University of Pune

Structure of
BE (PRODUCTION ENGINEERING) 2003 Course
Semester- I
Subject Subject Teaching Examination Scheme
Code Scheme
(Hrs)
Lecture Pr Th Tw Or Pr Total
/D
w
411081 Production 4 2 100 50 - - 150
Management
411082 Machine Tool 4 2 100 50 50 - 200
Design
411083 Manufacturing 4 2 100 - 50 - 150
Automation
and Control
411084 Operations 4 2 100 50 - - 150
Research
411085 Elective I 4 - 100 - - - 100
411086 Project - 2 - - - - -
Work**
Total 20 10 500 150 100 750
** It is mandatory to submit preliminary project report for the grant of the term I

Semester II
Subject Subject Teaching Examination Scheme
Code Scheme (Hrs)
Lecture Pr/Dw Th Tw Or Pr Total
411086 Project Work - 6 - 100 100 - 200
411087 Material and 4 2 100 25 - - 125
Financial
Management
411088 Process Planning 4 4 100 - 50 - 150
and
Tool Selection
411089 CAD/CAM/CIM 4 2 100 25 50 - 175
411090 Elective II 4 - 100 - - - 100
Total 16 14 400 150 200 750

Th: Theory Pr: Practical Dw: Drawing Tw: Term Work Or: Oral

Note: Practical/Oral based on Term Work

Elective I Elective II
1) Reliability Engineering 1) Robotics
2) Powder Metallurgy 2) Ergonomics and Human Factors in
3) Plant Engineering. and Maintenance Engg.
4) Material Handling and Engineering 3) Advanced Material Processing
Design 4) Advanced Production Technology

Detail B. E. Prod Syllabus

411081: PRODUCTION MANAGEMENT
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Practical: 2 hrs/week Duration: 3 hours
Term Work: 50 Marks
Objectives
• To learn and understand Concepts and functions of Production Management
• To learn and use software packages for decision making
Prerequisites
• Industrial Engineering and Management
• Production Planning and Control

Unit I
Scope of Production Management (4)
The evolution of Production management / Operations Management. Different
production eras - Mass production, flexible and mass customization and customization.
Relationship of Production / Operations Management with materials, maintenance,
quality control, design engineering, production engineering, material and sales. Scope,
Definition and its relationship with other management functions such as marketing,
finance and personal management. Production organizations for single product, multi
product, single location, multi location.
Product Design (4)
Product life cycle, Relationship between product design and product cost. Functional,
Economic, manufacturing and marketing aspects in product design, Concept of
Concurrent engineering.

Unit II
Location (2)
Facility-location: Objectives, site selection, floor rating, center of gravity method.
Layout (3)
Layout types, quantitative models for facility layout, locations, layout planning for
distribution centers.
Material handling (3)
Material handling: Its relation with layout, Objectives, principles and types of material
handling. Material handling analysis. Unit load concept.

Unit III
Manpower Planning and Capacity Planning
(4)
Manpower forecasting, manpower inventory, capacity and level strategies, aggregate
capacity planning, determining optimal operating levels and timing of capacity
increments.
Productivity Engineering (4)
Productivity: factor productivity, total productivity, labour Productivity, measurement of
productivity, improvement techniques of productivity. Development and implementation
of Productivity improvement programme.

Unit IV
World Class Manufacturing
(8)
Concept of World Class Manufacturing, Emergence of information age, Manufacturing
challenges of the information age, elements of business turbulent environment. Problems
in the manufacturing sector. Evolution and principles of WCM. Contribution of Hall,
Schoenberger, Gunn, Maskel, World class practices in the industry, WCM-Indian
Scenario.
Unit V
Industrial maintenance (8)
Organization, administration of maintenance function, types of maintenance, principles,
operating policies, scope of maintenance management, Work authorization, work
scheduling
maintenance budget and costs, Total productive maintenance.
Unit VI
Advanced topics in production Management
(8)
Energy conservation and Energy audit, Eco development considerations, Green
production, Lean and Agile manufacturing, Problems of technology choice and
technology transfer, environmental pollution and control strategies, computerized
production management systems.
Term Work:
1. Facility location models (any 3).
2. Study of Plant layouts: Manufacturing/Service unit using SLP
3. Computerized facility layout Planning – CORELAP, CRAFT, ADLEP,
4. Aggregate planning using MS Excel
5. Energy audit and Study of energy conservation practices for a specific industry
6. One Internet based assignment on any one of topics above

Text Books:
1. J. L. Riggs, “Production Systems”, John Wiley and Sons.
2. Mayer, “Production Management”, Tata McGraw Hill Publications
3. M. Telsang, “Industrial Engineering and Production Management”, S. Chand
Publication

Reference Books:
1. H. B. Maynard and others, “Modem manufacturing”, IVth edition - McGraw Hill
Publications, ISBN 0-07-041084-4.
2. H. B. Maynard and others, “Industrial Engineering Handbook”, IVth edition -
McGraw Hill Publications, ISBN 0-07-041084-4.
3. L. R. Higgnis, R. K. Mobley, Smith Ricky, “Maintenance Engineering
Handbook”, McGraw Hill Publications, ISBN 0-07-028819-4.
4. Kanter Jerome, “Management Information System”, Prentice Hall, ISBN 0-
87692-358-9.
5. H. Noori and R. Radford, “Production and Operation Management”, Total Quality
and
Responsiveness international Edition - 1995 - McGraw Hill Inc.
6. B.S. Sahay, K B C. Saxena, Ashish Kumar, “World Class Manufacturing-A
Strategic perspective”,McMillan India Ltd.
7. F. L. Francis, J. A. White, L. F. McGinnis, “Facilities Layout and Location”,
Prentice Hall of India Pvt. Ltd., ISBN 81-203-1460-3.
8. T. E. Vollmann, W. L. Bery, “Manufacturing Planning and control Systems”,
Galgotia Publication New Delhi, ISBN 81-7515-084-X.
9. Richard Muther, “Systematic Layout Planning”

411082: MACHINE TOOL DESIGN

Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Practical: 2 hrs/week Duration: 3 hours
Term Work: 50 Marks
Oral: 50 Marks
Objectives
• To learn and understand Machine Tool Design
• To learn and compute design aspects for machine tools
Prerequisites
• Design of Machine Elements
• Kinematics and Design of Manufacturing Machines

Unit I
Drives (4)
Design considerations for drives based on continuous and intermittent requirement
of power, Types and selection of motor for the drive, Regulation and range of speed
based on preferred number series, geometric progression. Design of speed gear box
for spindle drive and feed gear box.
Stepless drives
(4)
Design considerations of Stepless drives, electromechanical system of regulation,
friction, and ball variators, PIV drive, Epicyclic drive, principle of self locking,

Unit II
Design of Machine Tool Structures (8)
Analysis of forces on machine tool structure, static and dynamic stiffness.
Design of beds, columns, housings, bases and tables.

Unit III
Design of Guideways and Power Screws (8)
Functions and types of guideways, design criteria and calculation for slideways,
design of hydrodynamic, hydrostatic and aerostatic slideways, Stick-Slip motion in
slideways. Design of power screws: Distribution of load and rigidity analysis.

Unit IV
Design of Spindles and Spindle Supports (8)
Design of spindle and spindle support using deflection and rigidity analysis, analysis
of anti-friction bearings, preloading of antifriction bearing.

Unit V
Dynamics of machine tools (8)
Dynamic characteristic of the cutting process, Stability analysis, vibrations of machine
tools.
Control Systems: Mechanical and Electrical, Adaptive Control System, relays, push
button control, electrical brakes, drum control.

