Industrial Engineering & Management 6th Semester Syllabus

Download INDUSTRIAL ENGINEERING AND MANAGEMENT Scheme 2010 [PDF File]
Download INDUSTRIAL ENGINEERING AND MANAGEMENT Syllabus 2010 [PDF File]

MATERIALS MANAGEMENT
Subject Code : 10IP /IM 61

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION: Dynamics of Materials Management – Materials Management at Micro-level, Materials Management at Macro-level, Inventories of Materials, Total Concept-Definition – A Brief History of Development: An Overview. SYSTEMS APPROACH TO MATERIALS MANAGEMENT: Systems Approach – The Process of Management and the Materials Function, Interfaces, An Overview of the Systems Concept, Benefits of the Integrated Systems Approach.
6 Hours

UNIT – 2
FORECASTING Objectives and the Materials Organization: Systems Design, Integral Control of the Flow of Materials, Forecasting and Planning, Forecasting Methods, Objectives of Materials Management – Organization of Materials Management, Environmental Change, Functional Organization Model for Materials Management.
MATERIALS PLANNING: Making the Materials Plan Work, The Materials Cycle and Flow Control System, Materials Budget.


6 Hours

UNIT – 3
PURCHASING: Purchasing Principles, Procedures and Practices, Fundamental Objectives of Purchasing – Scope, Responsibility and Limitations, Sources of Supply and Supplier Selection, Purchasing Policy and Procedures – Purchase Budgets and Statistics.
PURCHASING IN MATERIALS MANAGEMENT SYSTEM CONCEPT: Price Determination, Price Forecasting, Price-Cost Analysis, The Learning Curve, Negotiation, Reciprocity, Cost-Plus Contracts, Hedging, Forward Buying, Buying Ethics, Principles and Standards of Purchasing, Make-or-Buy, Information, Documentation and Purchasing Library, Legal Aspects of Purchasing, Law of Agency, Law of Contract, Legal Status of the Buyer, Warranties and Conditions, Right of Inspection, Right of Rejection, Vendor-Vendee Relations, Vendor Development, Vendor Rating. 8 Hours

UNIT- 4
PURCHASING AND PROCUREMENT Activities under Materials Management: Supplier Quality Assurance Programme, Buyer-Supplier Relationship.
INCOMING MATERIAL QUALITY CONTROL: Significance of Inspection, Purchase Inspection, Sampling Inspection, Sampling Technique, Different Types of Population, Different  Types of Sampling, Risks of Sampling.SQC in Operation: A Work-site Problem Study.
6 Hours

PART – B

UNIT – 5
PURCHASING CAPITAL Equipment, Plant and Machinery: Responsibility and Decision, Purchasing v/s Leasing, International Buying, Import Purchasing, and Governmental Purchasing: Industrial Needs, Import Procedure and Documents, Classification of Stores- Categories of Importers-Import Application, Basis of Licensing, Import Purchasing Procedures, Letter of Credit, Income-Tax Clearance, Customs Tariff-Registration of Licenses at Port. Governmental Purchasing: Policy and Procedures, Tenders, Inspection of Articles.
6 Hours

UNIT-6
REGISTRATION of Firms, Procedure for Registration, Terms of Registration, Removal of the Firms from the List, Blacklisting of Firms, Banning of Firms, Suspension of Firms, Purchases of the Stores by the DGS&D – Surplus Disposals by the DGS&D, Pre-disposal Inspection of Surpluses.
Inventory Management and Control Systems: Definition of Inventories, The Need for Inventory Audits Control, Types of Inventories, Inventory Control, Max-Min System, Inventories and Demand Uncertainty, Determining Safety Stock. 7 Hours

UNIT – 7
INVENTORY MODELS: Deterministic Inventory Models with numerical examples, Q-system or Quantity Control System or Re-order Point System- Effect of Quantity Discounts, P-system or Periodic Review or Periodic Count System or Replenishment System, Optional Replenishment System or “S, s” Policy, ABC Inventory Classification (Selective Inventory Control – SIC). The Need for a Systems Approach, Materials Planning System (MPS)/Materials Requirement Planning (MRP), Basic Tool.
7 Hours

