09ML01 STATISTICS AND RELIABILITY ENGINEERING

vide Computer Integrated Manufacturing 09MC23

09ML02 DESIGN OF LEAN PRODUCTION SYSTEM 3003

INTRODUCTION: Functional areas of firm product design, manufacture, delivery principles of production system role of inventory and information types of waste lean tools. (4) LAYOUT: Types of layout - process layout product layout cell layout performance measure of layouts. (6)

VALUE STREAM MAPPING: The current state diagram - the future state map - application to the factory simulation scenario - line balancing - poke yoke overall equipment effectiveness. (7) JUST IN TIME: Improving the production environment quality engineering improving product flow the transition to lean. (6)

MANUFACTURING STRATEGY AND SUPPLY CHAIN: Forecasting systems supply chain management concepts aggregate planning master production schedule. (7) DECENTRALIZED PULL SYSTEMS: Kanban systems constant work in process pull alternative. (6)

MULTI STAGE PRODUCTION SYSTEMS: Material requirements planning manufacturing resource planning capacity planning managing change. (6) Total 42 REFERENCES: 1. Ronald G Askin, Design and Analysis of Lean Production system, John Wiley and Sons, New York, 2003. 2. Bedworth D D, "Integrated Production Control Systems Management, Analysis, Design, John Wiley and Sons, New York, 1987. 3. Vollman T E, "Manufacturing Planning and Control Systems", Galgotia Publication (P) Ltd., New Delhi,2004. 4. Dennis P Hobbs, Lean Manufacturing Implementation: A complete Execution Manual for any Size Manufacturing, J Rose Publishing Inc, 2004. 5. Taiichi Ohno, Toyoto Production System: Beyond Large Scale Production Productivity Press, New York, 1988.

09ML03/09MM03 LEAN TOOLS AND MANAGEMENT SYSTEMS 3003

INTRODUCTION TO LEAN MANUFACTURING: Objectives of lean manufacturing-key principles and implications of lean manufacturing- traditional Vs lean manufacturing. (5) LEAN MANUFACTURING CONCEPTS: Value creation and waste elimination- main kinds of waste- pull production-different models of pull production-continuous flow-continuous improvement / Kaizen- worker involvement -cellular layout- administrative lean. (7) LEAN MANUFACTURING TOOLS AND METHODOLOGIES: Standard work -communication of standard work to employees standard work and flexibility -visual controls-quality at the source- 5S principles -preventative maintenance-total quality management-total productive maintenance -changeover/setup time -batch size reduction -production leveling. (7) VALUE STREAM MAPPING: The as-is diagram-the future state map-application to the factory simulation scenario-line balancing Poke Yoke -Kanban overall equipment effectiveness. (6) JUST IN TIME MANUFACTURING: Introduction - elements of JIT - uniform production rate - pull versus push method- Kanban system - small lot size - quick, inexpensive set-up - continuous improvement. Optimised production technology. (6) ONE-PIECE FLOW: Process razing techniques cells for assembly line case studies. IMPLEMENTING LEAN: Road map-senior management Involvement-best practices. (4) (4)

RECONCILING LEAN WITH OTHER SYSTEMS: Toyota production system-lean six sigma-lean and ERP-lean with ISO9001:2000. (3) Total 42 REFERENCES: 1. Askin R G and Goldberg J B, Design and Analysis of Lean Production Systems, John Wiley and S ons Inc., 2003. 2. Michael L George, David T Rowlands, Bill Kastle, What is Lean Six Sigma, McGraw Hill, New York, 2004. 3. Micheal Wader, Lean Tools: A Pocket Guide to Implementing Lean Practices, Productivity and Quality Publishing Pvt Ltd, 2002. 4. Kenichi Sekine, One-Piece Flow, Productivity Press, Portland, Oregon, 1992. 5. Alan Robinson Continuous Improvement in Operations, Productivity Press, Portland, Oregon, 1991. 6. Joseph A De Feo, William W Bearnard , Juran Institutes Six Sigma Break Through and Beyond, Tata McGraw Hill Edition, New Delhi, 2004. 7. Richard B Chase F Robert Jacobs and Nicholas J Aquilano, Operations Management for Competitive Advantage, McGraw Hill/Irwin; Tenth Edition, 2003. 8. Poke - Yoke, "Improving Product Quality by Preventing Defects", Productivity Press, 1992.