Unit VI
Advances in Machine Tool Design (8)
Design considerations for SPM, NC/CNC, and micro machining, Retrofitting,
Recent trends in machine tools, Design Layout of machine tool using matrices.

Term work:
Term work shall consist of record of assignments on following topics. Oral shall be based
on term work.
1. Design and working drawing of speed gear box
2. Design and working drawing of feed gear box
3. Study of stepless drives
4. Design of bed or column.
5. Design for spindle or power screw.
6. Design for guideways and slideways.
7. Internet assignment based on any one of the topics above.
Text Books:
1. N. K. Mehta, “Machine Tool Design”, Tata McGraw Hill, ISBN 0-07-451775-9.
2. A. Bhattacharya and S. G. Sen., “Principles of Machine Tool”, New central book
agency Calcutta, ISBN 81-7381-1555.
3. D. K Pal, S. K. Basu, “Design of Machine Tool”, 4th Edition. Oxford IBH 2005,
ISBN 81-204-0968.

Reference Books:
1. N. S. Acherkan, “Machine Tool”, Vol. I, II, III and IV, MIR publications.
2. F. Koenigsberger, “Design Principles of Metal Cutting Machine Tools”, The
Macmillan Company New York 1964.

411083: MANUFACTURING AUTOMATION AND CONTROL

Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Practical: 2 hrs/week Duration: 3 hours
Oral: 50 Marks
Objectives
• To learn and understand Hard and Soft Automation
• To learn and perform experiments with hydraulic and pneumatic circuits

Prerequisites
• Machine Tools and Advance Manufacturing Systems

Unit I
Basics of Automation and Industrial Hydraulics (8)
Basic concepts of automated system, Advanced automated functions, levels of
automation, Principles of hydraulics, hydraulic fluids, filtration technology, hydraulic
pumps, hydraulic valves, and hydraulic actuators.

Unit II
Design of Hydraulic Circuits
(8)
Basic hydraulic circuits such as regenerative circuits, sequencing circuit, meter in and
meter out circuit, standards in circuit diagram representation, power pack design layout,
design of pumps, reservoir, accumulators and intensifiers, selection of standard
components, hydraulic servo mechanism, proportional valves.

Unit III
Pneumatic Systems (6)
Operational principles and application, air compressors, pneumatic cylinders and air
motors, pneumatic valves, Design of pneumatic circuits, hydro-pneumatic, control in
pneumatic system.

Unit IV
Programmable Automation (10)
Microprocessor, microprocessor instrumentation system for process control, logic gate
and control, programmable logic control, computer process controls.

Unit V
Control System (7)
Electric control: - features and design principles of electrical circuits in drives, PLC, data
conversion (ADC/DAC), interfacing circuits, actuating signals, relays, contactors, types
of control systems, linear feedback control system, optimal control system.

Unit VI
Factory Automation (9)
Transfer systems-Continuous, intermittent, Indexing mechanisms, vibratory bowl
feeders, non-vibratory feeders, hopper feeders, rotary disc feeder, centrifugal, revolving
feeder, assembly systems, automated assembly, design for automated assembly,
synchronous and non synchronous material transfer, industrial robots, Automated Guided
Vehicles and FMS, automated warehouse.
Term Work:
The term work shall consist of record of any eight assignments on following topics.
1. Study of control valves, actuators, accumulators and pumps.
2. Study of hydraulic circuits: - hydraulic press, machine tools, automobile systems,
etc
3. Performance analysis of positive displacement pumps.
4. Comparative studies on hydraulic circuit design for suitable industrial
applications.
5. Study of pneumatic circuits.
6. Study of automation in material handling system.
7. Use of microprocessors: applications in manufacturing engineering.
8. Study and experiments in programmable logic controllers: ladder logic
programming
9. Study of displacement, level and pressure controls
10.Measurement and design circuits for speed and temperature measurement.
Oral shall be based on the above Term work. ,
Text Books:
1. B. C Kuo, “Automatic control systems”, Prentice Hall India Pvt. Ltd., ISBN 0-
87692-480-1.
2. Peter Rohner, “Industrial hydraulic control”
3. Mikell P Groover, “Automation, Production System and Computer Integrated
Manufacturing”, Prentice Hall Publications, ISBN 81-203-0618-X.
4. S. R. Mujumdar, “Pneumatic system”, Tata McGraw Hill 2002 Edition.
5. Gopal, “Control systems Engineering”, Willey Eastern Ltd., ISBN 0-85226-605-
7.

Reference Books:
1. E. O Doebelin., “Measurement System, Application and Design”, Tata McGraw
Hill Publications Ltd., New Delhi, ISBN 0-07—17338-9.
2. W Bolton., “Mechatronics Electronic Control Systems in Mechanical and
Electrical
Engineering”, Pearson Education (Singapore) Pvt Ltd., ISBN 81-7808-339-6.
3. C S Rangan, G R Sharma, V S Mani, “Instrumentation - Devices and Systems”,
Tata
McGraw Hill Publications Ltd., New Delhi, ISBN 0-07-463350-3.
4. B H Histand, D G Alciatore, “Introduction to Mechatronics and Measurement
Systems”, ISBN 0-07-052910-8.
5. C D Johnson, “Process Control Instrumentation Technology”, Prentice Hall of
India Pvt. Ltd., New Delhi, ISBN 81-203-0987-1.
6. HMT Mechatronics, HMT, ISBN 0-07-462147-5..
7. Vickers manual on hydraulics
8. G. Boothroyd , C. Poli, L. Murch, “Automatic Assembly”, Marcel Dekker Inc.
1982.
9. Ramesh Gaonkar, “Microprocessor”, Penram International Pub. Pvt. Ltd., ISBN
81-900-828-7-6.
10. Werner Deport and Kurt Stool, "Mechanization by pneumatic control", Vol. I and
II

411084: OPERATIONS RESEARCH

Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Practical: 2 hrs/week Duration: 3 hours
Term Work: 50 Marks
Objectives
• To learn and understand Quantitative Techniques
• To learn and use software packages for quantitative techniques
Prerequisites
• Production Planning and Control
• Data Base and Information Technology for Production Engineers

Unit I
Linear programming
(8)
Definition of Operations Research: objectives, formulation of problem, graphical method,
simplex methods for maximization and minimization problems, degeneracy in L.P.,
duality in L. P.; Sensitivity analysis,

Unit II
Transportation and assignment problem (8)
Structure, industrial and business application Transportation problems- use of various
methods for solving transportation problem, degeneracy and its solution, transhipment
problem. Assignment problem- solutions of various types of problems, travelling
salesman Problem.
Unit III
Introduction to Integer, Dynamic and Non-linear programming
(6)
Simulation (3)
Introduction, application, Monte Carlo simulation of queuing system, inventory system,
capital budgeting, new product planning etc.

Unit IV
Introduction to Geometric and Goal Programming.
(3)
Replacement models (4)
Replacement of capital equipments that deteriorates with time,
time value of money (a) remains same (b) changes with constant rates during period.
Equipment renewal policy, group and individual replacement.

Unit V
Queuing theory (3)
Operating characteristics, Poisson single and multi channel queuing system M/M/1: /
FCFS.
Games Theory
(4)
Introduction, two -person zero sum game, minimax and maximin principle, saddle point,
methods for solving game problems with mixed strategies, Graphical and iterative
methods.

Unit VI
Network modeling (3)
Fundamentals of CPM. and PERT networks.
CPM (3)
Construction of networks, critical paths, forward and backward pass, floats and
their significance, crashing for optimum and minimum duration and the cost, resource
allocation and leveling
PERT (3)
Time estimates, construction of networks, probability of completing projects by given
date.