UNIT – 8
STORES MANAGEMENT AND OPERATION: Storage System, Stores Location and Layout, Development of Storing, Centralization and Decentralization of Stores, Standardization and Variety Reduction, The Systems, Merits and Demerits of Codification.
MATERIALS MANAGEMENT INFORMATION SYSTEM AND COMPUTER: MIS – Management and MM, Computer System for MIS and MM, In-process Materials and Management Control.
6 Hours

Text Book:

  • 1. Materials Management – A.K. Datta – PHI Pvt. Ltd, New Delhi – 2001.
  • 2. Operations Research – S.D. Sharma – Kedarnath, Ramnath & Co – 1996.

Reference Book:

  • 1. Handbook of Materials Management – P. Gopalakrishnan – PHI Pvt. Ltd, New Delhi – 2002.
  • 2. Principles of Operations Research Theory and Practice – Philips, Ravindran and Soleberg – Wiley India Pvt Ltd.

HUMAN RESOURCE MANAGEMENT
Subject Code : 10IP / IM 664

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION: Evolution of HRM, Objectives, Functions and Policies.
6 Hours

UNIT – 2
HUMAN RESOURCE PLANNING: Uses and benefits, Man Power Inventory, Man Power Forecasting, Methods of Man Power Forecasting, job Description, Job Specification
7 Hours

UNIT – 3
RECRUITMENT: Sources of Man power, Advertisement, Short Listing of Candidates calling Candidates for selection Process.
6 Hours

UNIT – 4
SELECTION: Selection procedure – Written Test, Group Discussion. Interview – Different methods, advantages and limitations, Psychological testing – Advantages and limitations, Induction procedure, transfers, promotion, exit interview, (Tutorial on written test, Group Discussion, Interviews)
7 Hours

PART – B

UNIT – 5
TRAINING AND DEVELOPMENT: Identification of Training needs, Training Evaluation, Training Budget, Executive Development – Different Approaches, Non-executive development – Different methods.
7 Hours

UNIT – 6
PERFORMANCE APPRAISAL: Components (all round performance appraisal), Methods. Advantages and limitations of different methods, Personal Counselling based on Annual Confidential Reports.
7 Hours

UNIT – 7
COUNSELLING AND HUMAN RESOURCE ACCOUNTING: Characteristics, Need, Function, Types, Suggestions for personnel development, communication function, communication process, effective communication. Human resource records, Advantages of HR accounting, Various methods of accounting.
6 Hours

UNIT – 8
INDUSTRIAL RELATIONS: Indian trade union act, standing orders act, Indian factories act,
INDUSTRIAL DISPUTES AND SETTLEMENT: Indian Industrial Disputes act, Industrial disputes settlement machinery. Works committee, Board of Conciliation, Voluntary Arbitration, Compulsory arbitration, Court of inquiry, Industrial tribunal, Adjudication.
6 Hours

TEXT BOOKS

  • 1. Human Resources Management – Dr. K Ashwathappa – Tata McGraw Hill – Edition 1999.
  • 2. Management of Human Resources – CB Mamoria – Himalaya Publication House – 2003.

REFERENCES BOOKS:

  • 1. Personnel / Human resource Management – Decenoz and robbins – PHI – 2002
  • 2. Industrial Relations – Arun Monappa – TMH – ISBN – 0-07- 451710-8.
  • 3. Human Resources Management – VSP Rao
  • 4. Human Resources Management – Ravi Dharma Rao

OPERATIONS RESEARCH
Subject Code : 10IP/IM 63

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION: OR Methodology, Definition of OR, Application of OR to Engineering and Managerial Problems, Features of OR models, Limitation of OR. Models of OR.
LINEAR PROGRAMMING: Definition, Mathematical formulation.
6 Hours

UNIT-2
LINEAR PROGRAMMING Standard form, solution space, Solution – Feasible, basic feasible, Optimal, Infeasible, Multiple, Optimal, Redundancy, Degeneracy. Graphical Method
6 Hours

UNIT -3
LINEAR PROGRAMMING: Simplex method, variants of simplex algorithm – Artificial basis techniques, Duality, Economic interpretation of Dual, Solution of LPP using duality concept, Dual simplex method.
7 Hours

