200 Level Production Engineering

SEMESTERCOURSE CODECOURSE TITLEHOURS PER WEEKCOURSE CREDIT
1ST  EMA 281Engineering Mathematics I22
ECP 281Engineering Computer Programming22
MEE 211Engineering Mechanics I33
CVE 211Strength of Materials33
MEE 221Engineering Drawing I33
EEE 211Electrical Engineering I33
PRE 211Manufacturing Technology I32
ENS 211Engineering in Society22
ELA 201Engineering Laboratory & Workshop Practice*62
Total Credits2722
2ND  EMA 282Engineering Mathematics II34
MEE 212Engineering Mechanics II23
MEE 222Engineering Drawing II23
CHE 222Materials Science23
EEE 212Electrical Engineering II23
PRE 212Manufacturing Technology II22
ELA 202Engineering Laboratory & Workshop Practice*62
PRE 222Introduction to Computer Graphics & Drafting22
 Total Credits2122

300 Level Production Engineering

SEMESTERCOURSE CODECOURSE TITLEHOURS PER WEEKCOURSE CREDIT
1ST  EMA 381Engineering Mathematics III33
MEE 361Fluid Mechanics I32
MEE 351Engineering Thermodynamics I32
MEE 311Mechanics of Machines I33
MEE 321Engineering Drawing III33
EEE 317Electrical Engineering III33
PRE 321Production Technology I33
CVE 311Theory of structures & Strength of Materials13
ELA 301Engineering Laboratory & Workshop Practice62
Total Credits2824
2ND  EMA 382Engineering Mathematics IV34
MEE 362Fluid Mechanics II22
MEE 352Engineering Thermodynamics II22
MEE 312Mechanics of Machines II23
EEE 318Electrical Engineering IV22
PRE 322Applied Materials Science22
PRE 332Design of Machine Elements I23
PRE 314Industrial Engineering Statistics22
ELA 302Engineering Laboratory & Workshop Practice*62
 Total Credits2422

400 Level Production Engineering

SEMESTERCOURSE CODECOURSE TITLEHOURS PER WEEKCOURSE CREDIT
1ST  PRE 411Mathematical & Methods in Prod Eng.33
MEE 441Metallurgy22
PRE 441Machine Tool Technology I33
PRE 431Design of Machine Elements II33
PRE 421Production Technology II33
PRE 451Metrology33
PRE 461Introduction to Industrial Engineering33
PRE 401Production Laboratory*62
PRE 473Human Factors Engineering/Fact. Layout I33
CED 300Entrepreneur Development22
Total Credits                                                                     3127
2NDUBT400Faculty of Engineering Industrial Training (SIX MONTHS UBITS)66
Total Credits                                                                     66

500 Level Production Engineering

SEMESTERCOURSE CODECOURSE TITLEHOURS PER WEEKCOURSE CREDIT
1STPRE 541Machine Tool Technology II32
PRE 573Human Factors Engineering & Factory Layout II22
PRE 571Engineering Economics and Administration33
PRE 531Design for Production23
PRE 581Automation & Control I33
PRE 521Production Management I33
PRE 561Principles of Operations Research32
PRE 551Computer Applications in Production Engineering32
PRE 501Project93
Total Credits2923
2NDPRE 592Plastic Working of Metals23
PRE 522Production Management II33
PRE 582Automation & Control II33
PRE 532Tool Design (Including Jigs & Fixtures)33
PRE 562Operations Research II22
PRE 564Technology Policy & Entrepreneurship22
PRE 502Project93
PRE 572Engineering Management II33
Total Credits2819

COURSE CONTENT FOR B.ENG (PRODUCTION ENGINEERING)

200 Level Production Engineering

PRE211: MANUFACTURING TECHNOLOGY I(2 CREDITS)

Elementary introduction to types and organization of engineering workshops covering jobbing, batch, mass production.  Engineering materials:  Their uses and properties.  Safety in workshops and general principles of working.   Bench work and fitting:  Hand tools, instruments.  Carpentry:  Hand tools, materials, types of joint, processing of timber.  Blacksmithing, and tools and working principles.  Joints and fastenings: threaded fasteners, riveting, welding, brazing, and soldering.  Measurement and marking out for uniformity, circularity, concentricity, etc.  Standard measuring tools used in the workshop.