Term Work
One exercise on each unit. At least one Computer software package such as Lindo/Lingo,
MATLAB, MS-Excel and Tora should be used.
Oral shall be based on the term work.

Text Books:
1. S. D. Sharma, “Operations Research”, Kedarnath Ramnath and company
Publications.
2. P. K. Gupta, D. S. Hira, “Operations Research”, S Chand and Co. Ltd., ISBN 81-
219-0281-9.
3. H. A Taha., “Operations Research”, An introduction Prentice Hall Pvt. Ltd., ISBN
81-203-1222-8.

Reference Books:
1. F. S. Hillier, G. J Lieberman, “Introduction to Operations Research”, Tata
McGraw-Hill, ISBN 0-07-047387-0.
2. H. M. Wagner, “Principles of Operations Research”, Prentice-Hall India, ISBN
81-203-0162-5.
3. A. Ravindran, “Operations Research”, Tata McGraw-Hill.
4. S. K. Basu, D. K. Pal, H. Bagchi, “Operations Research for Engineers”, Oxford
and IBH Publishing Co. Pvt. Ltd., ISBN 81-204-1251-6.
5. R. Panneerselvam, “Operations Research”, Prentice Hall of India Ltd., ISBN 81-
203-
1923-0.
 411085: RELIABILITY ENGINEERING
ELECTIVE I
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Reliability Engineering
Prerequisites
• Metrology and Quality Control

Unit I
Introduction to Reliability (8)
Importance of reliability, performance cost and reliability, quality and safety, system
configuration with examples, stochastic processes, bathtub concept, MTBF, MTTR,
hazard rate, failure rate, probability and sampling, cumulative probability distribution
function, data and distributions.

Unit II
System safety analysis (8)
Fault tree and event tree concept, construction and analysis, failure modes effects and
criticality analysis, systems approach, techno-physio constraints, typical failure analysis,
risk priority number and its allocation.

Unit III
Reliability in design and Life Cycle costing
(8)
Survival rate, bath-tub curve analysis of characteristics of failure regimes, design
synthesis, reliability effort function, safety margin, allocation of reliabilities by AGREE,
ARINC, proportional distribution of unreliability, heuristic method, mean and median
methods.

Unit IV
System reliability and redundancy
(8)
Active and Passive Redundancy, redundancy allocation and limitations, Evaluation of
overall system reliability, Conditional probability, Matrix methods, set theory analysis of
system reliability.

Unit V
Loads, capacity, maintainability and availability
(8)
Reliability and safety factors, Repetitive loading, Preventive maintenance, Testing and
repair, reliability centered maintenance, system availability and maintainability.

Unit VI
Reliability testing and Failure Interactions
(8)
Reliability growth models, grouped. and ungrouped data, censored data, accelerated life
testing, Markov analysis .of two independent components, reliability with standby
system, multicomponent systems, DTMC and CTMS models.

Text Books:
1. E. E. Lewis, “Introduction to Reliability Engineering”, John Wiley and Sons.
2. L. S. Srinath, “Reliability Engineering”, Affiliated East-West Press Pvt. Ltd.,
ISBN 81-85336-39-3.
3. S. S. Rao, “Reliability Engineering”.

References Books:
1. S. K. Basu, B. Bhadury, “Terotechnology-Reliability Engineering and
maintenance”, Asian books Pvt. Ltd (2003), ISBN 81-86299-40-6.
2. Sheldon M. Ross, “Stochastic Processes”, John Wiley and Sons.

411085: POWDER METALLURGY

ELECTIVE I
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Powder Metallurgy and Applications
Prerequisites
• Engineering Metallurgy-I
 • Material Science and Composite Materials

Unit I
Powder Metallurgy (8)
Historical development, Introduction, Basic principles, techniques, classification,
applications, merits and demerits. Production of metal powders: reduction, atomization,
and electrolysis etc. Characteristics of powders and properties, production methodology
and quality control. Preparation of powder: grading, sizing, blending, handling and
storage. Testing of powders. Particle size distribution, surface conditions, purity, flow
properties, porosity, true and apparent density, Green compact strength.

Unit II
Compaction (8)
fundamentals of compaction, presses used, selection of presses, Automation and
Handling of powder, tool clearances, Die design principles, wear reclamation, Die and
punch materials selection and heat treatment, surface treatment properties, compact
density variations, effect of blending powders, lubricants and lubrication in process.

Unit III
Sintering (8)
principle, time temperature effects, theories of sintering mechanism. Sintering methods,
sintering furnaces-characteristics and selection. Dimensional and property changes after
sintering, sintering atmosphere and its impact on process performance. Hot compaction,
hot and cold pressing, spot sintering operations, impregnation.

Unit IV
Special P.M. processes (8)
Hot isostatic pressing, merits, demerits and typical applications. Powder Metal products
with polymer blends, expendable and retaining roll compaction. P.M. forging, Spray,
deposition and surface structure development.

Unit V
Powder Metallurgy Applications (8)
As structural parts, gears, levers, ratchets, etc. lamp filament and filament support,
refractory metal components, electrical contact material, Cemented Carbide tools and
wear parts, brakes and clutch lining material, porous bearings and filters, catalytic
components etc.
Unit VI
Powder Metallurgy Components characteristics (8)
Economics, Quality, Manufacturing Competitiveness due to conservation of energy,
Materials, Operations, Durability, rigidity, near net – shape, surface finish and
machining.
Heat treatment of Powder Metallurgy parts, advantages and limitations, typical
applications.
Quality control and quality assurance. Newer materials, production of nano-composites.

Text Books:
1. A.K Sinha, “A textbook of power Metallurgy”, D.P. Tai.
2. Schartz Kopf, “Powder Metallurgy”, McmilJar Company.
3. W.D Jone, “Fundametal principals of power Metallurgy”, Edword Arnold (UK)

Reference Books:
1. J. S Hirschhorn, “Introduction to powder Metallurgy”, America P .M. Institute
New York
2. H. H. Hausner, M. kumar Lal, “Handbook of Powder Metallurgy”, Chemical
Publishing Company, New York, ISBN 0-8206-0301-5.
3. Goetzel C. G., “Treatise on power Metallurgy “, Vol I to IV Inter Science
publisher Company, New York.
4. A.R. Poster (Editor), “Handbook of Metal powder Van Norstar Rembold
Company”, New York.
5. “A practical Guide to Metal Powder”, Hogans India Ltd.
6. Yarten, Argly, “Power Metallurgy”, Machinery Publishing U.K.
7. Hari Singh Nalwa (Editor), “Handbook of Nano-structured Materials and
Nanotechnology”Vol 1-5, Springer Verlang

411085: PLANT ENGINEEREING AND MAINTAINANCE

ELECTIVE I
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Plant Engineering function
Prerequisites
Unit I
Introduction (4)
Scope and importance of plant engineering. function – estimation of capacity for services
like manpower, water resource, power, choice of factors involving environment,
pollution control, sewage and waste disposal. Importance of location,

Location (4)
Economics, social, climatological, legal, political and industrial factors affecting site
selection. Establishing various kind of weighing coefficients of these factors in relation to
the nature of plant.

Unit II
Plant Layout
(4)
Types of production and their influence on layout, layout planning for various types of
production- functional layout, cellular layout, PQ analysis, PQRST analysis, Space
requirement analysis and space diagram, REL chart, Material flow analysis; layout
analysis for operation and maintenance of auxiliary services; Systematic layout planning
(SLP), Computer aided planning for layout design- types of layout problems, use of
computers in planning and solving layout problems.
Plant Safety
(4)
Planning for safety against mechanical, chemical hazards, pollution, sewage and waste
disposal, prevention practices against accident, fire, pollution, noise- safety codes
introduction, introduction to industrial safety Acts.