UNIT – 4
TRANSPORTATION PROBLEM: Formulation of transportation model, Basic feasible solution using different methods (North-West corner, Least Cost, Vogel’s Approximation Method) Optimality Methods. Unbalanced transportation problem, Degeneracy in transportation problems, Variants in Transportation Problems, Applications of Transportation problems.
7 Hours

PART – B

UNIT – 5
ASSIGNMENT PROBLEM: Formulation of the Assignment problem, unbalanced assignment problem, travelling salesman problem
6 Hours

UNIT – 6
QUEUING THEORY: Queuing system and their characteristics, The M/M/1 Queuing system, Steady state performance analysing of M/M/1 queuing model. M/M/K/ Model
6 Hours

UNIT – 7
PROJECT MANAGEMENT USING NETWORK ANALYSIS: Network construction, determination of critical path and duration, CPM Structured approach, Calculations of schedules and floats, Network crashing. PERTEstimation of project duration and variance.
8 Hours

UNIT -8
GAME THEORY: Formulations of games, Two person zero sum game, games with and without saddle point, graphical solutions (2xn, mx2 game), dominance property. Solution of game through LPP.
6 Hours

TEXT BOOKS:

  • 1. Introduction to Operation Research -Taha H A – Prentice Hall of India – 6th edition, 1999.
  • 2. Principles of Operations Research theory and Practice -Philips, Ravindran and Soleberg – Wiley India Pvt Ltd.

REFERENCE BOOKS:

  • 1. Introduction to Operation Research -Hiller and Libermann – McGraw Hill – 5th edn.
  • 2. Operations Research -S.D. Sharma – Kedarnath, Ramnath & Co – 1996
  • 3. Operations Research Theory and Application – J K Sharma – Pearson Education Pvt Ltd – 2nd Edn, ISBN-0333-92394-4.

SIMULATION MODELLING AND ANALYSIS
Subject Code : 10 IM 64

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION TO SIMULATION: Simulation, advantages & disadvantages, Areas of application, System environment, Components of a system, Model of a system, Types of models, Steps in a simulation study.
6 Hours

UNIT – 2
SIMULATION EXAMPLES: Simulation of Queuing systems, Simulation of Inventory System, Other simulation examples.
6 Hours

UNIT – 3
GENERAL PRINCIPLES: Concepts in discrete – events simulation, event scheduling / Time advance algorithm, simulation using event scheduling.
6 Hours

UNIT – 4
RANDOM NUMBERS: Properties, Generations methods, Tests for Random number- Frequency test, Runs test, Auto correlation test, Gap test, Poker test 6 Hours

PART – B

UNIT – 5
RAMDOM VARIATE GENERATION: Inverse Transform Technique- Exponential, Uniform, Weibull, Triangular distributions, Direct transformation for Normal and log normal Distributions, convolution methods- Erlang distribution, Acceptance – Rejection Techniques – Poisson Distribution, Gamma Distribution.
7 Hours

UNIT – 6
ANALYSIS OF SIMULATION DATA: Input Modelling: Data collection, Identification and distribution with data, parameter estimation, Goodness of fit tests, Selection of input models without data, Multivariate and time series analysis
Verification and Validation of Model – Model Building, Verification, Calibration and Validation of Models.
7 Hours

UNIT – 7
OUTPUT ANALYSIS: Stochastic Nature of output data, Measures of Performance and their estimation, Output analysis of terminating simulation, Output analysis of steady state simulations
7 Hours

UNIT – 8
OPTIMISATION VIA SIMULATION: Meaning, difficulty, Robust Heuristics, Random Search
APPLICATIONS
Simulation of Manufacturing and Material Handling Systems, Simulation of Computer Systems, Simulation of Plant Layout, Simulation of Project Management
SIMULATION SOFTWARES
Selection of Simulation Software, Simulation packages, Experiment and Statistical Analysis tool, Trend in Simulation Software
7 Hours

TEXT BOOKS:

  • 1. Discrete Event system Simulation – Jerry Banks, John S Carson, II, Berry L Nelson, David M Nicol – Pearson Education, Asia – III Edition, ISBN – 81- 7808 – 505 – 4.

