ISYE 415: INTRODUCTION TO MANUFACTURING SYSTEMS DESIGN AND ANALYSIS FALL 2013

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LECTURES TUESDAY,THURSDAY 2:30-3:45 PM ME1152

LAB 301 MONDAY 12:00-12:50 PM ME2109

LAB 302 TUESDAY 12:00-12:50 PM ME2109

LAB 303 WEDNESDAY 12:00-12:50 PM ME2109

LAB 304 THURSDAY 12:00-12:50 PM ME2109

Instructor

Prof. Ananth Krishnamurthy

Associate Professor, Department of Industrial and Systems Engineering ME 3258, 1513 University Avenue, Madison, WI-53706

Phone: 608-890-2236; Fax: 608-262-8454 Email: [email protected]

Office Hours: Fri 12:00-1:00 pm, or by appointment.

Teaching Assistants (301, 302, 303, 304)

Soham Anand

Email: [email protected] Office: ME 3146

Office Hours: 1 pm -2 pm on Tue and Thu

Predeep Ravichandran

Email: [email protected] Office: ME 3146

Office Hours: 1 pm -2 pm on Mon and Wed

Course Website: Access through Learn@UW Course Description:

Introduction to the technologies, processes and systems of modern discrete part manufacturing. Emphasis on development of an understanding of the behavior of integrated systems.

Pre-requisites: ISyE 315, 320, 321; or consent of instructor.

Course Objectives:

This course will provide an introduction to the design and analysis of manufacturing systems. The course will develop students’ knowledge in three areas: manufacturing processes and computer-integrated manufacturing systems, manufacturing system design and analysis, and modern manufacturing management strategies.

Course Textbook (mandatory):

Instructor prepared course packet including lecture notes and laboratory manual

Evaluation and Grading:

Team % Individual % Class Project Lab Project Lab Homework 15 15 5 Review Exercises Lab Homework Midterm 1 Midterm 2 Final Exam 10 5 10 15 25 Total 35 65

Rules and Responsibilities:

Class meetings and attendance policy: The class meets twice weekly (Tuesdays and

Thursdays) in ME 1152 from 2:30 pm to 3:45 pm. Discussion in class will comprise of lecture material and solution of numerical examples to illustrate concepts covered in the lecture. Attendance may be taken in class and could be used in assigning the final course grade.

Class discipline: Students are expected to be in class on time. Cell phones, personal

computers, and headphones must be turned off during class. The use of calculators to solve the numerical problems discussed will be permitted.

Lab meetings and attendance: Lab sessions will be held on Mondays (301), Tuesdays (302),

Wednesdays (303), and Thursdays (304). Labs would be held either in ME 2109 or ME 2145. During lab sessions, students will be split into groups. It is important that you attend the lab session you are enrolled in and work with your assigned groups on the various assignments. Attendance at scheduled lab hours is mandatory. If you have constraints, please inform the instructor and the TAs at the earliest. See the lab manual for additional instructions.

Lab discipline and safety: The ISyE 415 laboratory activities require hands-on use of computers,

automatic machinery, and other manufacturing equipment. There are dangers present from machinery in motion, materials being processed, debris or spills on the floor, and other unanticipated events. To maintain a safe atmosphere, all users have certain responsibilities. Detailed safety instructions are provided in the lab manual. Please familiarize yourself with these instructions.

Office hours: Office hours will be maintained by the instructor and the TAs. Students are

strongly encouraged to make use of these hours to clarify concepts covered in class when needed. For instructor: Weekly office hour schedules will be posted on the office door and students can make appointments by recording their name on a slot in the posted schedule, or can walk-in as long as others have not signed up for specific slots. For TAs: Students can consult TAs via email or during office hours. The TAs will provide additional details about his office hour sessions.

Review Exercises: Review exercises will be issued weekly (roughly) during the semester and

would contribute to 10% of the final grade in the course. The goal of these exercises is to help the student review the key concepts covered in class each week and keep pace with the course material. Review exercises can be done individually or in pairs. The specific due dates for these assignments will be mentioned on each review exercise. Most often these exercises would be due at the beginning of class on Tuesdays and will be accepted in paper form only. Any review exercise submitted after the start of the class will be considered late. Late submission would result in loss of letter grades on the particular assignment. Review exercises submitted more than a day late will be assigned an F grade.

