Sem 6
Sem 6
RATIONALE
Diploma holder is responsible for controlling production and quality of the product on
the shop floor as well as for production planning and control. He is also required to
supervise erection, installation and maintenance of equipment including material handling
and undertake work-study for better utilization of resources. For this purpose, knowledge
and skills about these topics need to be imparted to them. This subject aims at
development of competencies to prepare material, equipment schedule and production
control schedules and maintain required quality levels. In addition, it will also help in
developing skills in erection, installation and testing of equipment.
Learning Outcomes
DETAILED CONTENTS.
1.1 Introduction.
1.2. Objectives and factors affecting PPC
1.3. Functions(Elements) of PPC - Planning, Routing, Loading, scheduling,
dispatching, progressing and inspection
1.4. Types of production system - Flow or continuous production, Intermittent
Production
1.5. Production Control - Objectives and fields of production control,
Production control system
1.6 Break even analysis and Gantt chart.
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2.1 Definition and Factors affecting the plant location, Rural versus Urban
Plant sites.
2.2 Definition and importance of Plant layout, Factors affecting plant layout.
2.3 Types of Plant layout- Process, product, combination and fixed position
layout..
2.4 Methods of plant layout - Process flow charts, layout analogues Travel
chart, distance, volume matrix.,
2.5. Plant layout procedure and work station design.
2.6. Material Handling- Definition, Significance and objectives of material
handling, Principles of economic material handling,. Types of material
handling equipment - Characteristics and classification of material handling
equipment, Hoisting and conveying equipment (different types), Safety
requirements while using material handling equipment
8.7 Cost estimation for machining processes like turning, drilling, and milling.
Cost estimation of forming processes like forging, pattern making, and
casting .
INSTRUCTIONAL STRATEGY
1. Teacher should put emphasis on giving practical problems related to plant location
and plant layout
2 Students should be taken to industrial units to give an exposure of production
environment, plant layout and material handling
3 Live problems may be given to students to carry out case studies in teams under
guidance of teacher
RECOMMENDED BOOKS
A diploma holder in this course is required to assist in the Design and Development of
Prototype and other components. For this, it is essential that he is made conversant with
the principles related to design of components and machine and application of these
principles for designing. The aim of the subject is to develop knowledge and skills about
various aspects related to design of machine components.
LEARNING OUTCOME
1.2 Design terminology: stress, strain, factor of safety, factors affecting factor
of safety, stress concentration, methods to reduce stress concentration,
fatigue, endurance limit.
3.1 Type of shaft, shaft materials, Type of loading on shaft, standard sizes of
shaft available
3.2 Shaft subjected to torsion only, determination of shaft diameter (hollow
and solid shaft) on the basis of :
- Strength criterion
- Rigidity criterion
3.3 Determination of shaft diameter (hollow and solid shaft) subjected to
bending
3.4 Determination of shaft diameter (hollow and solid shaft) subjected to
combined torsion and bending .
5.1.1 Knuckle Joints – Different parts of the joint, material used for the
joint, type of knuckle Joint, design of the knuckle joint. (Figures
and problems).
5.1.2 Cotter Joint – Different parts of the spigot and socket joints,
Design of spigot and socket joint.
INSTRUCTIONAL STRATEGY
RECOMMENDED BOOKS
1. Machine Design by R.S. Khurmi and JK Gupta, Eurasia Publishing House (Pvt.)
Limited, New Delhi.
2. Machine Design by V.B.Bhandari, Tata McGraw Hill, New Delhi.
3. Engineering Design by George Dieter; Tata McGraw Hill Publishers, New Delhi.
4. Mechanical Engineering Design by Joseph Edward Shigley; McGraw Hill, Delhi.
5. Machine Design by Sharma and Agrawal; Katson Publishing House, Ludhiana.
6. Design Data Handbook by D.P. Mandali, SK Kataria and Sons, Delhi.
7. Machine Design by A.P.Verma; SK Kataria and Sons, Delhi
8. Machine Design by AR Gupta and BK Gupta ; Satya Parkashan, New Delhi.
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LEARNING OUTCOMES
After undergoing this course, the students will be able to :
identify and explain the function of different chassis components and drive types.
maintain transmission system.
carry out balancing of wheels to maintain steering geometry.
carry out routine servicing of brake system and bleeding of hydraulic brakes
carry out testing and charging of Lead-acid battery.
interpret Bharat norms of exhaust emissions.
DETAILED CONTENTS
2.1 Clutch - Function, Constructional details of single plate and multi plate
friction clutches, Centrifugal and semi centrifugal clutch, Cone clutch,
Hydraulic clutch
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2.2 Gear Box - Function, Working of sliding mesh, constant mesh and
synchromesh gear box, Torque converter and overdrive, Introduction to
Automated Manual Transmission, Automatic transmission and
Continuously Variable Transmission.
2.3 Propeller shaft and rear axle - Function, Universal joint, Differential,
Different types of rear axles and rear axle drives.
2.4 Wheels and Tyres - Types of wheels, Types and specifications of tyres
used in Indian vehicles, Toe in, toe out, camber, caster, kingpin
inclination, Wheel balancing and alignment, Factors affecting tyre life.
Function and principle, Ackerman and Davis steering gears, Types of steering
gears - worm and wheel, rack and pinion, Power steering-Hydraulic and
Electrical.