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09ML04 SIMULATION MODELING AND ANALYSIS

vide Computer Integrated Manufacturing 09MC15

09ML05 COST MANAGEMENT AND LEAN ACCOUNTING 3003

COST CONCEPTS: Cost structure labour, material, overhead cost nature of overhead cost overhead absorption methods direct labour, direct material, number of pieces, labour hour rate, machine hour rate methods cost control labour, material, overhead variance analysis. (5) ACTIVITY BASED COSTING: Concept objectives comparison with conventional costing activity cost drivers resource mapping resource driver activity cost shifting costs to activities designing the optimal ABC system. (5) ACTIVITY BASED MANAGEMENT: Concept value added analysis tree value added activity, strategic activity, support activity value added analysis in manufacturing. (5) TARGET COSTING AND TOTAL COST MANAGEMENT: Concept different approaches price based, cost based, value based target costing- strategies for achieving target cost value analysis, vendor development, outsourcing, core competence. (6) LEAN ACCOUNTING: Financial bridge, profit and loss model understanding earnings changes Du pont return on net assets model, six sigma financial trading and reporting, governance model overview, savings, analytical guide lines, Lean accounting, define, voice of the customer/business, pulling the voices, together, actions to avoid metric problems. (6) MEASURE: Develop and track bridge metrics, purpose, measure phase in bridge process, measurement system analysis, tools for measure phase, product and service quality , customer/supplier requirements, QFD, value stream mapping, lead time, YX matrix, statistical, analysis of process matrics, why-why, matrix for mixed, model manufacturing and mass customization, logistics and supply chain matrics. (5) ANALYSE: Current capabilities, technical processes, people processes, pulling together, bridge structure, analysis sub steps, analyse out of bounds values for root causes; tools for analysis, product and quality work flow linearity, process synchronization and work load balancing, process characteristics charts, miscellaneous analytical tools, statistical correlation analysis. (5) IMPROVE: People and processes, selecting a solution open dialog, alternate solutions, action plans, cost and financial benefits, people and accountabilities, communications, improvement, control, pilot evaluation plan, implementation and execution, rollout plan, standardization and replication, classified roles and responsibilities, process and performance control, financial assessment, leadership governance and sustaining the gains. (5) Total 42 REFERENCES: 1. Blocher Chen and Lin, Cost Management A Strategic Emphasis, McGraw Hill Irwin, 2002. 2. Micheal Breamer, Brain Mckibben, Thomas Mccarting, Six Sigma Financial Tracking and Reporting McGraw Hill, 2006. 3. Monden Y, Cost Management in the New Manufacturing Age, Productivity Press, 1992. 4. Cooper R and Slagmulder R, Target Costing and Value Engineering, Productivity Press, 1997.

09ML06 DESIGN FOR MANUFACTURE AND ASSEMBLY

vide Engineering Design 09MD06

09ML07 SIX SIGMA IN MANUFACTURING AND SERVICING

vide Industrial Engineering 09MN15

09ML08 SUPPLY CHAIN MANAGEMENT

vide Computer Integrated Manufacturing 09MC12

09ML09/09MM09 COMPUTER INTEGRATED MANUFACTURING 3003

INTRODUCTION: Evolution of CAD/CAM and CIM, scope of CIM, segments of generic CIM, computers and workstations, an overview of CIM software. (4) GEOMETRIC MODELING AND DESIGN OPTIMISATION: Geometric modeling techniques, automated drafting, graphic standards, engineering analysis, optimisation, principles of concurrent engineering. (4) CNC TECHNOLOGY AND ROBOTIC SYSTEMS: Principles of numerical control, types of CNC machines, features of CNC systems, programming techniques, capabilities of a typical NC, CAM software, integration of CNC machines in CIM environment, DNCflexible manufacturing systems. Robotic systems-types of robots and their performance capabilities, programming of robots, hardware of robots, kinematics of robots, product design for robotized manufacturing, applications of robots in manufacturing and assembly. (8)