Class Project and Lab Project: All students will be expected to undertake a team based course

project based on the lecture material during the course of the semester. In addition students will carry out a lab project that integrates class and lab materials. The projects provide experience in applying concepts learnt in class in settings that go beyond what is covered in class and will provide experience in independent thinking and group work. Specific instructions regarding project objectives, tasks, deliverables and due dates will be provided.

Lab Homework: Graded homework sets will be issued periodically during the lab sessions and

would contribute to 10% of the final grade in the course. Homework will comprise of individual and team assignments. The homework handout will clearly specify whether a particular homework needs to be attempted individually or as a team. The specific due dates for these assignments will be mentioned on each homework. Homework will be due at the start of the class on the due date. Any homework submitted after the start of the class will be considered late. Late submission would result in loss of letter grades on the particular homework. Homework submitted more than a week late will be assigned an F grade.

Exams: The course will have three exams: two mid-term exams (10% and 15%) and a final

exam (25%). Only permitted reference material and computational aids may be used during an exam. Tentative dates for these exams are provided in the course schedule. Additional instructions regarding syllabus and permitted reference materials will be provided before each exam. Exams must be the sole work of the individual student. Collaboration of any kind, such as reading from another’s exam, using the answers of another student (in written, verbal or electronic form) is not allowed. Make up exams will be given only if the reason for missing an exam is illness or sudden and grave personal matters and the situation arises in the 24 hour period preceding an exam. When it is known in advance that an exam cannot be taken at the scheduled time, the student must make arrangements to complete the exam prior to the scheduled date and time. Both email and voicemail notice must be given to arrange an advance exam. When advance intimation is not possible, students are required to notify the instructor (using email and voicemail) within 24 hours of the missed date with the expectation that work will be completed within 48 hours of the missed date.

Re-evaluation of exams, homework, and assignments: Requests for re-evaluation of exams,

homework, or assignments must be submitted in writing immediately after the class in which the homework or exam is handed back to the students for the request to be considered. Exams, homework or assignments submitted for re-evaluation must not be altered from the original work.

Academic integrity: Student teacher relationships are built on trust. Students must trust that

teachers have made appropriate decisions about the structure and content of the course they teach, and teachers must trust that the assignments that the students turn in are their own. Acts that violate this trust undermine the educational process. The University of Wisconsin-Madison’s Academic Policies defines various forms of Academic Dishonesty and you should make yourself familiar with these. Violation of the policies stated above will result in severe academic penalties. Violation of these rules on exams will receive the grade F for the course and are subject to further disciplinary actions from the university. Violations on homework/project will result in a reduction of two letter grades for each infraction and no credit issued for any homework/project in the course. Penalties will be assessed against the person committing the fraudulent action as well as any supporters of the action. In case of questions concerning these policies, clarifications must be sought prior to submission of assignments.

Feedback: Students are strongly encouraged to provide feedback regarding various aspects of

this course during the course of the semester. While end-of-semester evaluations help influence the quality of the course in future offerings, periodic and timely feedback regarding all aspects of the course including, quality of instruction, lectures, text-book, homework, exams, grading, etc. would help improve the quality of instruction received by students currently taking the course.

List of Reference Books

(will be placed on course reserve at Wendt Library)

1. Groover M.P, Fundamentals of Modern Manufacturing: Materials, Processes and Systems, Prentice-Hall, 2002

2. Kalpakjian, S. Manufacturing Processes for Engineering Materials, 5th edition. Addison-Wesley Publishing Company, New York, 2003.

3. Hopp W.J and Spearman M.L, Factory Physics :Foundations of Manufacturing Management, Richard D Irwin, 2001

4. Suri, R., Quick Response Manufacturing: A Companywide approach to Reducing Lead Times, Productivity Press, 1998.

5. Womack, J.P., D.T. Jones and D Roos, The Machine that Changed the World, HaperPerennial, 1991.

Other Reference Books

Perspective on Manufacturing in America

 Dertouzos, M.L., R.K. Lester, R.M. Solow and the MIT Commission on Industrial Productivity, Made in America: Regaining the Productive Edge, MIT Press, 1989.  Hayes, R.H., S.C. Wheelwright and K.B. Clark, Dynamic Manufacturing: Creating the

Learning Organization, Free Press, 1988. -- See mainly Chapter 2.

