govt.tool room & training centre term... · 2015. 6. 15. · govt.tool room & training...

Govt.Tool Room & Training Centre Bangalore -10 VITH SEMESTER D.P.M. COURSE P a g e | 1

GOVT.TOOL ROOM & TRAINING CENTRE

SEMESTER: SIXTH

Course: DIPLOMA IN PRECISION MANUFACTURING

Syllabus -Theory and practical Subjects

SL.

NO CODE SUBJECTS

Contact

Hours/Week

Contact

Hours/Semester

1 DPM601 Advanced Manufacturing Technology 3 60

2 DPM602 Industrial Maintenance 3 60

3 DPM603 Process Engineering & Productivity 3 60

4 DPM604 Industrial Management 2 40

5 DPM605 Total Quality Management 2 40

Practical

6 DPM606 CNC Lab-II 28.5 570

7 DPM607 CAD/CAM Lab-II 3 60

8 DPM608 ISAP Lab 3 60

Scheme of Examination

Course: DIPLOMA IN PRECISION MANUFACTURING

SI. No

Sub. Code

Subjects Contact Hours

per Week

Exam.

Duration

Scheme of Examination

Total Marks

Min marks

for passing

Exam Internal

Assessment

Theory Max Min Max Min

Marks Marks Marks Marks

1 DPM601 Advanced Manufacturing

Technology 3 3 100 50 20 10 120 60

2 DPM602 Industrial Maintenance 3 3 100 50 20 10 120 60

3 DPM603 Process Engineering &

Productivity 3 3 100 50 20 10 120 60

4 DPM604 Industrial Management 2 3 100 50 20 10 120 60

5 DPM605 Total Quality Management 2 3 100 50 20 10 120 60

Practical

6 DPM606 CNC Lab-II 28.5 10 900 540 100 60 1000 600

7 DPM607 CAD/CAM Lab-II 3 3 100 50 20 10 120 60

8 DPM608 ISAP Lab 3 3 100 50 20 10 120 60

Total 47.5

1600 890 240 130 1840 1020


ADVANCED MANUFACTURING TECHONOLOGY

SUBJECT CODE: DPM 601

Learning goals for ADVANCED MANUFACTURING TECHONOLOGY

On completion of this subject, the trainees will be able to:

Principle and about EDM machine

Die electric media

Principle of Electrolyte and its system

Principle of CM, Need for CM

Need for USM, Equipment and process

Principle of AJM, Need for AJM

Need for WJM, WJM equipment and process

Principle of LBM, Need for LBM


ADVANCED MANUFACTURING TECHONOLOGY

SUBJECT CODE: DPM 601 Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80 SPECIFIC INSTRUCTIONAL OBJECTIVES: 1. EDM:

- Introduction - Principle, about machine - Die electric, Spark generator - Electrode (Types, Spark gap - Electrode wear - Electrode folders - Electrode materials) Flushing mechanism - Effect of parameters - Advantages, Disadvantages and Applications.

2. WEDM:

- Introduction - Principle, about machine and features - Types of wires - Types of material which can be wire cut - Die electric media - Machine parameters and Effect of parameters - Simple programming examples for cut out parts - Advantages, Disadvantages and Applications.

3. ELECTRO CHEMICAL MACHINING (ECM):

- Introduction

- Principle, Electrolyte and its system

- Types of electrolytes

- Faraday’s laws of electrolysis

- Experiment on electrolysis of copper on iron

- ECM equipment and process

- Advantages, Disadvantages and Applications.

4. CHEMICAL MACHINING (CM)

- Introduction

- Principle of CM, Need for CM

- Chemical blanking process

- Chemical milling process

- Difference between Chemical blanking and milling

- Machine parameters, Advantages

- Limitations and application of CM.

5. ULTRASONIC MACHINING:

- Introduction,

- Principle of USM,

- Need for USM, Equipment and process,

- Tool holders, Tool material,

- Machine parameters, Advantages,

- Limitations and application of USM.


ADVANCED MANUFACTURING TECHONOLOGY 6. ABRASIVE JET MACHINING:

- Introduction - Principle of AJM, Need for AJM - Equipment and process, AJM elements and their Influence - Process parameters - Advantages, Disadvantages and Applications.