PRE212 MANUFACTURING TECHNOLOGY II (2 CREDITS)

Simple metal cutting applied to hand tools.  Single point tool geometry.  Cutting fluid General principles of working of standard metal cutting machine tools.  Work and tool movement, speed and feed range.  Centre lathe operations: Straight/taper turning.  Thread cutting.  Parts of lathes accessories and attachments used on centre lathe.  Drilling machine, drill bits and uses.  Production of pig iron, wrought iron, plain carbon and alloy steel and cast iron.

 300 Level Production Engineering

PRE311:  MANUFACTURING TECHNOLOGY III (3 CREDITS)

(For Non–Production Engineering Students)

Working principles, size and specification, classification, principal parts, work–holding and driving mechanisms of shaping, slotting, planing machines, turret and capstan lathes.  Applications of automatic and semi–automatic lathes.  Milling operations and machines: types, cutters, attachments, direct and simple indexing.  Grinding machines and wheels: wheel characteristics, selection, specification, etc.  Various methods of grinding processes, speed and feed applied.  Welding of ferrous/non–ferrous metals and alloys, cast iron. Uses of brazing and soldering.  Plastic and powder metallurgy.  Basic principles of pattern, mould, core making: their materials, allowances, etc.  Metal melting and casting.

PRE321: PRODUCTION TECHNOLOGY I: (3 CREDITS)

Working principles, specification, classification, features of construction, work – holding, driving mechanism, tools and cutters used in shaping, slotting and planning machines.  Turret, Capstan and Automatic lathes, operations planning, automation, and production economy.

Classification, features of construction and working principles of million machines, various operations and cutters, direct and simple indexing, compound and differential indexing and spiral milling, forces and power required in milling.  Further discussions on various drilling machines; Boring and Jig boring; tools and operations.

Selection and specification of grinding wheels, their mountings, dressing, etc. Working principles of surface, cylindrical, and centreless grinders: speed and feed applied.  Welding and allied processes: Principles, classification, welding metallurgy of ferrous and non–ferrous metals, gas cutting, AC/DC welding, etc.  Brazing, soldering and adhesive bonding.

Sand casting: Basic principles of pattern, mould and core making, their materials, allowances, etc.  Metal melting and casting.  Special moulding and casting processes, including centrifugal casting, shell casting and CO2 process.  Plaster mould casting Investment casting, die casting and continuous casting etc.

PRE314: INDUSTRIAL ENGINEERING STATISTICS (2 CREDITS)

Sample and population.  Empirical distributions.  Descriptive measures.  Introduction to Probability Theory.  Discrete distributions.  Continuous distributions.  Moment-Generating function.  Sums and Products of random variables.Sampling distributions.  Order Statistics.  Estimation and testing.  Some standard tests of significance and confidence intervals.  Distribution – Free methods.

PRE322: APPLIED MATERIAL SCIENCE (2 CREDITS)

Basic Metallurgy, Engineering Materials.  Iron and Steel.  Plastics, ceramics, composite materials: properties, applications and selection.  Corrosion and its prevention.  Materials Testing.  Shaping Processes for rheogical materials and metal powders:  Powder metallurgy, injection moulding, compression moulding, blow moulding, transfer moulding, etc.

PRE332: DESIGN OF MECHINE ELEMENTS I:(3 CREDITS)

Principles and methods of design.  Strength calculations.  Standards.  Preferred numbers and fits.  Materials, standard sections and dimensions.  Failure and factors of safety.

Machine Elements

Design of the following:  Riveted joints.  Welded joints.  Threaded joints.  Springs.  Friction drives.  Belt and rope drives.  Chain drives.  Power screws.  Brakes.  Couplings and clutches.  Machine Frame.  Keys.  Cotters and spine joints.

400 Level Production Engineering

PRE411: MATHEMATICAL METHODS IN PRODUCTION ENGINEERING (3 CREDITS)

1.    Complex Variables:  Complex functions of a real variable. Elementary functions of a complex variable.  Differentiation of complex variables.  Cauchy-Riemann equations.  Analytic and Harmonic functions.  Integration of complex variables.  Cauchy’s theorem, poles and residues.  Simple examples of expansion in Taylor and Laurent series.  Conformal mappings.

