Design for Quality, Manufacturing and Assembly

By Prof. Palaniappan Ramu | IIT Madras

Learners enrolled: 4019

In the context of product design, it is very important to appreciate the limitations of a design from manufacturing and assembly perspective and to produce high quality products at low cost. This course will introduce methods that can provide guidance to design teams in simplifying product structure to reduce manufacturing and assembly costs, quantify improvements and how robust design concepts can be used for ensuring quality. This course aims at introducing the need to account for variability, mathematically represent it, formulate it and control it. Concepts such as quality, robustness, six sigma and orthogonal array will be discussed.

INTENDED AUDIENCE : Final year UG students, Masters and PhD Students, Engineering practitioners in industry

PREREQUISITES : Basic knowledge on manufacturing such as manufacturing techniques and probability

INDUSTRY SUPPORT : Fiat Chrysler Automotive, Daimler India, Cyient, Saint Gobain

Summary

Course Status :	Completed
Course Type :	Elective
Duration :	8 weeks
Category :	Mechanical Engineering
Credit Points :	2
Level :	Undergraduate
Start Date :	29 Jul 2019
End Date :	20 Sep 2019
Exam Date :	29 Sep 2019 IST

Note: This exam date is subjected to change based on seat availability. You can check final exam date on your hall ticket.

Page Visits

Course layout

Week 1 : Introduction, course expected outcomes, discussion on quality

Week 2 : Measuring quality: Quality loss function. Discussion on robustness, six sigma concepts

Week 3 : Quantifying robustness: Signal to Noise Ratio, problem formulation using SNR. Design of experiment discussions

Week 4 : Orthogonal array, linear graphs, triangular tables, finding optimum combinations. Case studies

Week 5 : Design for Manufacturing: over the wall design, most influential phase in design, best practices in injection molding and Design for additive
manufacturing

Week 6 : Do’s and dont’s in manual assembly, assembly time estimation, design for robotic assembly considerations

Week 7 : Design for Assembly: Boothroyd Dewhurst method, theoretical minimum number of parts, Xerox producibility index (XPI) method

Week 8 : Usage of DFMA software and Design for sustainability

Books and references

1.Madhav Phadke, “Quality Engineering Using Robust Design”, Prentice Hall, NJ, USA

2.Phillip J. Ross, Taguchi Techniques for Quality Engineering, McGraw-Hill , 1989

3.Geoffrey Boothroyd, Peter Dewhurst, “Product Design for Manufacturing and Assembly”, Winston Knight, Mercel Dekker, 2001

4.Daniel E. Whitney “Mechanical Assemblies” Oxford University Press, 2004

Instructor bio

Prof. Palaniappan Ramu’s research interest revolves around optimization and treating uncertainties in product and process design to obtain reliable, robust and quality designs. Most of his work is focused on reduction of computer or physical experiments, building better metamodels, intelligently explore design space and enable better predictions and optimal designs under uncertainties

Course certificate

The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: 29th September 2019, Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
Registration url: Announcements will be made when the registration form is open for registrations.
The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE

Average assignment score = 25% of average of best 6 assignments out of the total 8 assignments given in the course.
Exam score = 75% of the proctored certification exam score out of 100
Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75.

If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.
Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Madras. It will be e-verifiable at nptel.ac.in/noc.
Only the e-certificate will be made available. Hard copies are being discontinued from July 2019 semester and will not be dispatched

SWAYAM Helpline / Support