7. WATER JET MACHINING:

- Principle of WJM, - Need for WJM, WJM equipment and process, - Machine parameters, - Advantages, limitations and application of WJM.

8. LASER BEAM MACHINING: - Introduction, - Principle of LBM, Need for LBM, - LBM equipment and process, - Machine parameters, Types of LASER, - LBM Operations, - Advantages, limitations and application of LBM.


WEEKLY PLAN FOR

ADVANCED MANUFACTURING TECHNOLOGY

WEEK NO

CHAPTER TITLE CONTENTS OF TOPICS

1-3

EDM

Introduction Principle about machine Die electric, Spark generator Electrode (Types, Spark gap, Electrodes wear, Electrode folders Electrode materials) Flushing mechanism Effect of parameters Advantages, Disadvantages and Applications.

4-6 WEDM

Introduction Principle about machine and features, Types of wires Types of material which can be wire cut, Die electric media Machine parameters and Effect of parameters Simple programming examples for cut out parts Advantages Disadvantages and Applications.

8-10 ECTRO CHEMICAL MACHINING

(ECM)

Introduction Principle, Electrolyte and its system Types of electrolytes Faraday’s laws of electrolysis Experiment on electrolysis of copper on iron, ECM equipment and process Advantages, Disadvantages and Applications.

11-12 CHEMICAL MACHINING (CM)

Introduction Principle of CM, Need for CM Chemical blanking process Chemical milling process Difference between Chemical blanking and milling Machine parameters, Advantages Limitations and application of CM.

13-14 ULTRASONIC MACHINING:

Introduction, Principle of USM, Need for USM, Equipment and process, Tool holders, Tool material, Machine parameters, Advantages, Limitations and application of USM.


WEEKLY PLAN FOR

ADVANCED MANUFACTURING TECHNOLOGY

WEEK NO


15-16 ABRASIVE JET MACHINING:

Introduction Principle of AJM, Need for AJM Equipment and process, AJM elements and their Influence Process parameters Advantages, Disadvantages and Applications.

17-18 WATER JET MACHINING:

Principle of WJM, Need for WJM, WJM equipment and process, Machine parameters, Advantages, limitations and application of WJM.

19-20 LASER BEAM MACHINING:

Introduction, Principle of LBM, Need for LBM, LBM equipment and process, Machine parameters, Types of LASER, LBM Operations, Advantages, limitations and application of LBM.


INDUSTRIAL MAINTENANCE


Learning goals for INDUSTRIAL MAINTENANCE


Role of maintenance

Restoration and manufacture of machine parts

Accuracy measurements

Methods for checking and control

Rack and pinion

Fits and tolerances between lead-screw and nut

Lead screw repairs

Spindle wear and their repairs

Shanks and journal seats

Concept of preventive maintenance

Functions of the various sections of central maintenance workshop




Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60

SPECIFIC INSTRUCTIONAL OBJECTIVES

1. INTRODUCTION TO INDUSTRIAL MAINTENANCE

- Role of maintenance - Maintenance management - Restoration and manufacture of machine parts - Planted maintenance activities - Conclusion

2. MATERIAL FOR MACHINE PARTS AND HEAT TREATMENT OF STEEL

- Steels - Heat treatment of steel - Approximate determination of steel composition - Cast iron - Heat treatment (aging) of C.I castings - Non-ferrous metals and other materials - Materials for machine parts - Hardness numbers

3. GUIDE SURFACES

- Accuracy of straight edges and surface plates - Manufacture of standard surface plates - Accuracy measurements - Wear on guide surface and methods of determining the value of the wear - Method for short guides - Method for flat/prism long guides - Method for long guides, beds, or plates - Selection of repair method - Scraper - Guide characteristics and their control - Universal bridge for controlling guide surface characteristics of flat and prism guides - Drawing details - Scheme for installing the bridge - Methods for checking and control - Universal bridge for controlling dove-tail type guide surface characteristics - Drawing details

