazon.com/exec/obidos/search-handle-url/index=books&field-author-exact=F.%20Robert%20%20Jacobs/103-6646084-7639032http://www.amazon.com/exec/obidos/search-handle-url/index=books&field-author-exact=Richard%20B%20Chase/103-6646084-7639032


2/5

85

09ML04 SIMULATION MODELING AND ANALYSISvide Computer Integrated Manufacturing 09MC15

09ML05 COST MANAGEMENT AND LEAN ACCOUNTING3 0 0 3

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. (5)

ACTIVITY BASED COSTING: Concept objectives comparison with conventional costing activity cost drivers resourcemappingresource driveractivity costshifting costs to activitiesdesigning the optimal ABC system. (5)

ACTIVITY BASED MANAGEMENT:Conceptvalue added analysis treevalue added activity, strategic activity, support activityvalue added analysis in manufacturing. (5)

TARGET COSTING AND TOTAL COST MANAGEMENT: Conceptdifferent approachesprice based, cost based, value basedtarget costing- strategies for achieving target costvalue analysis, vendor development, outsourcing, core competence. (6)

LEAN ACCOUNTING: Financial bridge, profit and loss model understanding earnings changesDu pont return on net assetsmodel, six sigma financial trading and reporting, governance model overview, savings, analytical guide lines, Lean accounting,define, voice of the customer/business, pulling the voices, together, actions to avoid metric problems. (6)

MEASURE: Develop and track bridge metrics, purpose, measure phase in bridge process, measurement system analysis, tools formeasure phase, product and service quality , customer/supplier requirements, QFD, value stream mapping, lead time, YX matrix,statistical, analysis of process matrics, why-why, matrix for mixed, model manufacturing and mass customization, logistics andsupply chain matrics. (5)

ANALYSE: Current capabilities, technical processes, people processes, pulling together, bridge structure, analysis sub steps,analyse out of bounds values for root causes; tools for analysis, product and quality work flow linearity, process synchronization andwork load balancing, process characteristics charts, miscellaneous analytical tools, statistical correlation analysis. (5)IMPROVE: People and processes, selecting a solution open dialog, alternate solutions, action plans, cost and financial benefits,people and accountabilities, communications, improvement, control, pilot evaluation plan, implementation and execution, rolloutplan, standardization and replication, classified roles and responsibilities, process and performance control, financial assessment,leadership governance and sustaining the gains. (5)

Total 42

REFERENCES:

1. Blocher Chen and Lin, Cost Management A Strategic Emphasis, McGraw Hill Irwin, 2002.2. Micheal Breamer, Brain Mckibben, Thomas Mccarting, Six Sigma Financial Tracking and Reporting McGraw Hill, 2006.3. Monden Y, Cost Management in the New Manufacturing Age, Productivity Press, 1992.4. Cooper R and Slagmulder R, Target Costing and Value Engineering, Productivity Press, 1997.

09ML06 DESIGN FOR MANUFACTURE AND ASSEMBLYvide Engineering Design 09MD06

09ML07 SIX SIGMA IN MANUFACTURING AND SERVICINGvide Industrial Engineering 09MN15

09ML08 SUPPLY CHAIN MANAGEMENTvide Computer Integrated Manufacturing 09MC12

09ML09/09MM09 COMPUTER INTEGRATED MANUFACTURING3 0 0 3

INTRODUCTION: Evolution of CAD/CAM and CIM, scope of CIM, segments of generic CIM, computers and workstations, anoverview of CIM software. (4)

GEOMETRIC MODELING AND DESIGN OPTIMISATION: Geometric modeling techniques, automated drafting, graphic standards,engineering analysis, optimisation, principles of concurrent engineering. (4)

CNC TECHNOLOGY AND ROBOTIC SYSTEMS: Principles of numerical control, types of CNC machines, features of CNCsystems, programming techniques, capabilities of a typical NC, CAM software, integration of CNC machines in CIM environment,

DNCflexible manufacturing systems. Robotic systems-types of robots and their performance capabilities, programming of robots,hardware of robots, kinematics of robots, product design for robotized manufacturing, applications of robots in manufacturing andassembly. (8)