Unit III
Material handling (4)
Analysis and design of material flow; principles of material handling analysis system-
unit load concept, system approach – flow process charts; development of new systems/
quantitative analysis of material flow. Line balancing technique with optimal material
flow configuration, layout material handling and transportation and maintenance function
on productivity improvement.
Auxiliary Services Planning
(4)
Planning and maintenance of auxiliary services like security service, Transportation
service, water supply, recycling of disposal, effluent water treatment, Sewage water
treatment, scrap disposal or recycling.

Unit IV
Maintenance Organization and Management
(4)
Responsibilities and functions - operating policies-work allocation and scheduling-
distribution of work load –centralized Vs decentralized; organizational structures of
maintenance department- maintenance- history cards for equipments-maintenance
manual records- utilities generation.
Types of Maintenance
(4)
Concept of life cycle, maintenance- Breakdown, Corrective, Predictive, Elimination
(Design out) maintenance and Maintenance indication. Condition based maintenance

Unit V
Monitoring of Maintenance System
(4)
History records, Signature Analysis, Sound monitoring, Maintenability -Productivity and
reliability, Optimization of total maintenance. Lubrication and Lubricants- analysis of
effects of lubricants: Corrosion and wear their causes and prevention. Spectrometric Oil
Analysis Procedure (SOAP)

Spare Parts Management (4)

Financial aspects of spares- survey on spares practices-management of issues of spares-
lead time analysis-requirement planning- selective control of stock levels- spare parts
cost reduction-reliability and quality of spares-obsolescence and standardization. Logistic
management spare parts inventory.

Unit VI
Reliability (4)
Reliability Concepts- reliability-MTBF, MTTR, MTTF-reliability improvement: Fault
tree analysis and other techniques.

Maintainability (4)
Preventive maintenance principle-availability-optimum preventive maintenance, Analysis
of equipments-quantification of system effectiveness, Reliability Centered Maintenance
(RCM), Total Productive Maintenance (TPM), Merits, Demerits, House Keeping.
Computerized Maintenance Management System, Failure Mode and Effect Analysis
(FMEA).

Text Books:
1. H.P Garg.,”Industrial Maintenance”, S. Chand and co. New Delhi
2. Dr. S.K Basu., “Terotechnology :Reliability Engg. and Maintenance Mgt.”, Asian
Book (P) Ltd. (2003), ISBN 81-86299-40-8.

Reference Books:
1. H. B. Maynard and Others, “Industrial Engineering Handbook” Ivth edition,
McGraw Hill Publications, ISBN 0-07-041084-4.
2. L.S. Shrinath, “Reliability Engineering”, Affiliated East-West press (P) Ltd, New
Delhi, ISBN 81-85336-39-3.
3. R.C. Roslar, “Handbook of Plant Engg.”, McGraw Hill.
4. Higgins “Handbook of Plant Engg.” McGraw Hill.

411085: MATERIAL HANDLING TECHNOLOGY AND EQUIPMENT DESIGN

Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Material Handling concepts and Principles
• To learn design of Material Handling Equipment
Prerequisites
• Design of Machine Elements

Unit I
Introduction to Material Handling
(8)
Objectives of Material Handling, Basic storage methods and equipment. Factors
governing selection of Material Handling systems, Systems Approach to Material
Handling, Systematic Handling Analysis, Data Collection Analysis and
Development of New System. Unit load concept.

Unit II
Classification and Principles of Material Handling
(8)
I) Classification of various Material Handling Equipments and Accessories
a) Unrestricted b) Area Restricted c) Line Restricted d) Position Restricted
e) Auxiliary Restricted
II) Principles of Material Handling.

Unit III
Conventional Material Handling Equipments
(8)
Design Consideration for Material Handling Equipments e.g. Belt, Chain, Roller
Conveyor, Factors involved in Equipment Selection.
a) Manually Operated: Pallet Truck, Fork Lifts, Pillar and Overhead Cranes,
b) Liquid and Gas Handling, Pneumatic Conveying.

Unit IV
Automated Material Handling
(8)
Automation in Material Handling Equipment, Consideration for automating the material
handling equipment, Drives for Equipment e.g. Hydraulic, Pneumatic, Electrical.
Design considerations of Bulk Material Handling and Unit Load Handling. Advantages
and Disadvantages of Automated Material Handling. Financial Justification for
Implementing and automating Material Handling, Robot assisted Material Handling,
Actuators.

Unit V
Advanced Material Handling Equipment for Computer Integrated
Manufacturing (8)
a) Automated Guided Vehicles (AGV), Principle of its Working, Types of AGV’s, its
Control, its capabilities
b) Automatic Storage and Retrieval System (ASRS) Interfacing of Advanced Material
Handling Equipment with Manufacturing Equipment. Use of Advance Technology for
Material Handling Equipment like Vision System, Adaptive Control System, etc.

Unit VI (8)
Computer Applications in material handling, Packaging, Automatic identification
systems, RFID, Safety aspects considerations in design and operation of material
handling equipments, Environmental and Human factors considerations.

Text Books:
1. Allegri Theodore, “Material Handling Principles and practice” (CBS Publisher
Delhi)
2. Mikell P Groover, “Automation, Production System and Computer Integrated
Manufacturing”, Prentice Hall Publications, ISBN 0-87692-618-9.

Reference Books:
1. D. E. Mulcahy, “Material Handling Handbook”, McGraw-Hill
2. Kulwiec Raymond (editor), “Materials Handling Hand Book”, John Wiley (2nd
Edition)
3. R. G. T Lindkvist., “HandBook of Material Handling”, John Wiley and Sons, INC
New York, ISBN 0-85312-574-0.

411086: PROJECT WORK

Teaching Scheme Examination Scheme
Practicals: 2 hrs/week (I Semester) Term Work: 100 Marks
Practicals: 4hrs/week (II Semester) Oral: 100 Marks

Objectives
• To undertake small project in group related to application of principles studied
during the course
Prerequisites
The student shall take up suitable project, the scope of the project shall be such as to
complete it with the time schedule, The term work shall consist of,
1. Fabrication of models, machines, prototypes based on new ideas, robots and machine
based on hitech systems and automation, experimental set-up, fabrication of testing
equipment, renovation of machines, etc. Above work shall be taken up individually or in
groups. The group shall not be more than 4 students,
OR
Extensive analysis of some problems done with the help of a computer individually or in
a group not exceeding two students.
2. A detailed report on the work done shall include project specification, design
procedure, drawings, process sheets, assembly procedure and test results etc.