Manufacturing Processes

 Amstead, B.H., Phillip Ostwald, Myron Begeman. Manufacturing Processes, 8th edition. John Wiley and Sons, New York, 1987.

 Cubberly, William and Ramon Bakerjian (Eds.). Tool and Manufacturing Engineers

Handbook, Desk Edition. Society of Manufacturing Engineers, Dearborn, 1989.

 Riley, F. The Electronics Assembly Handbook, Springer-Verlag, 1988.

Manufacturing Cells and Systems

 Choobineh, F. and R. Suri, Flexible Manufacturing Systems: Current Issues and Models, Industrial Engineering & Management Press, 1986.

 Luggen, W.W., Flexible Manufacturing Cells and Systems, Prentice-Hall, 1991.

Modern Manufacturing Strategies

 Hammer, M. and J. Champy, Reengineering the Corporation, HarperBusiness 1993.  M. Imai, Kaizen, McGraw Hill, 1986.

ISyE 415 - Fall 2013 - Prof. Ananth Krishnamurthy - Schedule - Rev.1

Dates may be rescheduled as course progresses

Date Day Lecture Topic Assignments

3-Sep T Course Overview, Iron and Steel

5-Sep R Iron and Steel

10-Sep T Rolling of Metals RE-1 Due

12-Sep R Forging of Metals

17-Sep T Extrusion and Drawing of Metals RE-2 Due

19-Sep R Metal Casting Processes

24-Sep T Sheet Metal Forming Processes RE-3 Due

26-Sep R Turning and Hole Making

1-Oct T Milling Processes RE-4 Due

3-Oct R Forming and Shaping Plastics

8-Oct T Mid Term 1, Finishing Operations and Welding Processes

10-Oct R Advanced Machining Operations

15-Oct T IC Fabrication RE-5 Due

17-Oct R Electronics Assembly Class Project Due

22-Oct T Flexible Manufacturing Systems RE-6 Due

24-Oct R Role of Inventory in Manufacturing

29-Oct T Role of Inventory in Manufacturing RE-7 Due

31-Oct R Material Requirements Planning

5-Nov T Material Requirements Planning RE-8 Due

7-Nov R Mid Term 2, Just in Time and Lean Manufacturing

12-Nov T Just in Time and Lean Manufacturing RE-9 Due

14-Nov R Manufacturing System Dynamics

19-Nov T Manufacturing System Dynamics RE-10 Due

21-Nov R Manufacturing System Dynamics

26-Nov T Variability in Manufacturing Systems

28-Nov R Thanksgiving Recess

3-Dec T Variability in Manufacturing Systems RE-11 Due

5-Dec R Batching Policies in Manufacturing Systems

10-Dec T Batching Policies in Manufacturing Systems RE-12 Due

12-Dec R Batching Policies in Manufacturing Systems

ISyE 415: Team Effort Evaluation Form

Team Name: Your Name:

Circle the one that applies:

Mid Eval Class Project Mid Eval Lab Project Other

Please evaluate the contribution of each team member, excluding yourself, using the form below. Cross out the line with your name on it. Evaluate the most recent contributions (since the last evaluation was handed in):

Last Name Main Task Assigned

Punctuality, Attendance (0-10) Completion of Assigned Work (0-10) Contribution through Ideas (0-10) Contribution through Effort (0-10) Any Other Comments or Feedback Rodgers Cobb Lacy Kuhn Nelson Jones Any other comments:

Please evaluate the effectiveness of the following since the last evaluation:

Very Unproductive Unproductive Indifferent Productive Very Productive Team meetings

List one aspect that is going well that you would like your team to continue to do through the rest of the semester.

List one aspect that is NOT going well that you would like your team to improve during the rest of the semester.

SAMPLE ONLY

Actual form will be handed

out after teams are made