Mechanical Engineering

Indian Institute of Technology Kanpur

ME701A

ME701A
DESIGN FOR MANUFACTURE AND ASSEMBLY
Credits:
 3-0-0-9
Course-Title:
 Design for Manufacture and assembly
Course Number:
 ME701A
Department:
 Mechanical Engineering
Other interested faculty:
 Dr. J. Ramkumar (ME), Dr. S. Bhattacharya (ME), Dr. V.K. Jain (ME)
Expected enrollment:
 15-20 students
Pre requisites:
 TA 202 or equivalent
Aimed at:
 Advanced undergraduates and postgraduates
Other Departments:
 Aerospace Engineering, Chemical Engineering. Civil Engineering. and Design Programme
Course description:

The success of a product in the market depends on many factors. These include cost, reliability and time to market. With globalization, companies need to devise techniques in order to remain competitive in the current scenario. To this end, design and manufacturing operations no longer function in isolation but have to interact closely. Design for manufacture and assembly (DFMA) is a technique of integrated pro duct development process as opposed to the serial or "over the wall" philosophy. The advantages of implementing DFMA include reduced time-to- market, reduced number of subcomponents, enhancement in quality, and reduced product and process cost. DFMA has been applied successfully in many automobile, aerospace, telecommunications, medical equipment, and consumer products companies. The basic objective of this course is to acquaint the participants with the concepts of the pro duct design process and simultaneous engineering by integrating design for manufacturing and design for assembly to arrive at a good quality product in a cost effective way in less time. With consumers becoming environmentally conscious, design for environment will also be covered. Each module will cover relevant case studies during their discussion.

Course Contents
Module Topic No. of hours
1: Introduction DFMA: overview 01
2: Pro duct design Process Need identification and problem 01
  definition Conceptual design 02
  Embodiment design 02
3: Selection of materials and shapes Overview of engineering materials 01
  and standards for  
  materials selection Selection of materials 02
  Introduction to limits, fits and tolerances 01
  Selection of shapes 01
  Co-selection of materials and shapes 02
4. Design For X The concept of manufacturability 01
  Limitations of manufacturing 01
  Design of jigs and fixtures 01
  Design for manufacturability 05
  Design for assembly 05
  Design for environment 01
5: Modeling and simulation Mathematical modeling and 02
  Finite element analysis 02
  Simulation 02
  Rapid prototyping 02
6: Design for reliability Reliability theory and design for 02
  Failure mode and effects analysis 01
  Design for safety 01
  Design for Quality 01
  Design optimization 02
    Total = 42
Reference Texts:
  1. G. Dieter, Engineering Design - a materials and processing approach, 4th Edition, McGraw Hill, NY, 2009.
  2. G. Boothroyd, P. Dewhurst and W.  Knight, Product  design for manufacture and assembly, 3rd Edition, CRC Press, 2011.
  3. M. F. Ashby and K. Johnson, Materials and Design - the art and science of material selection in product design, ButterworthHeinemann, 2 003.
  4. 0. Molloy, S. T:lley and E.A. Warman, Design for manufacturing and assembly: Concepts, architectures anc implementation, Springer, 1998.
  5. David M. Anderson, Design for manufacturability and concurrent engineering; How to design for low cost, design in high quality, design for lean manufacture, and design quickly for fast production, CMC Press, 2004.
  6. Karl Ulrich and Steven Eppinger, Product design and development, 4th Edition, Tata McGraw Hill, 2008.
  7. G. Pahl, W. Beitz and J. Feldhusen, Engineering design: A systematic approach, 3rc Edition, Springer, 2007.
  8. S. S. Rao, Enginering optimization: theory and practice, 4th Edition, John Wiley, NJ, 2009.