Project may be of the following types:

1. Manufacturing / Fabrication of a prototype machine' including selection, concept,
design, material, manufacturing the components, assembly of components, testing and
performance evaluation.
2. Improvement of existing machine / equipment / process.
3. Design and fabrication of Jigs and Fixtures, dies, tools, special purpose equipment,
inspection gauges, measuring instruments for machine tools.
4. Computer aided design, analysis of components such as stress analysis.
5. Problems related to Productivity improvements.
6. Problems related to value engineering.
7. Problems relating to material handling system.
8. Energy Audit of organization, Industrial evaluation of machine devices.
9. Design of a test rig for performance evaluation of machine devices.
10. Product design and development.
11. Analysis, evaluation and experimental verification of any engineering problem
encountered.
12. Quality systems and management. Total Quality Management.
13. Quality improvements, In-process Inspection, Online gauging.
14. Low cost automation, Computer Aided Automation in Manufacturing.
15. Time and Motion study, Job evaluation.
16. Ergonomics and safety aspects under industrial environment
17. Management Information System.
18. Market Analysis in conjunction with Production Planning and Control.
OR
Computer based design / analysis or modeling / simulation of product(s), mechanism(s)
or system (s) and its validation or comparison with available benchmarks / results. When
a group of students is doing a project, names of all the students shall be included on every
certified report copy. Two copies of Project Report shall be submitted to the college. The
students shall present their Project before the examiners. The oral examination, shall be
based on the term work submitted and jointly conducted by an internal and an; external
examiner from industry, at the end of second semester. Format of the project report
should be as follows:
1. Paper: The Project report should be types. printed on white paper of A-4 size.
2. Typing: The typing shall be with single spacing and on one side of the paper.
3. Binding: The Industrial Inplant Report should be submitted with front and back cover
in black hand bound, with golden embossing.
4. Margins: Left - 1.25", Right - 1". Top and Bottom 1 "
5. Sequence of Pages:
1. Title page
2. Certificate form Institute
3. Completion Certificate form Industry, if sponsored.
4. Acknowledgement
5. Abstract
6. Index
7. Nomenclature and Symbols
8. Actual Content
9. Conclusion
10. References.
6. Front cover: The front cover shall have the following details in block capitals
i. Title at the top.
ii. Name of the candidate in the centre, and
iii. Name of the Institute, Name of Industry, if sponsored and the year of submission on
separate lines, at the bottom.
7. Blank sheets: No blank sheets be left any where in the report. 8. Project Completion
Certificate:
The approval sheet follow the title sheet and shall be as shown with proper spacing.

CERTIFICATE
This is to certify that Mr. /Ms ……………………………………………
……
Has carried out a Project entitled, (Name)

…………………………………………during the course of his

(Name of Project)
training at………………………………………………..in
(Name of Industry)
partial fulfillment of the requirement of the B.E. Production Course of
University of Pune
at ……………………………during the academic Year ………………
 (Name of Industry)

Date: (Guide)
Place:

(Examiner) (Head of Department)

 411087: MATERIALS AND FINANCIAL MANAGEMENT
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Practicals: 2 hrs/week Duration: 3 hours
Term Work: 25 Marks
Objectives
• To learn and understand Materials Management Functions
• To learn and understand Financial Management Functions
Prerequisites
• Industrial Engineering and Management
• Production Planning and Control
Unit I
Materials Management (2)
Introduction to Material Management functions, objectives, tools and techniques
Value analysis
(3)
Value engineering, concepts, advantages, applications, problem recognition, role of
creativity, analysis of functions, use, esteem and exchange values elimination of
unnecessary costs, value engineering techniques.
Inventory control (3)
Probabilistic models, Cost, Safety stocks, service levels, inventory control of finished
goods, single order inventory policies Inventory models under risk and under uncertainty.

Unit II
Supply Chain Management (4)
Design considerations, the role of safety inventory, planning and managing inventories,
order processing, Determining appropriate level of safety and economic considerations.
Logistics Management
(3)
Evolution of logistics, Objective and its functions, financial control of logistic
performance.
Waste Management (2)
Importance of waste management and techniques.
Unit III
Import and Import Substitution (4)
Factors affecting National and International markets, Import procedure and documents
(Bill of lading, letter of credit etc.), current EXIM policies, import Substitution, E-
procurement.
Warehouse Management (3)
Nature and importance of warehousing, warehousing operations and Facility
development.

Unit IV
Financial Management (3)
Financial Function, Scope, goals and tools. Sources of finance.
Ratio Analysis
(3)
Classification, Ratio Analysis and its limitations.
Working Capital Management (2)
Concept and design of Working Capital, types of working capital, sources of working
capital, Time value of money, definition of cost and capital.

Unit V
Costing (2)
Methods of costing and elements of cost.
Material Cost (2)
Different methods of pricing of issue of materials.
Labour Cost (2)
Different methods, wages and incentive plans. Principles of good remunerating system,
labour turnover.
Depreciation (2)
Concept, importance and different methods of depreciation

Unit VI
Overheads (2)
Classification, collection of overheads, Primary and Secondary apportionment of
overheads, absorption of overheads- Machine hour and labour hour rate. Under and over
absorption of overheads.
Standard costing (2)
Concept, development and use of standard costing, variance analysis.
Marginal Costing (2)
Use of Marginal Costing in decision-making.
Capital Budgeting (2)
Control of Capital Expenditure, Evaluation Process-Payback approach, IRR, present
value method.
Term Work:
The term work shall consist of record of assignments on following topics.
1. A case study of value analysis.
2. Assignment on inventory control and Supply Chain Management.
3. Study and consolidation of import documents.
4. Case study on financial statements and its analysis
5. Collection and consolidation of labour and material costing data from anyone
production company for a specific period.
6. Assignments on overheads and depreciation.

Text Books:
1. Dobler and Lee, “Purchasing and Material Management”, Tata McGraw Hill,
ISBN 0-07-462082-7
2. Henry M. Steiner, “Engineering Economics Principles”, McGraw Hill
Publication.
3. N. K. Prasad, “Principles and Practice of Cost Accounting”, Book Syndicate Pvt.
Ltd., Calcutta 700009.
4. L. C. Jhamb, “Inventory Management”, Everest Publications, ISBN 81-86314-54-
7
5. S. Chopra, Peter Meindl, “Supply Chain Management: Strategy: Planning and
Operation”, Sunil– 2nd Ed, Pearsoh Education.

Reference Books:
1. K. S. Menon, “Purchasing and Inventory Control”, Wheeler Publication, ISBN
81-85814-10-4
2. L. D. Miles, “Techniques of Value Analysis and Engineering”, McGraw Hill
Book Company.
3. C. B. Gupta, “Fundamentals of Business”, Sultan Chand and Co.,
4. P. A. Samualson, “Economics”, McGraw Hill International.
5. Colin Drury, “Management and Cost Accounting”, English Language Book
Society, Chapman and Hall London.
6. Simchi-Levi, Kaminsky, “Designing and Managing the Supply Chain, Concepts
Strategies and Case studies”, 2nd edition, Tata McGraw Hill, ISBN 0-07-058666-7
7. James R. Stock and Diouglas M. Lambert, “Strategic Logistics Management”
IVth edition, McGraw Hill International Edition.
8. D. J. Bowersox, D. J.Closs, “Logistical Managemant”, McGraw Hill Book
Company, ISBN 0-07

411088: PROCESS PLANNING AND TOOL SELECTION

Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Practicals: 4 hrs/week Duration: 3 hours
Oral: 50 Marks
Objectives
• To learn and understand Process Planning function
• To design Process sheet and estimate time requirement

Prerequisites
• Metal Cutting and Tool design
• Manufacturing Processes-II
• Machine Tool Design

Unit I
Product Engineering (4)
Concept of a product – Its elements, units, subassemblies and assemblies, scope of
product engineering function, Flow charts of assemblies, Product analysis and planning:
Design for Manufacturing and assembly (DFMA). Product selection and criteria of
Product acceptability based on market research.
Process Engineering (4)
Organizational activities, functional activities, relation with other departments,
classification of processes, manufacturing operations, operational elements - machining,
handling, setting, inspection and approach for selecting and planning a process:
determining machining sequences - criteria, classification of operations and
manufacturing sequence, criteria for analysis for selection of best process.

