2.810 Manufacturing Processes and Systems


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.


Date Lecture Textbook Readings
7th ed — 6th ed — 5th ed
Additional Readings
09.09 Course introduction & logistics skim ch. 1-9
skim pp. 1-33
Gutowski, "Competitive Attributes for Mfg. Processes and Systems"
Hardt, "Manufacturing Processes and Process Control"
"Geometric Tolerancing"
09.14 How is this part made?
09.16 Intro to processes figs. 23.14, 23.15, 35.20, 35.21
sec. 40.8, 40.9, 40.10
09.21 Process performance pp. 566-589, sec. 21.1-21.6
skim pp. 589-591
Gutowski et al, "Thermodynamic Analysis of Resources Used in Manufacturing Processes"
* Hogg et al, "Control Charts"
* Lipschutz, "Random Variables" (Chapter 5)
* Young, "Statistical Treatment of Experimental Data"
Standard tables for estimating the necessary factors for plotting control charts
09.23 Machining

Sample Process Plan
ch. 21-27, 36.7, 36.8
skim ch. 36, 38, 39
Polgar et al, "Time Estimation Booklet for Basic Machining Operations"
Dahmus et al, "An Environmental Analysis of Machining"
* Boothroyd et al, "Design Rules for Machining"
09.28 Metal forming
Lecturer: Dan Cooper
Reif, "Steps to Building a Sheet Metal Chassis for your 2.810 Car Using SolidWorks"
* Boothroyd et al, "Design for Sheet Metal Working"
09.30 Injection molding ch. 19 Thiriez et al, "An Environmental Analysis of Injection Molding"
"Injection Molding Case Study"
Lienhard, "A Heat Transfer Textbook" (4th ed.)
* Tadmore et al, "Molding and Casting"
* Boothroyd et al, "Design for Injection Molding"
10.05 Thermoforming sec. 19.6 Watch: Vacuum forming, Plastic cup thermoforming (1st min)
10.07 Additive manufacturing
Lecturer: John Hart
"Standard Terminology for Additive Manufacturing Technologies"
10.13 (Tue) Casting ch. 10-12, skim sec. 30.9, 30.10
skim ch. 32
Dalquist et al, "Life Cycle Analysis of Conventional Manufacturing Techniques: Sand Casting"
Note on Chvorinov's Rule
* Boothroyd et al, "Design for Die Casting"
* Flemings, "Solidification Process"
10.14 Quiz review Kalpakjian pp. 1147, 1149 (process & material energy) (not available in 5th-6th ed.)
10.19 QUIZ 1
10.21 Intro to manufacturing systems Womack et al, "The Monument of Monuments"
* Hounshell, "From the American System to Mass Production," Introduction, Ch. 6, Ch. 7
10.26 Manufacturing variability, time, rate
Lecturer: Stanley Gershwin

Time Analysis for Manuf Systems
Additional slides
Gershwin, "Notes on Manufacturing Systems"
Gershwin, "HP Case Study"
* Kleinrock, "Queuing Systems"
10.28 Assembly
Lecturer: Dan Whitney
sec. 37.10 GM, "A Machine-paced Line Flow Process"
* Boothroyd et al, "Product Design for Manual Assembly"
11.02 Process control
Lecturer: David Hardt
11.04 Toyota production system * 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"
11.16 Systems summary
11.18 QUIZ 2
11.23 Sustainable manufacturing
11.25 Team project work
11.30 Circular economy
Lecturer: Dan Cooper
12.02 Team project work
12.07 CAR RACE
12.09 Clean up and evaluations