REFERENCE BOOKS:

  • 1. Systems Simulation with Digital Computer – Narsingh Deo – PHI Publication (EEE), ISBN – 0-87692-028-8
  • 2. Simulation Modelling & Analysis – Averill M Law, W David Kelton – McGraw Hill International Editions – Industrial Engineering series, ISBN – 0-07-100803-9.

SOFTWARE ENGINEERING & MANAGEMENT
Subject Code : 10 IM 65

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
THE PRODUCT AND THE PROCESS: The product – Evolving role of Software, Characteristics, Components, and Applications. The Process – Software process, Models – Linear, sequential, Prototype, RAD, Process Technology, Software Development Life cycle.
6 Hours

UNIT – 2
SOFTWARE PROJECT MANAGEMENT CONCEPTS: The Management Specification, People, Problem, Process, project
6 Hours

UNIT – 3
SOFTWARE PROJECT PLANNING: Objectives, Scope, Resource, Project estimation, Décomposition Techniques, Empirical Estimation Models. Make-buy decision, Automated estimation tools.
7 Hours

UNIT – 4
RISK MANAGEMENT: Reactive v/s Proactive Risk Strategies, Software Risks, Risk identification, Risk projection, Monitoring.
6 Hours

PART – B

UNIT – 5
SOFTWARE PROJECT SCHEDULING AND TRACKING: Basic concepts, defining a task set selection, Defining Scheduling, Project Plan
SOFTWARE QUALITY ASSURANCE: Quality assurance concept, Cost impact of software defects, Technical review, statistical Quality assurance, software reliability, ISO 9000 Quality standards.
6 Hours

UNIT – 6
SYSTEM ANALYSIS CONCEPT AND PRINCIPLES: Requirement analysis, Principles, software prototyping, specifications, Data Modelling, Functional Modelling and Information Flow, Structured Analysis, Data Dictionary.
7 Hours

UNIT – 7
SYSTEM DESIGN CONCEPTS AND PRINCIPLES: Design Process Concept, Modular design, Documentation Design Methods, Data Design, Interface Design, Procedural Design, Design for Real Time Systems, System, Considerations in Real Time systems, Analysis and Simulation of Real Time Systems.
6 Hours

UNIT – 8
SOFTWARE TESTING: Objectives, Principles, Testability SOFTWARE QUALITY AND RELIABILITY: Introduction, Software failure modes, software structure and modularity, language, Data reliability, Fault tolerance, software checking and software testing.
OBJECT ORIENTED CONCEPT AND PRINCIPLES: Object Oriented Concepts, Identifying the elements of an object model, Examples.
8 Hours

TEXT BOOK:

  • 1. Software Engineering – Pressman – Computer Science Series – TATA McGraw-Hill Publications – 6th edition.
  • 2. Software Engineering – Shooman – TATA Mc Graw Hill Publications – 6th Edn.

REFERENCE BOOKS:

  • 1. Software Engineering – Somerville – Pearson Education, Delhi – 2001.

CAD/CAM LAB
Subject Code : 10IPL /IML 67

IA Marks : 25
Exam Marks : 50

Refer Syllabus Copy

SIMULATION LAB
Subject Code : 10IML 68

IA Marks : 25
Exam Marks : 50

Refer Syllabus Copy [PDF File]

Elective I (Group – A)
VALUE ENGINEERING
Subject Code : 10IP / IM 661

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION TO VALUE ANALYSIS: Definition of Value, Value Analysis, Value Engineering, Value management, Value Analysis versus Value Engineering, Value Analysis versus Traditional cost reduction techniques, uses, applications, advantages and limitations of Value analysis. Symptoms to apply value analysis, Coaching of Champion concept.
6 Hours

UNIT – 2
TYPE OF VALUES: Reasons for unnecessary cost of product, Peeling cost Onion concept, unsuspected areas responsible for higher cost, Value Analysis Zone, attractive features of value analysis. Meaning of Value, types of value & their effect in cost reduction. Value analysis procedure by simulation. Detailed case studies of simple products.
7 Hours