3/5

86

GROUP TECHNOLOGY AND AUTOMATED PROCESS PLANNING: Methods of developing part families, classification andcoding systems, process planning, variant and generative process planning methods, AI in process planning. (4)

MANUFACTURING SYSTEM SOFTWARE:Production controlforecasting, master production schedule, MRP, capacity planning,shop floor control, inventory management, product routing, job costing, marketing applications. (4)

FUNDAMENTALS OF NETWORKING: Networking concepts, networking devices repeaters, bridges, routers, gateways, hubsand switches. MAP, TOP, LAN, WAN. Network topologiesstar, bus, ring. (4)

RAPID PROTOTYPING SYSTEMS: Rapid prototyping techniques, software for rapid prototyping, process optimization. (4)

VIRTUAL ORGANISATION: Paperless factory, introduction virtual reality and application, virtual prototyping and manufacturinginstrumentation and measurement, virtual enterprises. (4)

PROJECT:Involving CAD/CAM/CAE activities for a selected product from industry. (6)Total 42

REFERENCES:1. Mikell P Groover, Automationof Production Systems and Computer Integrated Manufacturing, Pearson Education,

New Delhi, 2001.2. Lee Kunwoo, CAD/CAM/CAE Systems, Addition, Wesley, USA, 1999.3. Kant Vajpayee S, Principles of Computer Integrated Manufacturing, Prentice Hall, India, New Jersey, 2003.4. Radhakrishnan P, Subramanyan S and Raju V, CAD/CAM/CIM, Second Edition New Age International Pvt. Ltd,

New Delhi, 2008.

09ML10 QUALITY ENGINEERINGvide Computer Integrated Manufacturing 09MC10

09ML11 ENTERPRISE RESOURCE PLANNINGvide Computer Integrated Manufacturing 09MC11

09ML12 SAFETY AND ENVIRONMENT MANAGEMENT SYSTEMvide Industrial Engineering 09MN12

09ML13 CREATIVITY AND INNOVATION MANAGEMENT

vide Engineering Design 09MD25

09ML14 INDUSTRIAL SCHEDULINGvide Industrial Engineering 09MN14

09ML15 PROJECT MANAGEMENTvide Industrial Engineering 09MN24

09ML16 ARTIFICIAL INTELLIGENCE AND EXPERT SYSTEMvide Computer Integrated Manufacturing 09MC16

09ML17 OPTIMIZATION TECHNIQUESvide Computer Integrated Manufacturing 09MC17

09ML18 HUMAN RESOURCE MANAGEMENTvide Industrial Engineering 09MN25

09ML41 INDUSTRIAL VISIT AND TECHNICAL SEMINAR1 0 2 2

The student will make atleast two technical presentations on current topics related to the specialization. The same will be assessedby a committee appointed by the department. The students are expected to submit a report at the end of the semester covering thevarious aspects of his/her presentation together with the observation in industry visits. A quiz covering the above will be held at theend of the semester.


4/5

87

09ML51 LEAN MANUFACTURING LABORATORY0 0 3 2

1. Value Stream MappingCreation of current state diagram using eVSM software 2. Value Stream MappingDevelopment of future state map for the above set up3. Evaluation of cost benefit analysis of implementing lean systemA case study

4. Layout design and study of layout performance

5. Development of a Poke-Yoke (fool proof) system for a typical process

6. Generation of a Production plan using Pro-Planner7. Calculation of lead time and WIP using RFID8. Design of automatic inspection line using Machine Vision System and Pneumatic System9. Calculating Risk Priority number using XFMEA software10. Identification of VA, NVA, Standard time calculation and Line balancing using Timer pro Software11. Ergonomic risk assessment of assembly station using RULA method12. Process capability evaluation using Minitab software13. An exercise on 5S simulation

09ML52 MECHATRONICS SYSTEM LABORATORYvide Engineering Design 09MD53

09ML55 OBJECT COMPUTING AND DATA STRUCTURES LABORATORYvide Computer Integrated Manufacturing 09MC55


5/5

88

----------------------------

BLANK PAGE--------------------

Documents

ME LM Syllabus