- Scheme for installing the bridge

- Repair methods for beds/guide surfaces

- Scraping of the guide surface

- Grinding of the guide surface

- Machining on planer or Plano-miller

- Modernization with low-friction slide ways

- Non- metallic guide way linings

- Anti-friction guide way elements

- Hydrostatic slide ways

- Aerostatic slide ways

- Auto-lubrication systems



4. GEAR TRANSMISSION

- Classification of the gears - Gear transmission with parallel axes - Intersecting axes gear transmission - Non-parallel non-intersecting - Rack and pinion - Spur gear - Calculations for teeth profile elements - Accuracy control of gear milling - Measurement from worn-out gear - Gear milling - Teeth edges chamfering - Helical/spiral gear - Helix angle and gear correction - Calculations from measurements of used gears - Practical example for straight bevel gear - Bevel gear milling - Worm and worm gear - Bevel Gear

5. LEAD SCREW AND NUT

- Fits and tolerances between lead-screw and nut - Lead screw repairs - Thread wear up to 0.3mm - Thread wear exceeding 0.3mm - Manufacture of the lead screw - Repairs of lead nut - B1-metalling - Pouring “stellon” compound - Elimination of play - Ball lead screw - Construction of ball screw and nut - Selection of ball screw

6. MACHINE SPINDLE

- General defects in the spindle unit - Spindle wear and their repairs

- Shanks and journal seats

- Taper bore

- Threads

- Repair of keyways

- Manufacture of new spindle

- Manufacture of spindle from steel En8/En18

- Manufacture of spindle from steel En207

- Manufacture of spindle from steel En416



7. PREVENTIVE MAINTENANCE PLANNING

- Concept of preventive maintenance - Condition based maintenance - Corrective maintenance - Scheduled preventive maintenance - Repair cycle - Inspection-I - Small repair-S - Medium repair-M - Complete overhaul-O - Annual and monthly preventive maintenance schedules - Annual preventive maintenance schedule - Monthly preventive maintenance schedule - Main power planning - Machine stoppage - Norms for machine stoppage - Maintenance costs - Depreciation and machine life

8. LUBRICATION

- General purpose lubricants - Lubricating instructions for operator - Periodical replacement or addition of lubricant - Annual lubrication replacement schedule - Paint marks for lubricating points - Regeneration of oils - Storage of oils for regeneration - Various oils available for regeneration - Testing of used oils - Process of regeneration

9. PLANNING OF MATERIALS AND STANDARD SPARES

- Planning of requirements for subsequent year - Recommended welding electrodes, fasteners, etc. - Spare parts stock rate - Maximum and minimum stock of spare parts

10. ORGANISATION OF MAINTENANCE DEPARTMENT - Functions and organization - Control and co-ordination bureaus - Equipment bureau - Crane bureau - Design bureau - Maintenance centre for each shop - Duties and functions - Organization of maintenance centers - Lubricants and spare parts store - Sub-ordination of maintenance engineer - Maintenance centre and machines - Central maintenance workshop - Central maintenance workshop and machines - Functions of the various sections of central maintenance workshop

Reference book

1. Industrial Maintenance by; E.R H P Garg


WEEKLY PLAN FOR INDUSTRIAL MAINTENANCE

WEEK

NO CHAPTER TITLE CONTENTS OF TOPICS

1 INTRODUCTION TO


Role of maintenance Maintenance management Restoration and manufacture of machine parts Planted maintenance activities Conclusion

2-3

MATERIAL FOR MACHINE PARTS AND HEAT TREATMENT

OF STEEL

Steels Heat treatment of steel Approximate determination of steel composition Cast iron Heat treatment (aging) of C.I castings Non-ferrous metals and other materials Materials for machine parts Hardness numbers

4-5 GUIDE SURFACES

Accuracy of straight edges and surface plates Manufacture of standard surface plates Accuracy measurements Wear on guide surface and methods of determining the value of the wear Method for short guides Method for flat/prism long guides Method for long guides, beds, or plates Selection of repair method Scraper Guide characteristics and their control Universal bridge for controlling guide surface characteristics of flat and prism guides Drawing details Scheme for installing the bridge Methods for checking and control Universal bridge for controlling dove-tail type guide surface characteristics Drawing details Scheme for installing the bridge Repair methods for beds/guide surfaces Scraping of the guide surface Grinding of the guide surface Machining on planer or Plano-miller Modernization with low-friction slide ways Non- metallic guide way linings Anti-friction guide way elements Hydrostatic slide ways Aerostatic slide ways Auto-lubrication systems