Unit II
Analysis of Part Print
(4)
Method of reading and interpreting Part dimensions, part specification, identification of
nature of work to be performed, identification of functional surfaces, grouping of related
surfaces to be machined, size and shape needing, special handling, identification of basic
process for processing, sequences of operation from part print. Study of function of parts
in assembly and operations needed
Dimensional Analysis
(4)
Types of dimensions, concept of baseline dimension, basic geometrical surfaces, concept
of straightness, squareness, roundness, and concentricity. Surface Quality and surface
integrity, surface finish affecting product properties and product cost. Baselines, datum
surfaces selection, dimensional chain and linkage analysis, fixing in process dimensions

Unit III
Tolerance analysis (4)
Producing accuracies and attainable accuracies - process capability relation with
statistical accuracies, prime accuracies, Size and form, grades of tolerances, tolerance
grade calculations, Tolerance Stacks, Tolerance analysis for Assembly, purpose, use, and
layout of Tolerance charts development and balancing the Tolerance Chart, individual
size maintenance and automatic size maintenance
Work piece control (4)
Causes of Work piece variation, shape of part affecting processing, Variables influencing
Work piece control, Mechanical, Geometric and Dimensional Control, Equilibrium
Theories. Concept of Location - fundamental of Locating datum features, errors in
locating and clamping, establishing process areas, guide lines for identifying holding
areas, supporting areas and critical areas.

Unit IV
Selection of proper Equipment (4)
Process capability of Equipments, prime accuracies and producible accuracies of
Equipments, Factors influencing make or buy decisions, relation between Process
selection and Machine selection, basic factors in machine selection in terms of cost and
design factors, Determining machining conditions and computing manufacturing times.
Selection of Tooling (4)
Factors affecting selection of Tooling, commercial tooling, special tooling, selection of
Tools: jigs, fixtures, gauges, form tool in relation to process selected .Use of multi-
tooling set up, tooling economics as applied to Process Engineering.
Stock preparations and blank selection with material estimates.
UNIT V
Selecting and planning the process (4)
Study of Basic Processes Operations, Principal Processes and Auxiliary Processes.
Identification of major, critical, qualifying, re-qualifying and supporting operations.
Selection of single or combined operation, identification of finishing operations,
establishing of manufacturing sequence through classifying operation - critical analysis in
determining best operation sequence by selecting best process sequence.
Computer aided process planning (4)
CAPP -variant approach and generative approach. CAD database, work center database,
Automatic time standard system (ATS), sequencing operations and grouping, selection
of datum surfaces and holding devices, including inspection stages into computer
program, structured process planning software system, Computerized report generation,
Introduction to expert system for process planning.

Unit VI
Process Sheet design (8)
Study of the parts to be processed, Logical design of a process plan, stock preparations,
blank selection with material estimates, Selection of datum features, identification of
machining surfaces, incorporation of dimensions including tolerance analysis, selection
of machining methods with time estimates and time standard for each operation, Process
Picture sheet including process symbols, processing dimensions. Process plan sheet
design for complete manufacturing part
Term Work:
1. One case study of process documentation as per International Standards (ISO,
QS, TS etc) using cutting tool manufacturers’ catalogues.
2. Part print analysis of one industrial component drawing.
3. Process Sheet design of one component on GPM for batch production.
4. Process Sheet design of one component on CNC for batch production.
5. Process Sheet design of one component for mass production.
6. Time estimation for assembly using flow-charting techniques.
7. Industrial visit to study process designing and its report.
Oral shall be based on the above Term work.

Text Books:
1. D. F. Eary, G. E Johnson, “Process Engineering for Manufacturing”, Prentice Hall
of India Pvt. Ltd.
2. P.W. Wang, J.K Li, “Computer-Aided Process Planning”, Elsevier, Amsterdam.
3. Nanua Singh, “Systems Approach to Computer Integrated Design and
Manufacturing”

Reference Books:
1. H.W. Wage, “Manufacturing Engineering”, McGraw Hill.
2. “Manufacturers catalogues for cutting tools and inspection equipments”
3. P. Radhakrishanan, S. Subramanyan , V. Raju , “CAD/CAM/CIM”, New Age
International (P) Limited.
4. K. Hitomi , “Manufacturing System Engineering”, Taylor and Francis 1996, ISBN
0-7484-0324-8.
5. Groover, Mikell P., “Fundamentals of Modern Manufacturing- Materials,
Processes, and Systems”, Second Edition, Wiley, 2002.
6. K. L. Narayana, P. Kannaiah, K. Venkata Reddy, “Production Drawing”, New age
International Publishers, ISBN 81-224-0953-9.
 411089: CAD/CAM/CIM
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Practicals: 2 hrs/Week Duration: 3 hours
Term Work: 25 Marks
Oral: 50 Marks
Objectives
• To learn and understand Computer Aided Design and Manufacturing
• Learn to use CAD/CAM software packages
Prerequisites
• Machine Tools and Advance Manufacturing Systems
• Manufacturing Automation and Control
• Computer Graphics

Unit I
Computer Aided Design (8)
Fundamentals of CAD: CAD system definition and historical perspective design process,
application of computer for design and manufacturing database design, workstation,
graphics terminals, input and output devices. computer graphics software and database,
software configuration of a graphic system, functions of graphic package, constructing
the geometry, data base structure and content, wire frame, surface and solid modeling of,
hidden entity removal, real time picture, animation, CAD hierarchy.

Unit II
Computer Aided Manufacturing (CAM) (4)
Devices of NC system, data processing unit, linear and circular interpolations Control
loops, positioning control loops, continuous loops, incremental and absolute system,
computer control concepts, CNC and DNC system.
Advanced Topics in FMS (4)
Components of FMS, FMS planning, automated work piece –handling, layout, cost
feasibility typical application and emerging areas: Automated factory, remote control,
analytical models of FMS: CANQ, deterministic models, petrinets.

Unit III
Computer Integrated Manufacturing (CIM)
(8)
Computer application in manufacturing automation and Robotics, Robot programming,
computer aided inspection and quality control. Computer integrated production
management system, inventory, material requirement planning, manufacturing resource
planning, enterprise resource planning

Unit IV
Rapid Prototyping and Rapid Tooling
(8)
Methods of rapid prototyping: steriolithography, Laminated Object Manufacturing
(LOM), Fused Deposition Modeling (FDM), selective laser sintering, solid ground
curing, 3D Printing system, Application of rapid tooling methods to press tool
manufacture.

Unit V
Group Technology (4)
Part families, part classification and coding, Cell formation techniques, production flow
analysis; machine cell Design, cellular Manufacturing systems.
Computer Applications In Engineering Analysis (4)
Finite Element analysis, concept, mesh generation, elements. Examples of static, thermal
and vibration analysis, graphical analysis.

Unit VI
CIM Models (4)
Introduction, ESPRIT – CIM OSA Model, The NIST – AMRF Hierarchical Model, The
Siemens Model of CIM, The CIM model of Digital Equipment Corporation, IBM concept
of CIM, Present Scenario, Rapid Product Development and Manufacture, Extended
Enterprises.
Concurrent Engineering (4)
Sequential engineering versus Concurrent engineering, Mathematical model for
understanding between design and manufacturing, concurrent engineering techniques,
Characterization of the CE environment.

Term Work:
The term work shall consist six assignments on following topics
1. Construction of parametric solid model of any machine elements using software
package.
2. Programming on CNC machine.
3. Programming on Robot application.
4. Flexible Manufacturing System.
5. Manufacturing resource planning.
6. Simulation of a simple mechanical system.