2.    Integral Transforms:  Laplace and Fourier transforms.  Application to boundary value problems in mathematical physics.

3.    Introduction to Non-linear Differential Equations:

        (a)  Stability of linear systems and the phase portraits.

        (b)  Long time behaviour of the solution of non-linear differential equations deduced from related linear systems.

4.    Calculus of Variations:  Lagrange’s equation and applications.  Hamilton’s principle and Geodesic problems (formal proofs of the related theorems will not be required).  Iso-perimetric problems.

(a)          Probability: Probability laws, conditional probability and dependence of events.  Discrete and continuous probability distribution.  The probability functions:  the density function and the distribution function.  Expected values; moments, standard distributions, binomial, Poison normal.

(b)          Statistics:  Regression and Correlation:  The method of least squares: linear and curvilliar regression.  Correlation, total, partial and multiple.  Large sampling Theory: Sampling distribution of mean, proportion, difference of means and proportion.  Confidence interval for mean, proportion, difference of two means and proportions.

5.            Test of Hypotheses:  Types I and II errors.  Power of a test.  Large sample-test   concerning the mean, proportion, difference of two means and proportions.

6.            Quality control

PRE: 421: PRODUCTION TECHNOLOGY II (3 CREDITS)

Mechanics of Metal Cutting.  Tool life and Tool wear.  Cutting fluids and surface roughness.  Economics of metal cutting. Broaching:  Types of broaches, tool material, heat treatment, grinding, fixtures, broaching compared to other machining processes, pulling head. Surface finishing operations:  Lapping, Honing, Super-finishing, Polishing, etc.

Gear manufacturing methods:  Gear generation by Hobbing, Shaping, milling, Gear finishing and grinding.

Screw thread production: rolling, grinding, milling, Diehead Inspection. 

Non – traditional machining processes e.g. ultrasonic, electro – discharge machining (EDM), electro – chemical machining (ECM), etc.

Metal finishing operations: Surface preparation, Electroplating, dipping, diffusion and sprayed coating, etc.  Flow turning of metals.

PRE431: DESIGN OF MACHINE ELEMENTS II(3 CREDITS)

Design of the following:  Gears – spur gears, helical gears, bevel gears, worms, etc.  Reduction gears and variable – speed drives.  Shafts and axles, Shaft – hub joints, Sliding – contact bearings.  Rolling contact bearings.  Flywheels.  Levers.

Cam mechanism design.  Use of handbooks and standards.  Selection.  Electrical drives.  Optimum design of machine elements and mechanisms.  Choice of manufacturing processes on design of machine elements, assembly and performance.

 PRE441:  MACHINE TOOL TECHNOLOGY I (3 CREDITS)

Main features of machine tool design: Mechanical transmission.  Design of gear boxes. 

Speed characteristics, speed range, speed constant (ratio). Determination of the ratio and series of preferred numbers.  Design of simple gear trains and ray diagrams.  Determination of gear ratios for gear blocks and gear teeth number.  Slotted link-reciprocating motion.  Whitworth quick return mechanisms.

Hydraulic transmission.  Simple hydraulic circuit.  Pumps and elliptical gear pumps. 

Variable delivery pumps and piston pumps.  Design for rigidity.  Static and dynamic stiffness.  Compliance.  Stiffness and compliance of sub–assemblies.  Gear transmission.

Bearing design.  Journal bearings, ball bearings and roller bearings in machine tool.

Hydrostatic and aerostatic bearings.

Installation of machine tools. Basic consideration, damping and absorption methods.

PRE451: METROLOGY (3 CREDITS)

Measurement of length: Light rays. Block gauges. Comparison with known lengths. Graduated scales.

Angular Measurement: Combination angle gauges.  Sine bars. Auto-collimator. Angle dekkor. Precision level. Straightness and flatness of surfaces. Taper measurement.

Geometrical measurement with respect to another surface: Straightness, flatness, squareness, roundness, cylindricity, concentricity, parallelism and taper. 

Screw Thread Measurement: Thread elements. Measurement of major diameter, minor diameter, simple effective diameter, thread pitch, thread form, virtual effective diameter.

Gear measurement: The involute form. Gear tooth elements. Rolling gear test. Measurement of gear tooth profile, gear tooth thickness, gear pitch.

Measurement and analysis of surface finish.

