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Production Management

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Production Management

Issues

ELECTIVE- PRODUCTION MANAGEMENT

Subjects:-

 Product Design & Development- Paper 1st

 Quantitative Techniques- Paper 2nd

 Curriculum of Product Design & Development- Paper 1st (IBM- E1063)

S.No.

Topics

1

Introduction to Product Design:  Aimow’s Model:-Definition of Product Design ,

Design by Evolution, Design by Innovation, Essential Factors  of Product Design,

Production –Consumption Cycle, Flow and Value Addition in the Production –Consumption Cycle, The Morphology of Design (The Seven Phases),Primary Design Phases and Flowcharting,

Role of Allowance, Process Capability, and Tolerance in Detailed Design and Assembly, Summary of Detailed Design Phases.

2

Product Design Practice and Industry:-Product Strategies, Time to Market, Analysis of the Product, The Three S’s Standardization, Renard Series (Preferred Number), Simplification, The Designer and his Role ,The Designer: Myth and Reality,The Industrial Design Organization ,Basic Design Considerations, Problems Faced by Industrial Designer, Procedure Adopted by Industrial Designers, Types of Models Designed by Industrial Designers, What the Designer Contributes, Role of Aesthetics in Product Design, Functional Design Practice.

3

Strength Consideration in Product Design:-Principles Stress Trajectories (Force – Flow Lines), Balanced Design, Criteria and Objectives of Design, Material Toughness: Resilience, Design for Uniform Strength, Tension vis-a-vis Compression.

4

Design For Stiffness and Rigidity:-Pure Struts and Pure Columns, Structure Involving both Tension and Compression Members, Mapping of Principal Stresses, Buckling  and Instability , Theory of Long Columns, Hollow Columns, Plastic Design ,Practical Ideas for Material Saving in Design, Ribs, Corrugations, Laminates and Membranes.

5

Production Processes:-Introduction, Primary Processes, Welding Processes, Machining Process, Microfinishing Operations, Non –Traditional Machining Processes.

6

Design for Production :Metal Parts:-Producibility Requirements in the Design of Machine Components, Forging Design, Pressed Components Design, Casting Design, Design  for Machining Ease, The Role of Process Engineer, Ease of Location and Clamping, Some Additional Aspects of Production Design, Die Casting and Special Casting, Design of Powder Metallurgical Parts, Expanded Metal and Wire Forms.

7

Material Processing of Plastics , Rubber, Glass and Ceramics:-Plastics, Concepts in Chemistry of Plastics, Properties of Plastics, Classification of Plastics, Phenol Formaldehyde and Urea Formaldehyde Resin Products, Compression Moulding, Transfer Moulding, Injection Moulding, High-Pressure Laminates, Reinforced Plastic Moulding or Low Pressure Laminating, Forming and Drawing of Plastic Sheet, Design of Plastic Parts, Natural Rubber ,Artificial Rubber, Engineering Properties of Rubber, Glass, The Function of the Glass –Making Oxides, Manufacturing  of Glass, Ceramics.

8

Designing with Plastics, Rubber, Ceramics and Wood:Approach of Design with Plastics, Plastic Bush Bearings, Gear in Plastics, Fasteners in Plastics, Rubber Parts ,Design Recommendation for Rubber Parts, Distortion of Rubber, Dimensional Effects, Tolerances, Ceramics and Glass Parts, Production Design Factor for Ceramics Parts, Special Consideration for Design of Glass Parts, Dimensional Factor and Tolerance, Wood.

9

Optimization in Design:-Introduction, Siddal’s Classification of Design Approaches Optimization by Differential Calculus, Lagrange Multipliers, Linear Programming(Simplex Method),Geometric Programming, Johnson’s Method of Optimum Design.

10

Economic Factor Influencing Design:-Product Value, Design for Safety, Reliability and Environmental Considerations, Manufacturing Operations in Relation to Design, Economic Analysis, Profit and Competitiveness, Break –Even Analysis, Economics of New Product Design(Samuel Eilon Model).

11

Human Engineering Considerations in Product Design:-Human Being as Applicator of Forces, Anthropometry: Man as Occupant of Space, The Design of Controls, The Design of Display, Man/Machine Information Exchange, Workplace Layout from Ergonomic Considerations, Noise, Heating and Ventilating, Lighting, Concluding Remark.

12

Value Engineering and Product Design:-Historical Perspective, What is Value?, Nature and Measurement of Value, Maximum Value, Normal Degree of Value, Importance of Value, The Value Analysis Job Plan, Creativity, Steps to Problem –Solving and Value Analysis, Value Analysis Tests, Value Engineering Idea Generation Check –List, Cost Reduction through Value Engineering Case Study, Material and Process Selection in Value Engineering.