Text Books:
1. T. K. Kundra, P. N Rao, N. K. Tiwari, “Numerical control and Computer aided
manufacturing”, Tata McGraw Hill 1992, ISBN 0-07-451740-6.
2. Ibraim Zeid, “Mastering CAD/CAM” – Tata McGraw Hill Publishing Co. 2000,
ISBN 0-07-072857-7.
3. Nanua Singh, “System Approach to Computer Integrated Design and
Manufacturing”, John Wiley (1996), ISBN 0-471-58517-3.
4. P.Radhakrishanan, S. Subramanium, V. Raju, “CAD /CAM / CIM”, New Age
International Pvt. Ltd. New Delhi, ISBN 81-224-1248-3.

Reference Books:
1. Mikel P.Groover, Emory W. Zimmers, “Computer aided design and
manufacturing”, Prentice Hall India Ltd. 2000, ISBN 81-203-0402-0.
2. Paul C. Bave, “CAD principles and applications”.
3. Mikell P. Groover, “Automation, Production systems and Computer Integrated
Manufacturing”, Prentice Hall of India Pvt. Ltd. 1999, ISBN 81-203-0618-X.
4. D. F. Rogers, “Procedural elements for computer graphics”, TMH Book Co. New
Delhi 2004, ISBN 0-07-047371-4.
5. Harrrington Steven ‘ Computer graphics- a programming approach’, McGraw
Hills Inc. 2003, ISBN 0-07-100472-6.
6. T R Chandrupatla, A D Belegundu, “Introduction to finite elements in
engineering”, Prentice Hall of India 2003, ISBN 81-203-2106-5.
7. L J Segerund, “Applied finite elements analyses”, John Wiley and Sons.
8. K J Bathe, “Finite element procedures”, Prentice Hall of India 2001, ISBN 81-
203-1075-6.
9. V Ramamurti, “Computer aided mechanical design and analysis”, Tata McGraw
Hill Pub. Co. New Delhi 1987, ISBN 0-07-463352-X.

411090: ROBOTICS - ELECTIVE-II

Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To study and understand Robots
• To learn Robot applications in Manufacturing
Prerequisites
• Manufacturing Automation and Control

Unit I
Basic concept in Robotics (4)
Automation and robotics, robot anatomy, basic structure of robots, resolution, accuracy
and repeatability.
Classification and structure of robotics system (4)
Point to point and continuous path system control loops of robotics system, manipulators,
wrist motions and grippers.

Unit II
Drives and control system (4)
Hydraulic system, DC servo motors, basic control system, concept and models, control
system analysis, robot activation feed back components, positional and velocity sensor,
actuators, power transmission system, robot joint control design.
Robot arm kinematics and dynamics
(4)
The direct kinematics problem, the inversion kinematics solution, Lagrangian –Euler
formation, generalized D’Almbert equations of motion. Denavit Hartenberg convention
and its application.

Unit III
Sensor and Grippers in Robotics (4)
Tactile sensors, proximity and range sensors, force and torque sensors in robotics, design
consideration for gripper, mechanical gripper, vaccum gripper and magnetic grippers.
Vision systems
(4)
Vision equipment, CCD camera image processing, concept of low level and high level
vision, image smoothening and thresholding.

Unit IV
Robot Programming (4)
Methods of robot programming, lead through programming methods, a robot program for
generating a path in space, motion interpolation WAIT, SIGNAL and DELAY
commands, branching capabilities and limitations of lead through methods.
Robot languages (4)
The textual robot language, generation of robot programming language, structure,
constants, variable and other data objects motion commands end effectors and sensor
commands, computations and operations, program control and data monitor mode
commands. Introduction to artificial intelligence.

Unit V
Interfacing (8)
Interfacing robot with PC, handshaking, hardware handshaking, RS232C serial interface.
Robot Applications in Manufacturing: Material transfer and machine loading/unloading
processing, assembly and inspection, welding, concept of safety in robotics, social factors
in use of robots, economics of robots

Unit VI
Introduction of telechirs (8)
Robot walking, one legged robot, Telechiric machines and its application- handling
radioactive materials, work in space, exploration, mining and under water operations,
Telechiric surgery.

Text Books:
1. S. R. Deb. “Robotics”, Tata McGrawHill Publishing Co. Ltd., ISBN 0-07-460090-
7.
2. Yoren Koren, “ Robotics for Engineers”, McGraw Hill Book Co., ISBN 0-07-
035341-7.
3. M. P. Grover, M. Weiss, R. N. Nagel, N. G. Odrey, “Industrial Robotics
Technology”, ISBN 0-07-100442-4.
4. K. S. Fu, C. G. S. Lee, R. C. Gonzaler, “Robotics Control, Sensing, Vision and
Intelligence”, Tata McGraw Hill, ISBN 0-07-100421-4.

Reference Books:
1. H. Asada John, “Robot analysis and control”.
2. M. W. Thring, “Robots and telechirs”, Ellis Horwood Limited, ISBN 0-85312-
274-1.
3. Hall A. S., “Kinematics and Linkage Dynamics”, Jr. Prentice Hall.
4. J. Hirchhorn,, “Kinematics and Dynamics of Machinery”, McGraw Hill Book
Co.
5. Kafler, “Robotics Engineering”, Prentice Hall India Pvt. Ltd., ISBN 81-203-
0842-5.
6. Jankiraman, “Image Processing and Analysis”

411090: ERGONOMICS AND HUMAN FACTORS IN ENGINEERING

ELECTIVE-II
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Ergonomic aspects in Engineering
• To study the effect of Human Factors in Engineering
Prerequisites
• Industrial Engineering and Management
• Production Management

Unit I
Introduction (8)
Introduction to ergonomics and human factors engineering; physiological basis of human
work, biomechanics; psychology of work and work load perception; physical work
environment, basis of ergonomic problem identification, work and rest cycle.

Unit II
Anthropometry (8)
Anthropometry - Need, Important Body Dimensions, Data Collection, Statistical
Analysis.
Applied Anthropometry - Work design and Work Space Layout, physical space and
arrangement, design of MMH task.

Unit III
Environmental factors in design (4)
Atmospheric conditions: Heat, cold and humidity.
Noise: Measurement of sound Noise exposure and hearing loss and reduction of noise.
Effects of noise, heat, cold on human performance.
Illumination and contrast (4)
Concept of visibility, Effects of lighting on performance, glare, luminance, luminance
ratio, reflectance, Use of Photometers-Recommended illumination levels, The aging eye
-Use of in directed (Reflected) lighting - Cost efficiency of illumination-Special purpose
lighting for illumination

Unit IV
Design of systems (8)
Control: Types, control response ratio, Work place-Seating/Standing- Work process-
Duration of rest periods-Hand tool design-Design of visual display-design for shift work,
design considerations for knobs, foot and pedals, special control devices.

Unit V
Work Philosophy (8)
Provision of energy for muscular work-Full body, localised and static. Physical exertion
Measurement of energy expenditure and oxygen consumption, learning curves.
Respiration – Pulse rate and blood pressure during physical work-Physical work capacity
and its evaluation. Human factors applications in system design.
Unit VI
Advanced Time and Motion Study
(8)
Predetermined Motion Time Analysis (PMTS) Method Time Analysis (MTA), work
factor system (WFS), method time measurement (MTM-1, MTM-2, MTM-3), Maynard’s
operation sequence technique (MOST),

Text Books:
1. ILO, “Introduction to work-study”, Universal Publishing Company, ISBN 81-
8502700-4.
2. M.S. Saunders, EJ McCormick, “Human Factors Engineering and Design”,
McGraw Hill.
3. Maynard, Industrial Engineering Handbook.