Limits, Fits and Tolerances: Hole and shaft –basis systems. Basic simple assemblies. Limit gauging. Principles of gauging. Gauge  tolerances.

Optical Flat and interferometry. Accuracy of Measuring Systems. Alignment tests on machine tools. Principles of automatic dimensional control.


PRE461: INTRODUCTION TO INDUSTRIAL ENGINEERING (3 CREDITS)

Classification of modern Industry. Industrial activities. Productivity and its effect on economic development and the standard of living of the citizens of a nation.

Work design and Measurement: Control, Operation and Design of manned industrial and service systems. Methods and techniques to measure work performance. Safety engineering.  Principle and procedure to design and operate systems that involve people for maximal safety.  Job satisfaction and efficiency. Principles of motion economy.

Plant location. Selection and procedures for location. Plant and workplace layout.  Material Handling Principles. Selective treatment of other basic techniques actually used by industrial engineers.

PRE473: HUMAN FACTORS ENGINEERING (3 CREDITS)

Basic human factors.  Principles of Procrustean Ergonomics.  Task and skill analysis.  Design trade-offs Environment considerations.

Display design.  Mechanical and electrical displays.  Optical displays.

 Digital read outs. Auditory signals.

Fatigue.  Methods of measurement.  Illumination, Noise.  Pollution Control.  Ventilation and human comfort design.  Effects of training on productivity.  Learning curves.

Product liability.  Biodynamic and Biostatic Mechanics.  Introduction to Workspace and workplace design.  Kinesiology.

500 Level Production Engineering

PRE521:  PRODUCTION MANAGEMENT I (3 CREDITS)

Principles of production.  Types of production processes.  Development of Group Technology and cellular systems.

Materials management.  Purchasing methods.  Stores and Inventory Control.  Engineering Economy.  Economic analysis of engineering projects.  Selection of appropriate interest rates and methods of analysis, depreciation and tax considerations.  Break–even analysis and cost–benefit analysis.

Survey of manufacturing methods in a range of industries, textiles, timber, food, agriculture, etc.  Plant visits and essays.  Study of some manufacturing industries such as cement, electronics, etc.

Industrial computers and their applications.  Small–scale businesses in Production Engineering.

PRE522:  PRODUCTION MANAGEMENT II (3 CREDITS)

Production Planning and Control.  Principles of Control, Budgetary and cost control.  Information processing and control.

Forecasts, principles of forecasting, and simple forecasting models.  Scheduling Techniques.  Sequencing n–jobs through n–machines.  Project scheduling by CPM and PERT methods.  PERT–CAST.  Crashing of network.

Quality Control.  Quality Control principles, total quality concept, economics of quality, process capability, control charts, sampling systems, inspection systems, quality motivation and training.

Principles of reliability engineering, product and process reliability, measures of reliability. Maintenance and repair of systems, management for process reliability, maintainability.

PRE531:  DESIGN FOR PRODUCTION (3 CREDITS)

Introduction.  Selection of Production Processes.  Design of assemblies, sub–assemblies and components from production aspects.  Simplification, standardisation, interchangeability, application of limits, fits, surface finish, to design for production and how they affect production cost.

Design of castings avoiding common defects.  Design of riser, gating cores.  Design of mechanised foundry.  Die casting design.

Design of forgings and dies; extrusion, wire drawing dies, roll pass, etc.  Selection of welding processes.  Design of Weldments.  Heat affected zones and prediction of joint strength.  Residual stress and stress relieving.  Process layout design.  Operation planning as applied to semi–automatic and automatic lathes.  Design of cams for automatic lathes.  Design of limit gauges.  Planning of inspection procedures.  Case studies in designing for production.

PRE541:  MACHINE TOOL TECHNOLOGY II (2 CREDITS)

Trends in the development of machine tools.  Design of various types of feed mechanisms.  Error correction and compensation.  Design of beds, slideways, and columns.

Analysis of cutting forces: Turning and drilling processes.  Introduction to the determination of stiffness of lathe machines.  Calculation of power consumption of machine tools.

Machine toll spindles and mountings.  Design of spindles.  Simple treatment of machine tool vibration (chatter), different theories.  Methods of elimination and reduction.

Electrical equipment of machine tools: Types of motors and speed control.  Starting gears.  Electromagnetic devices.