WEEK


6-7 GEAR TRANSMISSION

Classification of the gears Gear transmission with parallel axes Intersecting axes gear transmission Non-parallel non-intersecting Rack and pinion Spur gear Calculations for teeth profile elements Accuracy control of gear milling Measurement from worn-out gear Gear milling Teeth edges chamfering Helical/spiral gear Helix angle and gear correction Calculations from measurements of used gears Practical example for straight bevel gear Bevel gear milling Worm and worm gear Bevel Gear

8-9

LEAD SCREW AND

NUT

Fits and tolerances between lead-screw and nut Lead screw repairs Thread wear up to 0.3mm Thread wear exceeding 0.3mm Manufacture of the lead screw Repairs of lead nut B1-metalling Pouring “stellon” compound Elimination of play Ball lead screw Construction of ball screw and nut Selection of ball screw

10-11 MACHINE SPINDLE

General defects in the spindle unit Spindle wear and their repairs Shanks and journal seats Taper bore Threads Repair of keyways Manufacture of new spindle Manufacture of spindle from steel En8/En18 Manufacture of spindle from steel En207 Manufacture of spindle from steel En416



WEEK NO CHAPTER TITLE CONTENTS OF TOPICS

12-14 PREVENTIVE MAINTENANCE

PLANNING

Concept of preventive maintenance Condition based maintenance Corrective maintenance Scheduled preventive maintenance Repair cycle Inspection-I Small repair-S Medium repair-M Complete overhaul-O Annual and monthly preventive maintenance schedules Annual preventive maintenance schedule Monthly preventive maintenance schedule Main power planning Machine stoppage Norms for machine stoppage Maintenance costs Depreciation and machine life

15-16 LUBRICATION

General purpose lubricants Lubricating instructions for operator Periodical replacement or addition of lubricant Annual lubrication replacement schedule Paint marks for lubricating points Regeneration of oils Storage of oils for regeneration Various oils available for regeneration Testing of used oils Process of regeneration

17-18 PLANNING OF MATERIALS AND STANDARD SPARES

Planning of requirements for subsequent year Recommended welding electrodes, fasteners, etc. Spare parts stock rate Maximum and minimum stock of spare parts

19-20 ORGANISATION OF

MAINTENANCE DEPARTMENT

Functions and organization Control and co-ordination bureaus Equipment bureau Crane bureau Design bureau Maintenance centre for each shop Duties and functions Organization of maintenance centers Lubricants and spare parts store Sub-ordination of maintenance engineer Maintenance centre and machines Central maintenance workshop Central maintenance workshop and machines Functions of the various sections of central maintenance workshop


PROCESS ENGINEERING & PRODUCTIVITY



Learning goals for PROCESS ENGINEERING & PRODUCTIVITY


Understand the necessity of process requirement,

Metal cutting process and materials

Concept of gauges

Tooling materials for plastics

Tooling for NC machines



Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60 SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. PROCESS ENGINEERING - Introduction - Initial data required for process planning - Process Engineering records - Terms used in process planning - Standard time - Machining allowance - Selection of cutting variables - Planning of operation sequence - Main conditions in selecting the machining method - Example of process sheet for turning, milling, grinding jobs

2. PROCESS OF METAL CUTTING

- Introduction - Cutting tool materials - Carbon tool steel - High speed steel - Cemented carbides - Ceramics - Diamonds - UCON - CBN - Principles of metal cutting - Orthogonal and oblique metal cutting - Comparison of orthogonal and oblique cutting - Type of chips - Nomenclature of single point cutting tool - Tool signature - Tool life and tool failure - Factor affecting tool life - Machinability - Machinability index - Cutting fluids - Purposes of cutting fluids - Properties of cutting fluids - Types of cutting fluids - Materials for multi point cutting tools - Problems on tool life and tool failure



