2.810 Manufacturing Processes and Systems

Lectures 2017

Textbook readings are all from the 7th Edition of Manufacturing Engineering and Technology by Kalpakjian and Schmid, Prentice Hall 2014. If you have an earlier edition (6th or 5th), you can see the corresponding pages by clicking on it in the table header.

Additional readings marked with an asterisk (*) cannot be posted online due to copyright restrictions. They are uploaded in the Dropbox folder that has been distributed to the class via e-mail. Readings marked with a double asterisk (**) are extra information and are not required.


Date Lecture Textbook Readings
7th ed — 6th ed — 5th ed
Additional Readings
09.06 Course Introduction (2017) skim ch. 1-9
skim pp. 1-33
Gutowski, "Competitive Attributes for Mfg. Processes and Systems"
Hardt, "Manufacturing Processes and Process Control"
"Geometric Tolerancing"
09.11 How is this part made? (2017)
09.13 Intro to Processes (2017) figs. 23.14, 23.15, 35.20, 35.21
sec. 40.8, 40.9, 40.10
09.18 Process Performance (2017) pp. 566-589, sec. 21.1-21.6
skim pp. 589-591
* Hogg et al, "Control Charts"
* Lipschutz, "Random Variables" (Chapter 5)
* Young, "Statistical Treatment of Experimental Data"
* Boothroyd, "Design for Manual Assembly"
Standard tables for estimating the necessary factors for plotting control charts
**Gutowski et al, "Thermodynamic Analysis of Resources Used in Manufacturing Processes"
09.20 Machining (2017)
Sample Process Plan
ch. 21-27, 36.7, 36.8
skim ch. 36, 38, 39
* Boothroyd et al, "Design Rules for Machining"
**Lieneke, "Tolerances for Additive Manufacturing"
**Polgar et al, "Time Estimation Booklet for Basic Machining Operations"
**Dahmus et al, "An Environmental Analysis of Machining"
09.25 Process Control (2017)
Lecturer: Dave Hardt
Control Chart Factors
*Levine et al., "Xbar charts"
09.27 Sheet Metal Forming (2017)
ch. 16 **Reif, "Steps to Building a Sheet Metal Chassis for your 2.810 Car Using SolidWorks"
* Boothroyd et al, "Design for Sheet Metal Working"
10.02 Assembly (2017)
Lecturer: Dan Whitney
*Available via Dropbox
sec. 37.10 * Boothroyd et al, "Product Design for Manual Assembly"
**GM, "A Machine-paced Line Flow Process"
10.04 Injection molding (2017)
Mahdi Takaffoli lecture slides
ch. 19 "Injection Molding Case Study"
Lienhard, "A Heat Transfer Textbook" (4th ed.)
**Thiriez et al, "An Environmental Analysis of Injection Molding"
* Tadmore et al, "Molding and Casting"
* Boothroyd et al, "Design for Injection Molding"
10.9 No Class
10.11 Thermoforming (2017)
Fused Deposition Modeling (2017)
sec. 19.6 (Thermoforming)
ch. 10-12, skim sec. 30.9, 30.10
skim ch. 32 Casting
Watch: Vacuum forming, Plastic cup thermoforming (1st min)
Note on Chvorinov's Rule
**Dalquist et al, "Life Cycle Analysis of Conventional Manufacturing Techniques: Sand Casting"
* Boothroyd et al, "Design for Die Casting"
* Flemings, "Solidification Process"
10.16 Quiz review Kalpakjian pp. 1147, 1149 (process & material energy) (not available in 5th-6th ed.)
10.18 QUIZ 1
10.23 Intro to manufacturing systems (2017)
American Precision Museum (by Emily and Victor)
Womack et al, "The Monument of Monuments"
* Hounshell, "From the American System to Mass Production," Introduction, Ch. 6, Ch. 7
10.25 Toyota Production System (2017)
Rod Support Systems Cost Comparison
* Black, "The Design of the Factory with a Future," Ch. 2, 4
* Womack et al, "The Machine That Changed The World," Ch. 3, 4
* Maccoby, "Is There A Best Way To Build A Car"
* Moden, "Toyota Production System"
10.30 Additive manufacturing
Lecturer: John Hart
*Prof Hart Lecture Slides
*D'Aveni, "The 3D Printing Revolution"
*Standard Terminology for Additive Manufacturing Technologies
11.01 Time and Variability in Manufacturing Systems (2017) Gershwin, "Notes on Manufacturing Systems"
**Gershwin, "HP Case Study"
* Kleinrock, "Queuing Systems"
11.06 Systems Summary (2016)
Time Analysis (2017)
TPS Cell Redesign (2017)
TPS Process Plan (2017)
Value Stream Mapping (2017)
11.08 Project Progress Reports
11.13 *Supply Chains (lecture 15 slides in dropbox)
Lecturer: Steve Graves
King, "Crack the Code"
*Inventory Note
*Explanation by Prof Graves
11.15 Quiz 2
11.20 Sustainable Manufacturing
11.22 Work on Projects
11.27 Additive Manufacturing Startup
Lecturer: Martin Feldmann
11.29 Life Cycle Assessment
12.04 Digital Manufacturing
Lecturer: Brian Anthony
12.06 Team Project Work
12.11 CAR RACE
12.13 Clean up and evaluations
Additional Circular Economy (2016)
Lecturer: Dan Cooper
Additional Casting (2016)
Metal Additive Manufacturing