Principles of machine tool design applied to the design of centre lathe and drilling machine.

PRE551: COMPUTER APPLICATIONS IN PRODUCTION ENGINEERING (2 CREDITS)

Microsoft Office Packages:  Microsoft Word, Excel, Access, Power Point

Computer Aided Design and Manufacturing; CAD/CAM: AutoCAD 2002, Alibre Design 2004, Solid Edge

Computer Programming Languages: Microsoft Visual Basic, Net, Visual C++. Net, MatLab

Operations Research and other relevant packages:  TOR A, Mdsolid, etc.

Computer practical sessions to demonstrate applications.

PRE561: PRINCIPLES OF OPERATIONS RESEARCH FOR INDUSTRIAL PROCESSES (2 CREDITS)

Development of O.R. techniques.  Tools. Deterministic, probabilistic and stochastic characters in industrial operations.  Scope, theory and application of linear programming models.

Simplex method.  Resource allocation, assignment and transportation problems.  Duality.

Review of computer programming with special reference to production problems.

PRE564:  TECHNOLOGY POLICY AND ENTREPRENEURIAL DEVELOPMENTIN PRODUCTION ENGINEERING (2 CREDITS)

Introduction:  Production engineering and the national economy:  its scope and impact.  The importance of manufacturing:  the role of small-scale enterprises (examples from India, Malaysia, Indonesia, etc).

Business ownership:  Types and features.  Business incorporation.  Feasibility Studies, Sources of capital.  Book-keeping.  Stock-taking.  Conducting a market survey, selecting a business opportunity selecting an appropriate technology, choice of location and site obtaining licenses, permits and approvals.

Core Investments:  Discussion of (I) organisation  (ii) operations (iii) common equipment used and procurement  (iv) raw materials:  types, brands, sources,  (v) personnel requirement,  (vi) types of products made, and  (vii)  investment analysis for the following.

Foundry  (b)  Machine shop (machine – building, tool making, general, etc)  (c) Press shop  (d) Welding and fabrication  (e)  Plastics moulding  (f)  Forge shop  (g)  Electro – plating and other metal finishing processes  (h)  Heat treatment shop  (i)  Pattern shop   (j)  Others.

Other Investments:  (a)  Oil-milling and refining (palm oil, palm kernel oil, groundnut, melon, lemon grass, etc)  (b)  Flour – milling (maize, yam, plantain, etc)  (c)  Soap – making  (d)  Pigments – making (paints, dyes, etc),   (e)  Others (e.g. solid mineral processing, chemical products, agro-processing, etc).

New Products and Technologies:  New products:  materials, machines and processes developed in the department, faculty and other universities and research institutes should be discussed.

Plant Visits:  Visit to at least 70 percent of the factories discussed is mandatory.

PRE573:  HUMAN FACTORS ENGINEERING & FACILITY LAYOUT (2 CREDITS)

Factory location.  Principal factors.  Locational model for single factory location and multi-factory location. Factory layout.  Flow and activity analysis.  Different types of layout.  Factors affecting layout.  Layout design.  Systematic layout planning.Discrete and continuous Facility Design and layout problems.  Minimax layout and location problems.

Work place design, Principles of motion economy as applied to human body, Anthropometry and Workspace.

Elements of Forensic Engineering

Applications of human factors data.

PRE581:  AUTOMATION AND CONTROL I (3 CREDITS)

Basic definitions and concepts.  Control systems in Production Engineering, e.g. NC machine tools, Production–Inventory Control, etc.

Block diagrams and their reduction.  Signal flow graphs.  Transfer functions.  State–space representations.  Some common transfer functions.

System Stability: Routh, Hurwitz, etc. stability criteria.  System Classification.  Error Constants and Sensitivity.  Types of System Inputs, Second – Order Systems.  Transient and Steady–State Responses.  Performance Indices.

Root–Locus Analysis.  Root–Locus Design.  Bode Analysis.  Bode Design.  Nyquist Analysis.  Nyquist Design.  Nicholas Chart Analysis.  Nicholas Chart Design.