Function and types of Coil spring, leaf spring, Air suspension, Shock
absorber –Function, construction and working of Telescopic type.
Types and use of catalytic converters, selective catalytic reduction methods for
emission control, emission norm standards i.e. Bharat norms.
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LIST OF PRACTICALS
INSTRUCTIONAL STRATEGY
RECOMMENDED BOOKS
Diploma holders are required to supervise and handle specialized machines and
equipment like CNC machines. For this purpose, knowledge and skills about NC
machines, part programming in NC machines and tooling for CNC machines are required
to be imparted for enabling them to perform above functions. This subject aims at
development of knowledge and skills about CNC machines, tools, equipment and use of
high tech machines for increased productivity and quality.
LEARNING OUTCOMES
After undergoing this course, the students will be able to :
Explain the construction and tooling of CNC machine.
Prepare simple part programme.
Operate a CNC lathe.
Operate a CNC milling machine.
Diagnose common problems in CNC machines.
Explain the trends in the field of automation.
DETAILED CONTENTS
1. Introduction (12 hrs)
LIST OF PRACTICALS
4. Develop a part programme for following lathe operations and make the job on
CNC lathe and CNC turning center.
5. Develop a part programme for the following milling operations and make the
job on CNC milling
- Plain milling
- Slot milling
- Contouring
- Pocket milling
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INSTRUCTIONAL STRATEGY
RECOMMENDED BOOKS
RATIONALE
Major Project Work aims at developing innovative skills in the students whereby they
apply in totality the knowledge and skills gained through the course work in the solution
of particular problem or by undertaking a project. In addition, the project work is intended
to place students for project oriented practical training in actual work situation for the
stipulated period.
LEARNING OUTCOMES
Apply in totality the knowledge and skills gained through the course work in the
solution of particular problem or by undertaking a project. In addition, the project
work is intended to place the learner for project oriented practical training in actual work
situation for the stipulated period with a view to:
Develop understanding regarding the size and scale of operations and nature of
field-work in which students are going to play their role after completing the
courses of study
Develop first hand experience and confidence amongst the students to enable them
to use and apply polytechnic/institute based knowledge and skills to solve
practical problems related to the world of work.
General Guidelines
The individual students have different aptitudes and strengths. Project work, therefore,
should match the strengths of students. For this purpose, students should be asked to
identify the type of project work, they would like to execute. The activity of problem
identification should begin well in advance (say at the end of second year). Students
should be allotted a problem of interest to him/her as a major project work. It is also
essential that the faculty of the respective department may have a brainstorming session to
identify suitable project assignments for their students. The project assignment can be
individual assignment or a group assignment. There should not be more than 3 students if
the project work is given to a group. The project work identified in collaboration with
industry should be preferred.
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This practical training cum project work should not be considered as merely
conventional industrial training in which students are sent at work places with either
minimal or no supervision. This experience is required to be planned in advance and
supervised on regular basis by the polytechnic faculty. For the fulfillment of above
objectives, polytechnics may establish close linkage with 8-10 relevant organization for
providing such an experience to students. It is necessary that each organization is visited
well in advance and activities to be performed by students are well defined. The chosen
activities should be such that it matches with the curricular interest to students and of
professional value to industrial/ field organizations. Each teacher is expected to supervise
and guide 5-6 students.
The projects given to students should be such for which some one is waiting for solution.
Some of the suggested project activities are given below:
NOTE: Each student has to take one project individually and one to be shared with a
group of four-five students depending upon cost and time involved. There is no binding to
take up the above projects as it is only a suggestive list of projects.
A suggestive criterion for assessing student performance by the external (person from
industry) and internal (teacher) examiner is given in table below:
Sr. Performance Criteria Max.** Rating Scale
No. Marks Excell Very Good Fair Poor
ent
Good
1. Selection of project assignment 10% 10 8 6 4 2
2. Planning and execution of 10% 10 8 6 4 2
considerations
3. Quality of performance 20% 20 16 12 8 4
4. Providing solution of the problems 20% 20 16 12 8 4
or production of final product
5. Sense of responsibility 10% 10 8 6 4 2
6. Self expression/ communication 5% 5 4 3 2 1
skills
7. Interpersonal skills/human relations 5% 5 4 3 2 1
8. Report writing skills 10% 10 8 6 4 2
9 Viva voce 10% 10 8 6 4 2
Total marks 100 100 80 60 40 20
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The overall grading of the practical training shall be made as per following table.
In order to qualify for the diploma, students must get “Overall Good grade” failing which
the students may be given one more chance to improve and re-evaluate before being
disqualified and declared “not eligible to receive diploma ”. It is also important to note
that the students must get more than six “goods” or above “good” grade in different
performance criteria items in order to get “Overall Good” grade.
Important Notes
1. This criteria must be followed by the internal and external examiner and they
should see the daily, weekly and monthly reports while awarding marks as per
the above criteria.
2. The criteria for evaluation of the students have been worked out for 200
maximum marks. The internal and external examiners will evaluate students
separately and give marks as per the study and evaluation scheme of
examination.
4. It is also proposed that two students or two projects which are rated best be
given merit certificate at the time of annual day of the institute. It would be
better if specific nearby industries are approached for instituting such awards.
The teachers are free to evolve other criteria of assessment, depending upon the type of
project work.
It is proposed that the institute may organize an annual exhibition of the project work