13

Role of Computer in Product Design, Manufacturing and Management:-CAD/CAM: Some Definitions, Product Cycle and CAD/CAM ,Role of Computer in Manufacturing, Role of Computer in Design Process, Creation of a Manufacturing Database, Computer Integrated Manufactured, Communication  Network, Group Technology, Production Flow Analysis (PFA),Computer Added Process Planning (CAPP), Material Requirement Planning, Moving Towards Total Automation :Role of Artificial Intelligence, Flexible Manufacturing Systems, Just –In –TIME((JIT) Manufacturing.

14

Modern Approaches to Product Design:-Concurrent Design, Quality Function Deployment (QFD), Rapid Prototyping.

15

Quality Assurance in Product Design and Manufacturing:-Evolution of Quality Concepts and Applications, Quality and Design Spiral, Theory of Sampling Inspection, Control Charts and In –Process Monitoring of Quality, Quality of Performance: Reliability and Allied Topics, Taguchi Method of Robust Design of Products, Six Sigma Quality Concepts.

16

New Product Development and Product Management:-What is Product?, Defining  Product by Nature of Demand, New Product Strategy, Product Classification, Product Development and Product Management, New Product Development, Models Utilized in Various Phases of New Product Development, Managing Product Life Cycle ,Diffusion Models: Models of First Purchase, Concluding Remarks.

17

Product Design for Environment:-Introduction, Importance of DFE, Environmental Factor, Scope of Environmental Impact, Design Guideline for DFEL if Cycle Assessment, The IVL/VOLVO EPS System for Life Cycle Assessment, Gradel and Allenby’s Environmentally Responsible Approach, Eco-Indicator 95 Method, Eco –Indicator 95 Worksheet, Technique to Reduce Environmental Impact.

 

 

Curriculum of Quantitative Techniques- Paper 2nd   (IBM- E1064)

 

S.No. Topics
 1 Linear Programming: Formulation and Graphical Method:-Introduction, Essentials of Linear Programming Model, Properties of Linear Programming Model, Formulation of Linear Programming, General Linear Programming Model, Maximization & Minimization Models, Graphical Method, Solving Linear Programming Graphically Using Computer, Unbounded LP Problem.
 2 Linear Programming: Simplex Method:-Introduction, Additional variables Used in Solving LPP, Maximization Case, Solving LP Problems using Computer with TORA, Minimization Problems, Big M Method, Degeneracy in LP Problems, Unbounded Solutions in LPP, Multiple Solutions in LPP, Duality in LP Problems, Sensitivity Analysis.
3 Transportation Model:-Introduction, Mathematical Formulation, Network Representation of Transportation Model, General Representation of Transportation Model, Use of Linear Programming to Solve Transportation Problem, Formulation of LP Model, Balanced Transportation Problems, Unbalanced Transportation Problems, procedure to Solve Transportation Problems, Solving Transportation Problems by Computer, Maximization Transportation Problem, Prohibited Routes Problem, Transshipment Problem.
4 Assignment Model:-Introduction, Mathematical Structure of Assignment Problem, Network Representation of Assignment Problem, Use of Linear Programming to Solve Assignment Problem, Types of Assignment Problem, Hungarian Method for Solving Assignment Problem, Unbalanced Assignment Problem, Restricted Assignment Problem, Multiple and Unique Solutions, Maximization Problem, Traveling Salesman Problem, Solving Problems on the Computer with TORA, Solving Maximization Problems Using Computers.
5 Network Analysis PERT-CPM:-Introduction, PERT/CPM Network Components, rules in Constructing a Network, Scheduling of Activities: Earliest Time and Latest Time, Determination of Float and Slack Times. Solving CPM Problems Using Computer with TORA, Project Evaluation Review Technique, PERT, Solving PERT Problems Using Computer, Cost Analysis.
6 Sequencing:-Introduction, Terminology, Types of Sequencing Problems, Algorithm for Solving Sequencing Problems.
7 Replacement Models:-Introduction, Types of Replacement Model, Types of Maintenance Cost, Replacement of items that deteriorate gradually, Replacement of Items that fail suddenly.
8 Queuing Theory:-Introduction, Characteristics of Queuing Systems, Poisson and Exponential Distributions, Symbols and Notations, Single server Queuing Model, System of steady-state Equations, Queuing Equations, Solving Queuing problems using Computer.
9 Game Theory:-Introduction, Terminology, two-person-zero-sum-game, Methods of Solving Mixed Strategy Problems, Dominance Property, Solving Problems on the computer with TORA, Solving games graphically using computer, Solving Linear Programming games using Computer.
10 Simulation:-Introduction, Simulation Process, Advantages and Disadvantages of Simulation, Monte Carlo Simulation, Simulation of Demand Forecasting Problem, Simulation of Queuing Problem, Simulation of Inventory Problem.


 

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