3. GAUGE DESIGN - Introduction - Types of gauge - Snap gauge - Plug gauge - Ring gauge - Receiver gauge - Gap gauge - Radius or fillet gauge - Taylor’s principle - Maximum and minimum metal limits - Gauge allowance and tolerance - Materials for gauges - Simple problems on gauges

4. PLASTIC AS TOOLING MATERIALS

- Introduction - Plastics commonly used as tooling materials - Merits and demerits of plastic tooling - Plastics tooling techniques - Repair of plastic tools - Safety precaution of plastic tooling material

5. TOOLING FOR N.C.MACHINES - Introduction - Spindling tooling for machining centers, - Shell mill adaptor - Collet chucks and extensions - End mill adaptor - Morse taper adaptor - Boring bars - Tooling for N.C. turing machines - Qualified tooling - Preset tooling

Reference Books:

1) Production Engineering Design by Dr. Surendrakumar & Dr.Umesh chandra Satya

Prakashan - New Delhi

2) Tool Engineering and Design by G.R.Nagpal Khanna publishers


WEEKLY PLAN FOR


WEEK NO


1-5 PROCESS

ENGINEERING

- Introduction - Initial data required for process planning - Process Engineering records - Terms used in process planning - Standard time - Machining allowance - Selection of cutting variables - Planning of operation sequence - Main conditions in selecting the machining

method - Example of process sheet for turning, milling,

grinding jobs

6-10 PROCESS OF METAL

CUTTING

- Introduction - Cutting tool materials - Carbon tool steel - High speed steel - Cemented carbides - Ceramics - Diamonds - UCON - CBN - Principles of metal cutting - Orthogonal and oblique metal cutting - Comparison of orthogonal and oblique

cutting - Type of chips - Nomenclature of single point cutting

tool - Tool signature - Tool life and tool failure - Factor affecting tool life - Machinability - Machinability index - Cutting fluids - Purposes of cutting fluids - Properties of cutting fluids - Types of cutting fluids - Materials for multi point cutting tools - Problems on tool life and tool failure

11-12 GAUGE DESIGN

- Introduction - Types of gauge - Snap gauge - Plug gauge - Ring gauge - Receiver gauge


WEEKLY PLAN FOR


WEEK NO


13-14 GAUGE DESIGN

- Gap gauge - Radius or fillet gauge - Taylor's principle - Maximum and minimum metal limits - Gauge allowance and tolerance - Materials for gauges - Simple problems on gauges

15-18

PLASTIC AS TOOLING

MATERIALS

- Introduction - Plastics commonly used as tooling

materials - Merits and demerits of plastic tooling - Plastics tooling techniques - Repair of plastic tools - Safety precaution of plastic tooling

material

19-20 TOOLING FOR

N.C.MACHINES

- Introduction - Spindling tooling for machining centers, - Shell mill adaptor - Collet chucks and extensions - End mill adaptor - Morse taper adaptor - Boring bars - Tooling for N.C. Turing machines - Qualified tooling - Preset tooling


INDUSTRIAL MANAGEMENT


Learning goals for INDUSTRIAL MANAGEMENT


Understand the estimation and costing procedure in industries

Know the actual costing process and calculation of selling prices

Understand the depreciation of equipments, plants and to know the

different methods of calculating depreciation

Know the procedure for calculating material cost of various components

Understand the procedure for estimation of various shops

Know the labour wages and incentives

Know about basics of financial management

Understand the concepts of project planning and breakeven analysis




SPECIFIC INSTRUCTIONAL OBJECTIVES: 1. INTRODUCTION TO ESTIMATION AND COSTING

- Estimation - Definition, Importance and Aims - Qualities and functions of an Estimator - Source of errors in estimation - Constituents of Estimation - Costing - Definition and Aims - Standard cost and its Advantages - Difference between estimation and costing - Advantages of efficient costing

2. ELEMENTS OF COST

- Elements of cost- material, labour, expenses - Material - Direct material, indirect material and examples - Calculation of Material cost - Labour - direct, indirect labour and examples - Calculation of labour cost - Expenses - direct, indirect expenses and examples - Classification of expenses - factory, administrative, selling and distribution expenses and examples - Fixed and variable expenses and examples - Components of cost - prime cost, factory cost, office cost, total cost - Selling price - Block diagram to show the relationship between elements and components of cost - Simple problems on above - Allocation of on-cost - methods and simple problems