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GROUP TECHNOLOGY AND AUTOMATED PROCESS PLANNING: Methods of developing part families, classification and coding systems, process planning, variant and generative process planning methods, AI in process planning. (4) MANUFACTURING SYSTEM SOFTWARE: Production controlforecasting, master production schedule, MRP, capacity planning, shop floor control, inventory management, product routing, job costing, marketing applications. (4) FUNDAMENTALS OF NETWORKING: Networking concepts, networking devices repeaters, bridges, routers, gateways, hubs and switches. MAP, TOP, LAN, WAN. Network topologies star, bus, ring. (4) RAPID PROTOTYPING SYSTEMS: Rapid prototyping techniques, software for rapid prototyping, process optimization. (4)

VIRTUAL ORGANISATION: Paperless factory, introduction virtual reality and application, virtual prototyping and manufacturing instrumentation and measurement, virtual enterprises. (4) PROJECT: Involving CAD/CAM/CAE activities for a selected product from industry. REFERENCES: 1. Mikell P Groover, Automation of Production Systems and Computer Integrated Manufacturing, Pearson Education, New Delhi, 2001. 2. Lee Kunwoo, CAD/CAM/CAE Systems, Addition, Wesley, USA, 1999. 3. Kant Vajpayee S, Principles of Computer Integrated Manufacturing, Prentice Hall, India, New Jersey, 2003. 4. Radhakrishnan P, Subramanyan S and Raju V, CAD/CAM/CIM, Second Edition New Age International Pvt. Ltd, New Delhi, 2008. (6) Total 42

09ML10 QUALITY ENGINEERING

vide Computer Integrated Manufacturing 09MC10

09ML11 ENTERPRISE RESOURCE PLANNING

vide Computer Integrated Manufacturing 09MC11

09ML12 SAFETY AND ENVIRONMENT MANAGEMENT SYSTEM

vide Industrial Engineering 09MN12

09ML13 CREATIVITY AND INNOVATION MANAGEMENT

vide Engineering Design 09MD25

09ML14 INDUSTRIAL SCHEDULING

vide Industrial Engineering 09MN14

09ML15 PROJECT MANAGEMENT

vide Industrial Engineering 09MN24

09ML16 ARTIFICIAL INTELLIGENCE AND EXPERT SYSTEM

vide Computer Integrated Manufacturing 09MC16

09ML17 OPTIMIZATION TECHNIQUES

vide Computer Integrated Manufacturing 09MC17

09ML18 HUMAN RESOURCE MANAGEMENT

vide Industrial Engineering 09MN25

09ML41 INDUSTRIAL VISIT AND TECHNICAL SEMINAR 1022

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

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09ML51 LEAN MANUFACTURING LABORATORY 0032

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Value Stream Mapping Creation of current state diagram using eVSM software Value Stream Mapping Development of future state map for the above set up Evaluation of cost benefit analysis of implementing lean system A case study Layout design and study of layout performance Development of a Poke-Yoke (fool proof) system for a typical process Generation of a Production plan using Pro-Planner Calculation of lead time and WIP using RFID Design of automatic inspection line using Machine Vision System and Pneumatic System Calculating Risk Priority number using XFMEA software Identification of VA, NVA, Standard time calculation and Line balancing using Timer pro Software Ergonomic risk assessment of assembly station using RULA method Process capability evaluation using Minitab software An exercise on 5S simulation

09ML52 MECHATRONICS SYSTEM LABORATORY

vide Engineering Design 09MD53

09ML55 OBJECT COMPUTING AND DATA STRUCTURES LABORATORY

vide Computer Integrated Manufacturing 09MC55

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