PRE532:  DESIGN OF TOOLS, JIGS AND FIXTURES (4 CREDITS)

Problem of tool design: Historical background.  Development and selection of tool materials.  Design of cutting tools: geometry of single and multiple point tools.  Special purpose tools, etc.  Design of turning, boring, form turning tools, chip breakers, throw–away tools, etc.  Design of drills, milling cutters, gear cutting tools and broaches.

Press tool design: Calculation of shearing load, tonnage capacity, centre of pressure.  Design of punch and die for blanking, piercing, bending, deep drawing, hydroforming etc.  Progressive, compound and combination press tools.

Design of Jigs and Fixtures:  Introduction, general design principles and methods of location, clamping, indexing.  Drill jig bushes.  Examples of drilling jigs.  Fixtures for lathe, milling, broaching, grinding and welding.  Universal standard built up jigs, standard components: Fabrication and material.  Economic analysis.

PRE562:  INDUSTRIAL OPERATIONS RESEARCH (2 CREDITS)

Queuing problems.  Nature and solution of queuing problems.  Dynamic programming, applications to industrial problems.  Simulation techniques. Monte Carlo methods; Use of computer for system simulation, Introduction to non–linear programming. Geometric Programming. Numerical Methods in Operations Research.

PRE582: AUTOMATION & CONTROL II (3 CREDITS)

General Control System Components; Analogue and digital control systems.  Electrical, mechanical, and fluid power transmission.  Analogue computation.  Digital computer control systems.

Numerical Control of Machine Tools

Philosophy; types (e.g. point–to–point, and contouring), and economics of NC machine tools. Elements of NC machine tools.  Some commercially available NC systems.  Programming.  Elements of post – processor contours and surfaces.  Special computer languages.  Fluidics components, principles and application to production and handling processes.  Introduction to CAD/CAM.

PRE592:  PLASTIC WORKING OF METALS (3 CREDITS)

Simple stress and strain.  True and engineering strains; strain rate.  Determination of flow stress: tensile tests, pure compression, plane–strain compression, ring compression, torsion tests, high strain–rate test.  Volume constancy.

Yield in metals: Yield under combined stresses:  Mohr’s circle for plane and three–dimensional stresses.  Yield criteria: Tresca and Von Mises yield criteria.  Types of plastic materials:  Perfectly rigid perfectly plastic, elastic–workhardening, workhardening, etc.

Loads and power from local stress evaluation for drawing, forging, extrusion, rolling and press–working operations.

Slip–line field theory.  Henky’s equations, velocity fields, velocity discontinuities, hodographs.  Applications to forging, drawing and extrusion.

The principle of upper bound analysis.  Application to forging, extrusion, deep drawing and metal cutting.

PRE571:  ENGINEERING ECONOMICS & ADMINISTRATION (3 CREDITS)

The Management Environment – Formation of a company, sources of finance, money and credit.  Insurance, National policies, GNP growth rate and prediction.  Balance of payments.  Letal liabilities under company law, legal and contractual obligations to employees and the public, contractual obligations.

Organization Management – Principles of organization, span of control.  Elements of organization.  Types.  Principles of management.  Schools of thought.  Management by objectives.

Financial Management – Accounting methods.  Financial statement.  Elements of costing.  Cost planning and control.  Budget and budgetary control.  Cost reduction programmes.  Depreciation accounting, valuation of assets.

Personal Management – Selection, recruitment and training.  Job evaluation.  Merit rating.  Incentive schemes.  Trade unions and collective bargaining.

Industrial Psychology – Individual and Group behaviour.  The learning processes.  Motivation and Morale.  Influence of the Industrial Environment.

PRE572: ENGINEERING MANAGEMENT II (For Non-Production Engineering Students)(3 CREDITS)

Resource Management:  Materials Management.  Purchasing Methods.  Contracts.  Stores and Inventory Control. Time Value of Money, Interest formulae.  Rate of Return.  Methods of Economic Evaluation.  Selection between Alternatives.

Planning Decision-Making Forecasting, planning, scheduling.  Production control.  Gantt Chart.  C.P.M. and PERT.

Optimisation.  Linear programming as an aid to decision-making.  Elementary treatment of decision-making policies under risks and uncertainties.

Transport and Materials Handling Selection of transport media for finished goods, raw materials and equipment.  Facility layout and location.

Basic principles of work-study.  Principles of motion economy.  Ergonomics in the design of equipment and process.  Maintenance Engineering