UNIT – 3
FUNCTIONAL COST AND ITS EVALUATION: Meaning of Function and Functional cost, Rules for functional definition, Types of functions, primary and secondary functions using verb and noun, Function evaluation process, Methods of function evaluation. Evaluation of function by comparison, Evaluation of Interacting functions, Evaluation of function from available data, matrix technique, MISS technique, Numerical evaluation of functional relationships and case studies.
7 Hours

UNIT – 4
PROBLEM SETTING & SOLVING SYSTEM: A problem solvable stated is half solved, Steps in problem setting system, Identification, Separation and Grouping of functions. Case studies.
PROBLEM SETTING & SOLVING SYSTEM: Goods system contains everything the task requires. Various steps in problem solving, case studies.
6 Hours

PART – B

UNIT – 5
VALUE ENGINEERING JOB PLAN: Meaning and Importance of Value Engineering Job plan. Phases of job plan proposed by different value engineering experts, Information phase, Analysis phase, Creative phase, Judgement phase, Development planning phase, and case studies. Cost reduction programs, criteria for cost reduction program, Value analysis change proposal. 6 Hours

UNIT – 6
VALUE ENGINEERING TECHNIQUES: Result Accelerators or New Value Engineering Techniques, Listing, Role of techniques in Value Engineering, Details with Case examples for each of the Techniques.
6 Hours

UNIT – 7
ADVANCED VALUE ANALYSIS TECHNIQUES: Functional analysis system technique and case studies, Value Analysis of Management Practice (VAMP), steps involved in VAMP, application of VAMP to Government, University, College, Hospitals, School Problems etc., (service type problems).
TOTAL VALUE ENGINEERING: Concepts, need, methodology and benefits. 8 Hours

UNIT – 8
APPLICATION OF VALUE ANALYSIS: Application of Value analysis in the field of Accounting, Appearance Design, Cost reduction, Engineering, manufacturing, Management, Purchasing, Quality Control, Sales, marketing, Material Management Etc., Comparison of approach of Value analysis & other management techniques. 6 Hours

TEXT BOOKS:

  • 1. Techniques of Value Analysis and Engineering – Lawrence D. Miles – McGraw Hill Book Company – 2nd Edn.
  • 2. Value engineering for Cost Reduction and Product Improvement – M.S. Vittal – Systems Consultancy Services – Edn. 1993
  • 3. Value Management, Value Engineering and Cost Reduction – Edward D Heller – Addison Wesley Publishing Company -1971.

REFERENCE BOOKS:

  • 1. Value Analysis for Better Management – Warren J Ridge – American Management Association – Edn 1969
  • 2. Getting More at Less Cost (The Value Engineering Way) – G.Jagannathan – Tata Mcgraw Hill Pub. Comp – Edn 1995.
  • 3. Value Engineering – Arther E Mudge – McGraw Hill Book Comp.- Edn 1981.

THEORY OF METAL FORMING
Subject Code : 10IP / IM 662

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
BASICS OF PLASTIC DEFORMATION: Concept of true stress and true strain. Flow stress and strain hardening. State of stress (both biaxial and triaxial). Normal and shear stresses on a inclined plane. Principal stresses and maximum shear stress. Tresca’s and Von-Mise’s yield criteria and yield surface. 07 Hours

UNIT – 2
INTRODUCTION TO METAL FORMING: Classification of forming processes. Importance of temperature in metal forming. Hot and cold working. Effect of strain rate. Friction and its role in metal forming. Influence of metallurgical structure and hydrostatic stress in metal forming. Different methods of analysis of metal forming. 06 Hours

UNIT – 3
FORGING PROCESS: Open-die and close-die forging processes. Different types of forging operations. Brief description of the forging machines, equipments and heating furnaces. Slab analysis of upset forging of rectangular slab under plane strain condition and upset forging of circular disc. Forging load calculation. Common forging defects 06 Hours

UNIT – 4
ROLLING OF METALS: Flat rolling and section rolling. Different types of rolling mills. Geometrical considerations in rolling. Role of friction in rolling and neutral point location. Simplified methods for calculating rolling load, torque and power required for rolling. Effect of back and front tension on rolling force. Elastic deformation of rolls, its effect and controlling methods. Residual stresses in rolling and common rolling defects 07 Hours