References Books:
1. Curie R M Faraday, “Work study”, The English Language Book Society, ISBN 0-
273-00959-1.
2. M. S. Sanders and Ernest J. McCormick, “Engineering and Design”
3. E Grad, “Fitting Task to the Man”, McGraw Hill.
4. Grandjean E, “Fitting the Task to the man”, Taylor and Francis London.
 411090: ADVANCED MATERIAL PROCESSING
ELECTIVE II
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Advanced Manufacturing Processes
Prerequisites
• Engineering Metallurgy-I
• Manufacturing Processes-II

Unit I
Advanced machining processes and tools (8)
Recent developments in tool materials, Special machining processes like dynamic turning
oscillating turning and drilling, hard turning, ultrasonic vibration assisted machining,
modern techniques in grinding operations and grinding wheels, high productivity
machining such as high speed machining.

Unit II
Advances in non-conventional machining processes
(8)
Rotary ultrasonic machining, ultrasonic impact grinding, electrochemical grinding and
honing, electric discharge grinding, wire cut EDM, shaped tube electrolytic machining
(STEM), thermal energy method. Chemical Milling (CM), Photochemical Machining.

Unit III
Advanced Forming processes
(4)
Ring rolling, roll forming, high energy rate forming, flow forming forging of stainless
steel and heat resisting alloys Developments in hydro forming. Auto-for-cast processes.
Impact extrusion
Advanced Forging Processes
(4)
Radial forging, orbital forging, isothermal and hot die forging, precision forging, powder
forging, magneto forging.

Unit IV
Advanced Casting Processes
(8)
Injection casting, No-flask. Casting, continuous casting- Reciprocating mould processes,
Asarco process, Brass mould process and direct chill process.

Unit V
Processing of Plastic, Ceramics, Glass
(8)
Different methods like casing, moulding, forming, Process equipment, joining, Printing.
Simulation and fault prediction. Processing of mushy materials. Ceramic shell process.
Master mould casting.

Unit VI
Surface cleaning and coating
(8)
Different cleaning methods, Metal coating, electro plating, ceramic coating, polymer,
paint coating Nano surface machining, MEMS fabrication, photo electrical polishing,
LIGA technique for fabrication.

Text Books:
1. A.Ghosh, A. K. Mallik, “Manufacturing science”, East-West Press Private
Limited, ISBN 81-85095-85-X
2. V. K. Jain, A. Ghosh, “Advances in Non-Traditional Machining”, ISBN 0-07-
096553-6
3. P. C. Pandey, H. S. Shan, “Modern Machining Processes”, Tata McGraw hill
publication.

Reference Books:
1. “Metal Handbook”, 9th Edition. Vol-14 Forging and Forming Processes, ISBN 0-
87170-020-4
2. “Metal Handbook”, 9th Edition. Vol-16 Machining.
3. J. Delmonte, “Plastic Molding”, John Wiley 8th Edition.
4. Marc Madou, “Fundmentals of Micro Fabrication”, CRC press.
5. B.H. Amstead, Phillip F Ostwald and Myron L Begeman., “Manufacturing
Processes”, John Wiley and Sons. (8th Edition), ISBN 0-471-85403-4
6. C.D. Varghese, “Electroplating and other surface treatments”, Tata McGraw hill
publication.
 411090: ADVANCED PRODUCTION TECHNOLOGY
ELECTIVE II
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Advanced Manufacturing Techniques
Prerequisites
• Design of Machine Elements
• Production Management

Unit I
System design for product:
Basic concepts of a system and application in engineering design, definition and
systematic steps / methodology for a design, morphology of design and feasibility
analysis, design based on characteristics attributes of product : viz strength , surface
topography , dimensional tolerances and customer preferences.

Unit II
Design synthesis and analysis:
Design synthesis and functional analysis of design, quality function deployment (QFD) in
design, design based on reliability, probabilistic design against traditional design, form
design, ergonomic design, etc

Manufacturing process selection for the product:

Basic and advanced manufacturing processes for quality production, process capability
and its relationship to design tolerances and selection of processes

Unit III
Productivity basics:
Concern and the significance of productivity management, the rationale of productivity
measurement, productivity verses production, profitability, financial statements, quality,
and technology
Productivity measurement models:
Concepts of productivity, review of models of productivity measurement, a chronological
review of development of various models, a critical appraisal of various approaches
Unit IV
Productivity measurement:
Objectives of productivity measurement, management by objectives (MBO) and
productivity measurement, system approach to productivity measurement, performance
objectives- productivity (PO-P)- the concept, its model and methodology, setting of
performance objectives of (PO-P), objectivated output, productivity measurement in a
small scale industries, productivity measurement in a medium scale industries,

Unit V
Productivity measurement:
Productivity measurement in large-scale industries, goal programming formulations,
productivity indices calculations, identification of areas for improvement,
Productivity measurement in service sector:
Need for measuring productivity in service sector, difficulties in measuring productivity
in service sector, productivity of an R & D system, productivity of and educational
institutions productivity of higher educations system.

Unit VI
The role of external environment on productivity measurement:
External environment and organization, impact of external environment, external
environment and its subsystems, approaches to measure impact of external environment,
concept of upper bound productivity.

Productivity management and implementation strategies:

Productivity measurement system, productivity policy, productivity; measurement and its
evaluation, productivity improvement strategies, productivity audit and control.

References
1. Nash Ben, “Design of marketable products”, McGraw Hill Publications
2. N. Cron, “Engineering design methods” 1994, Jon Wiley New York.
3. W. D. Cane, “Engineering Product Design”, Business Book Ltd.
4. Praem Vrat, G D Sardana, B S Sahay, “Productivity management, A system
approach” Narosa publishing house.

411090: ADVANCED PRODUCTION TECHNOLOGY

ELECTIVE II
Teaching Scheme Examination Scheme
Lectures: 4 hrs/week Theory: 100 Marks
Duration: 3 hours
Objectives
• To learn and understand Advanced Manufacturing Techniques
Prerequisites
• Design of Machine Elements
• Production Management

Unit I
Toyota Production Systems
Key features of Toyota’s Strategy, The philosophy of Toyota Production System, Basic
Frame work of TPS, Kanban System, Production Smoothing in TPS, Adaptability to
demand fluctuations. Framework of the information system supporting Kanban,
Shortening Lead times in TPS, Automation in TPS. Comparison of Toyota with other
manufacturers.

Unit II
Issues in the design of Competitive Manufacturing systems Benchmarks and Best
practices
Concept of Benchmarking, Bench marking process, Findings of Benchmarks, making the
comparison, comparative data for world class and typical performance, Bottlenecks – A
dynamic view. Performance metrics Definition, concept and issues in Lean
manufacturing and Agile Manufacturing Green Manufacturing: Definition, concept and
issues

Unit III
Simulation and Artificial Intelligence in Manufacturing
Definition of Artificial Intelligence, AI Knowledge based expert systems in
Manufacturing, logical rules and decision-making in AI. Inference engine.

Virtual Manufacturing
Concept and issues and importance of Virtual Manufacturing
Enter Prise Wide Integration: Concept and levels.

Text Books:
1. M.G. Korgaonkar, “Just in time manufacturing”, Macmillan India Limited,
2. M.P Chowddiah, Gopinath Gargesa, V. Arunkumar., “Agile Manufacturing”, Tata
McGraw Hill Publishing Copmany Ltd.,
3. Nauna Singh, “System Approach to Computer – Integrated Design and
Manufacturing”, John Willey and Sons,
Reference Books:
1. J.M Juran, Gryna Frank M , “Quality Planning and Analysis”, Tata McGraw Hill
Publishing Copmany Ltd.
2. B.H Amstead., Ostwald Phillip F. and Begeman Myron L., “Manufacturing
Processes”, John Wiley and Sons. (8th Edition)