Lectures

Readings and Handouts

Readings in Kalpakjian and Schmid edition 6 (edition 5)

1.

Introduction updated

9/14

T. Gutowski,  "Competitive Attributes for Mfg. Processes and Systems"   

D. Hardt, "Manufacturing Processes and Process Control"

"Geometric Tolerancing"

Kalpakjian  pp 1-42, Skim Ch 1-9 (pp 1-35, Skim Ch 1-9)

Optional: The exergy concept

2.

How is this part made? updated

9/14

3.

Intro to Mfg Processes updated

9/16

Kalpakjian Figs 23.13, 23.14, 35.19, 35.20 (Figs 22.14, 22.15, 35.22, 35.23),
Sec 40.7, 40.8, 40.9 (40.5, 40.6, 40.7)

4.

Machining updated

9/21

Max Milling Rate Video (handout)

Machine Training: Introduction to the Mill

G. Boothroyd et al., “Design Rules for Machining” (handout)

K.C. Polgar et al., “Time Estimation Booklet for Basic Machining Operations” (handout)

Dahmus et al, "An Environmental Analysis of Machining"  

Kalpakjian Ch 21-27, 36.7, 36.8, Skim 36, 38, 39 (Ch 20-26, 36.7, 36.8, Skim Ch 36, 38, 39)

5.

Injection Molding updated

9/28

Lienard, "A Heat Transfer Textbook" 3rd Edition

Tadmore et al, "Molding and Casting"  (handout)

Boothroyd et al, "Design for Injection Molding"  (handout)

Thiriez et al, "An Environmental Analysis of Injection Molding"

"Injection Molding Case Study"

Kalpakjian: Chapter 19 (Chapter 18)

6.

Thermoforming updated

9/30

Kalpakjian: Sec 19.6 (Sec 18.6) “Trimming”

7.

Sheet Forming updated

10/5

Boothroyd et al, "Design for Sheet Metal Working" (handout)

Reif, "Steps to Building a Sheet Metal Chassis for your 2.810 Car Using SolidWorks"

Kalpakjian: Ch 16 (Ch 16)

8.

Casting updated

10/7

Boothroyd et al, "Design for Die Casting" (handout)

Flemings, "Solidification Process"

Dalquist et al, "Life Cycle Analysis of Conventional Manufacturing Techniques: Sand Casting"

Kalpakjian Ch 10-12, Skim Sec 30.9, 30.10, Skim Ch 32 (Ch 10-12, Skim Ch 29, 30) 

9.

D. Whitney,“Mechanical Assembly” updated

Boothroyd Dewhurst lecture with an example

10/13

10/14

Boothroyd et al,"Product Design for Manual Assembly" (handout)

"A Machine-paced Line Flow Process"

Kalpakjian Sec 37.10 (Sec 38.10)

YouTube videos of things being assembled

10.

Thermodynamic Analysis of Manufacturing Processes updated

10/14

Gutowski et al, "Thermodynamic Analysis of Resources Used in Manufacturing Processes"

11.

Car Design/Fabrication for Contest

10/19

QUIZ I

Sample Quizzes

13.

Intro. to Mfg. Systems  updated

10/26

From the American System to Mass Production: Introduction (handout), Chapter 6 (handout), Chapter 7 (handout)

Hounshell, David A.  "Automation, Transfer Machinery, and Mass Production in the US Automobile Industry in the Post-World War II Era," Enterprise & Society 1 (March 2000):100-138.  Available through MIT Libraries VERA system.

Kalpakjian: Skim Ch 37 & Read Ch 39 [V5 & V6]; Skim Ch 38 & Read Ch 39 [V4]

14.

Toyota Production System updated

10/28

Womack et al., "The Machine that Changed the World", Chapter 3 (handout)

Maccoby, "Is There a Best Way to Build a Car?" (handout)

Black,  "The Design of the Factory With a Future" (handout)

15.

Time Variability in Manufacturing updated

10/28

Gutowski, "Comments on Little's Law"  

Gershwin, "Time Variability in Manufacturing Systems"

Salzman and Gutowski, "Flexible Manufacturing System - Evaluation and Redesign"

16.

Quality & Variation updated

11/2

Phadke, "A Brief Intro to Designed Experiments" (handout)

Lipschutz, "Random Variables" (handout)

Hogg and Ledolter, "Control Charts" (handout)

17.

DOE (Dan Frey) updated

11/4

18.

Manufacturing System Overview updated

11/9

McKay, "The Evolution of Manufacturing Control - What Has Been, What Will Be" (handout)

Womack and Jones, "The Monument of Monuments" (handout)

"Competitive Analysis: Selecting the Best Prodcution System" (handout)

20.

TPS Cells vs. Other systems

21.

Duane Boning's lectures:

Microelectronics Fabrication

Integrated Circuit Manufacturing Processes

22.

Environmentally Benign Manufacturing