PART – B

UNIT – 5
EXTRUSION: Types of extrusion processes. Metal flow pattern in extrusion. Extrusion dies and other equipments used. Extrusion of hollow sections. Slab analysis of extrusion of strips and circular sections and calculation of force and power required for extrusion. Common extrusion defects.
07 Hours

UNIT – 6
DRAWING OF RODS, WIRES AND TUBES: Drawing equipments and dies. Tandem drawing of wires. Analysis of rod or wire drawing and calculation of draw force and power required. Maximum possible reduction in drawing. Tube drawing using different types of mandrels, residual stresses and defect in drawn products. 07 Hours

UNIT – 7
SHEET METAL WORKING: Classification of sheet metal working and equipments used, Blanking and Piercing operation – Die design, cutting force required, slitting, trimming and shaving operations
Bending operation – Types of bending. Bend angle, bend radius, bend allowance and force required for bending. Springback effect in bending. Roll bending process. Brief description of spinning and stretch forming processes.
06 Hours

UNIT – 8
SHEET METAL DRAWING: Process, Die design, Number of draws required, Blank size calculation, and drawing force necessary. Drawability and defects in drawn products.
HIGH ENERGY RATE FORMING (HERF): Introduction to the process and brief description of Explosive forming, Electro discharge forming, and Electromagnetic forming. 06 Hours

TEXT BOOKS:

  • 1. Mechanical Metallurgy – Dieter G.E – McGraw Hill publication.
  • 2. Fundamentals of Metal Forming Processes – Juneja B.L – New age International
  • 3. Principle of Industrial Metal Working Processes – Rowe Edward – CBS Publication

REFERENCE BOOKS:

  • 1. Materials and Processes in Manufacturing – E.Paul, DeGarmo etal – PHI publication.
  • 2. Fundamentals of Working of Metals – Sach G. – Pergamon press.

FINITE ELEMENT METHOD
Subject Code : 10IP / IM 663

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION TO FEM: Need for use of FEM – Advantages and Disadvantages of FEM Matrix algebra – Terminologies relating to matrices, methods of solution of linear algebraic equations. Eigen values and eigen vectors, Simple numeric Gaussian Quadrature – 1 pt. 2pt and 3pt formula.
7 Hours

UNIT – 2
BASIC OF THEORY OF ELASTICITY: Definition of stress and strain, stress-strain relations; strain-displacement, Relations in 2D and 3D Cartesian and Polar coordinates.
6 Hours

UNIT – 3
CONTINUUM METHODS: Variational methods Raleigh-Ritz method applied to simple problems on axially loaded members cantilever. Simply supported and fixed beam with point loads and UDL Galerkin method as applied to simple elasticity problem.
7 Hours

UNIT – 4
FEM- BASIC DEFINITIONS: Displacement method, Nodal degrees of freedom, different coordinate systems shape functions. Lagrangian polynomial; complete formulation of bar-truss-beam-triangular-quadrilateral Tetrahedral hexahedral elements.
6 Hours

PART – B

UNIT – 5
BOUNDARY CONDITIONS: SPC and MPC. Methods of handling boundary conditions eliminating method-penalty method. Simple numerical, ISO parametric sub parametric super parametric elements Convergence criteria – requirements of convergence of a displacement model.
7 Hours

UNIT – 6
HIGHER ORDER ELEMENTS: Bar – triangular-quadrilateral elements. Tetrahedral and hexahedral elements (non-Formulation) – Pascal triangle – Pascal pyramid. Introduction to axis symmetric problems-formulation of axis symmetric triangular element.
7 Hours

UNIT – 7
DYNAMIC ANALYSIS: Formulating-element mass matrices for 1D and 2D element, computation of Eigen value and vector for simple one Dimensional analysis.
6 Hours

UNIT – 8
One dimensional steady state heat conduction. Formulation of 1D element simple numerical using 1D element. Structure of a commercial FE package. Pre-processor. Solver post processor.
6 Hours

TEXT BOOKS:

  • 1. Finite Element Method – J.N.Reddy – Tat McGraw Hill – edition 2002.
  • 2. Introduction to Finite elements in engineering – Chandraupatla and Belegundu – Pearson edn – 2002.