3. INDIRECT EXPENSES AND DEPRECIATION

- Indirect expenses - depreciation, obsolescence, inadequacy, idleness, repair and maintenance - Depreciation - causes, methods of calculating depreciation

4. MENSURATION AND ESTIMATION OF MATERIAL COST

- Area of regular plane figures - Volume and surface area of solids (formulae only) - Estimation of material costs of tool elements and total cost of tool. - Mechanical Estimation - Estimation in machine shop - Definition of cutting speed, feed, depth of cut - Estimation of time for various operations like Turning, Knurling, Facing, Drilling, Boring,

Reaming, Threading, Tapping, Milling, Grinding, Shaping and Planning - Estimation in sheet metal shop - Sheet material and gauge number, Select suitable formula for

Estimation



5. WAGES AND INCENTIVES

- Definition of wages, normal wages, real wages, living wages, fair wages - Minimum wages, methods of wage payment - Incentives - definition of incentive, types of incentives, examples - Characteristics of a good wage and incentive systems - Standard time - work measurement - Bonus system - collective bonus system, group bonus system

6. INTRODUCTION TO FINANCIAL MANAGEMENT

- Definition of terms such as assets, liabilities, current and long term assets and liabilities, capital, income, expenses, gain

- Working capital - definition - net and gross working capital - factors affecting working capital. - Maintenance of accounts through journal ledger, cash book, balance sheet. - Transaction with bank - credits, payments overdraft, current account, securities.

-

7. PROJECT PLANNING AND BREAK EVEN ANALYSIS

- Concept of project work. - Project planning like market survey, project capacity, selection of site, plant Layout, product design, drawing, specification, material requirement operation planning, - Break even analysis - break event chart, diagram to illustrate break event point, Simple

problems on break even analysis

8. OPERATION RESEARCH

- Game theory: definitions- strategy, saddle point, two person zero sum game, dominance property, problems

- Transportation problem: NW corner rule, Least cost method (simple problems) - Assignment problem (balanced problems only)

REFERENCE BOOKS 1. Mechanical estimation and costing- T.R.Banga and S.C.Sharma

2. Estimation and costing – by Acharya and Narang

3. Industrial Organisation and Engineering Economics by Banga and Sharma

4. Mechanical Estimation by Malhotra

5. Operations research by S D Sharma

6. Operations research by Phaneesh


WEEKLY PLAN FOR


WEEK


1-3

INTRODUCTION TO

ESTIMATION AND COSTING

Estimation - Definition, Importance and Aims Qualities and functions of an Estimator Source of errors in estimation Constituents of Estimation Costing - Definition and Aims Standard cost and its Advantages Difference between estimation and costing Advantages of efficient costing

4-6 ELEMENTS OF COSTS

Elements of cost- material, labour, expenses Material - Direct material, indirect material and examples Calculation of Material cost Labour - direct, indirect labour and examples Calculation of labour cost Expenses - direct, indirect expenses and examples Classification of expenses - factory, administrative, selling and distribution expenses and examples Fixed and variable expenses and examples Components of cost - prime cost, factory cost, office cost, total cost Selling price Block diagram to show the relationship between elements and components of cost Simple problems on above Allocation of on-cost - methods and simple problems

7-9 INDIRECT EXPENSES AND

DEPRECIATION

Indirect expenses - depreciation, obsolescence, inadequacy, idleness, repair and maintenance Depreciation - causes, methods of calculating depreciation

10-13

MENSURATION AND

ESTIMATION OF MATERIAL

COST

Area of regular plane figures Volume and surface area of solids (formulae only) Estimation of material costs of tool elements and total cost of tool. Mechanical Estimation Estimation in machine shop - Definition of cutting speed, feed, depth of cut Estimation of time for various operations like Turning, Knurling, Facing, Drilling, Boring, Reaming, Threading, Tapping, Milling, Grinding, Shaping and Planning Estimation in sheet metal shop - Sheet material and gauge number, Select suitable formula for Estimation