REFERENCE BOOKS:

  • 1. A First course in Finite Element methods – Daryl.L.Logon – Thomson Learning – 3rd edition, 2001.
  • 2. Fundamentals of Finite Element method – Hutton – Mc Graw Hill – 2004.
  • 3. Concepts & applications of FEA – Robert Cook et,al – Jonh willey & sons – 2002.
  • 4. Finite element analysis – Chandrupatla – University press – 2002.
  • 5. Theory and Practice of Finite elements – Alexandre ERN – I K International Publishing house Pvt. Ltd – 2004.

QUALITY ASSURANCE AND RELIABILITY
Subject Code : 10IP/IM 62

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION: Definition of Quality, Quality function, Dimensions of Quality, Quality Engineering terminology, Brief history of quality methodology, Statistical methods for quality improvement, Quality costs – four categories of costs and hidden costs. Brief discussion on sporadic and chronic quality problems. Introduction to Seven QC tools.
6 Hours

UNIT – 2
STATISTICAL PROCESS CONTROL: Introduction to statistical process control – chance and assignable causes for variation. Basic principles of control charts, choice of control limits, sample size and sampling frequency, rational subgroups. Analysis of patterns of control charts. Case Studies on application of SPC. Process capability – Basic definition, standardized formula, relation to product tolerance and six sigma concept of process capability,
6 Hours

UNIT – 3
PROBABILTY DISTRIBUTION – Hyper Geometric, Binomial, Poisson and Normal distribution.
CONTROL CHARTS FOR VARIABLES: Controls Charts for X Bar and Range (R) , Statistical basis of the charts, Development and use of X bar and R charts, Interpretation of charts. Control charts for X bar and Standard Deviation (S), Development and use of X bar and S chart. Brief discussion on – Pre control X Bar and S control charts with Variable sample size, Control charts for individual measurements, cusum chart, Moving-range charts.
8 Hours

UNIT – 4
CONTROL CHARTS FOR ATTRIBUTES: Control chart for fraction non- conforming (defectives), development and operation of control chart, brief discussion on variable sample size. Control chart for non-conformities (defects) – development and operation of control chart for constant sample size and variable sample size. Choice between variables and attributes control charts. Guidelines for implementing control charts.
7 Hours

PART – B

UNIT – 5
SAMPLING INSPECTION: Concept of accepting sampling, economics of inspection, Acceptance plans – single, double and multiple sampling. Operating characteristic curves – construction and use. Determination of average outgoing quality, average outgoing quality level, average total inspection, producer risk and consumer risk.
7 Hours

UNIT – 6
USE OF PUBLISHED SAMPLING PLANS: Gauge Repeatability & Reproducibility & Measurement system analysis.
STATISTICAL THEORY OF TOLERANCES: Application of statistical theory of tolerances to design tolerances in random assemblies and application in other areas. 6 Hours

UNIT – 7
RELIABILITY AND LIFE TESTING: Failure models of components, definition of reliability, MTBF, Failure rate, common failure rate curve, types of failure, reliability evaluation in simple cases of exponential failures in series, parallel and series-parallel device configurations, Redundancy and improvement factors evaluation. 6 Hours

UNIT – 8
QUALITY ASSURANCE: Definition and concept of quality assurance, departmental assurance activities. Quality audit concept, audit approach etc. structuring the audit program, planning and performing audit activities, audit reporting, ingredients of a quality program. 6 Hours

TEXT BOOKS:

  • 1. Introduction to statistical Quality Control – D C Montgomery – John Wiley and Sons – 3rd Edition.
  • 2. Quality Planning & Analysis – J M Juran, Frank M Gryna – Tata McGraw Hill – 3rd edition,
  • 3. Statistical Quality Control – Grant and Leavenworth – McGraw Hill-6th Edition

REFERENCE BOOKS:

  • 1. The QS9000 Documentation Toolkit -Janet L Novak and Kathleen C Bosheers – Prenctice Hall PTR – 2nd Edition
  • 2. ISO 9000 a Manual for Total Quality Management – Suresh Dalela and Saurabh – S Chand and Co. -1st Edition
  • 3. Total Quality Management – NVR Naidu, KM Babu and G. Rajendra – New Age International Pvt. Ltd – 2006

ADVANCED MACHINING PROCESSES
Subject Code : 10 IM 665

IA Marks : 25
Exam Marks : 100

PART – A

UNIT – 1
INTRODUCTION: History, Classification, Comparison between conventional and non-conventional machining process selection. MECHANICAL PROCESS: Ultrasonic machining (USM) : Introduction, Equipment, tool materials & tool Size, Abrasive slurry, Cutting tool system design : Magnetostriction assembly, Tool cone (Concentrator), Exponential concentrator of circular cross section & rectangular cross section Hallow cylindrical concentrator. Mechanics of cutting : Theory of Miller & Shaw Effect of parameter : Effect of amplitude and frequency and vibration, Effect of grain diameter , Effect of applied static load, Effect of slurry, Tool and work material, USM process Characteristics ; Material removal rate, tool wears, Accuracy, surface finish., Applications, Advantages & Disadvantages of USM.
8 Hours

UNIT – 2
ABRASIVE JET MACHINING (AJM): Introduction, Equipment, Variables in AJM: carrier Gas Type of abrasive, Size of abrasive grain, velocity of the abrasive jet, Mean No. abrasive particles per unit volume of the carrier gas, Work material, stand off distance (SOD) nozzle design shape of cut. Process characteristics – Material removal rate, Nozzle wear, Accuracy & surface finish. Applications, Advantages & Disadvantages of AJM.
6 Hours

UNIT – 3
ELECTROCHEMICAL AND CHEMICAL METAL REMOVAL PROCESS: Electrochemical machining (ECM): Introduction, Study of ECM machine, Elements of ECM process: Cathode tool, Anode work piece, source of DC power, Electrolyte, Chemistry of the process ECM process characteristics – Material removal rate, Accuracy, Surface finish.
6 Hours

UNIT – 4
ECM TOOLING: ECM tooling technique 7 example, Tool &insulation materials, Tool size Electrolyte flow arrangement, Handling of slug., Economics of ECM, Applications such as Electrochemical turning, Electrochemical Grinding, Electrochemical Horning, deburring, Advantages, Limitations. 6 Hours

PART – B

UNIT – 5
CHEMICAL MACHINING (CHM): Introduction, Elements of process Chemical blanking process :- Preparation of work piece. Preparation of masters, masking with photo resists, etching for blanking, applications of chemical blanking, chemical milling (Contour machining) :- Process steps – masking, Etching, process characteristics of CHM :- material removal rate accuracy, surface finish, Hydrogen embrittlement, Advantages & application of CHM.
8 Hours

UNIT – 6
EDM PROCESS: Introduction, machine, mechanism of metal removal, dielectric fluid, spark generator, EDM tools (electrodes) Electrode feed control, Electrode manufacture, Electrode wear, EDM tool design : Choice of matching operation, electrode material selection, under sizing and length of electrode Machining time.
6 Hours

UNIT – 7
EDM PROCESS CHARACTERISTICS: Flushing – Pressure flushing synchronized with electrode movement, EDM process characteristic: Metal removal rate, Accuracy surface finish, Heat affected Zone. Machine tool selection, Application: EDM accessories / applications, electrical discharge grinding, Travelling wire EDM.
6 Hours

UNIT – 8
PLASMA ARC MACHINING (PAM): Introduction, equipment, generation of plasma, Mechanism of Metal removal, PAM parameters, Process characteristics.
LASER BEAM MACHINING & ION BEAM MACHINING: Introduction, metal removal mechanism, advantages and application.
6 Hours

TEXT BOOKS:

  • 1. Modern machining process – PANDEY AND SHAH – TATA Mc Graw Hill -2000.
  • 2. Unconventional Manufacturing process – M K Singh, New age publications, ISBN 978-81-224-2244-3

REFERENCE BOOKS:

  • 1. Production Technology – HMT – TATA McGraw Hill – 2001.
  • 2. Thermal Metal cutting processes – B G Ranganath – I K International Publishing house Pvt. Ltd,
  • 3. Fundamentals of Machining and Machine Tools – R.K.Singal – I K International Publishing house Pvt. Ltd.

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