WEEKLY PLAN FOR


WEEK


14-16 WAGES AND INCENTIVES

Definition of wages, normal wages, real wages, living wages, fair wages Minimum wages, methods of wage payment Incentives - definition of incentive, types of incentives, examples Characteristics of a good wage and incentive systems Standard time - work measurement Bonus system - collective bonus system, group bonus system

17-18

INTRODUCTION TO FINANCIAL

MANAGEMENT

Definition of terms such as assets, liabilities, current and long term assets and liabilities, capital, income, expenses, gain Working capital - definition - net and gross working capital - factors affecting working capital. Maintenance of accounts through journal ledger, cash book, balance sheet. Transaction with bank - credits, payments overdraft, current account, securities.

19-20

PROJECT PLANNING AND

BREAK EVEN ANALYSIS

Concept of project work. Project planning like market survey, project capacity, selection of site, plant Layout, product design, drawing, specification, material requirement operation planning, Break even analysis - break event chart, diagram to illustrate break event point, Simple problems on break even analysis

OPERATION RESEARCH

Game theory: definitions- strategy, saddle point, two person zero sum game, dominance property, problems Transportation problem: NW corner rule, Least cost method (simple problems) Assignment problem (balanced problems only)


TOTAL QUALITY MANAGEMENT



SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. OVERVIEW OF TQM

- Definition of TQM - Definition of quality and its characteristics - TQM concepts - Deming’s philosophy - Principles of TQM - Benefits of TQM - TQM organization

2. LEADERSHIP

- Characteristics of TQM leaders - Role of TQM leadership - Continuous process improvement - The PDSA (Plan-Do-Study-Act) cycle - Six sigma (6σ) quality

3. QUALITY MANAGEMENT TOOLS

- Nominal group technique - Affinity diagram - Inter relationship diagram - Tree diagram - Matrix diagram - Activity network diagram

4. STATISTICAL PROCESS CONTROL

- Seven quality control tools - Process Capability - Defect v/s defective

5. FUNDAMENTAL STATISTICS AND PROBABILITY DISTRIBUTIONS

- Measures of central tendency- mean mode, median, standard deviation Problems - Definition and Properties of Probability - Poisson distribution- simple problems - Binomial distribution -simple problems - Normal distribution- simple problems

6. DESIGNS FOR SIX SIGMA

- Tools for concept and design development - Design optimization - Design verification



7. RELIABILITY AND LIFE TESTING

- Definitions of Reliability, Life testing and Redundancy - Failure rate curve - MTBF, MTTR, MTTF (simple problems) - Systems reliability – series and parallel configuration - Improvement factor

REFERENCE BOOKS

1. Total Quality Management by NVR Naidu 2. Total Quality Management By S D Ramachandra 3. Statistics by Mahajan 4. Statistics by Raj Mohan –volume 1 & 2


WEEKLY PLAN FOR


WEEK


1-3

OVERVIEW OF TQM

Definition of TQM Definition of quality and its characteristics TQM concepts Deming’s philosophy Principles of TQM Benefits of TQM TQM organization

4-6 LEADERSHIP

Characteristics of TQM leaders Role of TQM leadership Continuous process improvement The PDSA (Plan-Do-Study-Act) cycle Six sigma (6σ) quality

7-9

QUALITY MANAGEMENT

TOOLS

Nominal group technique Affinity diagram Inter relationship diagram Tree diagram Matrix diagram Activity network diagram

10-12 STATISTICAL PROCESS

CONTROL

Seven quality control tools Process Capability Defect v/s defective

13-15

FUNDAMENTAL STATISTICS AND PROBABILITY

DISTRIBUTIONS

Measures of central tendency- mean mode, median, standard deviation Problems Definition and Properties of Probability Poisson distribution- simple problems Binomial distribution -simple problems Normal distribution- simple problems

16-18 DESIGNS FOR SIX SIGMA

Tools for concept and design development Design optimization Design verification

19-20

RELIABILITY AND LIFE TESTING

Definitions of Reliability, Life testing and Redundancy Failure rate curve MTBF, MTTR, MTTF (simple problems) Systems reliability – series and parallel configuration Improvement factor

govt.tool room & training centre term... · 2015. 6. 15. · govt.tool room & training...

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