ME455 S11

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[edit] Official Syllabus

  • Will be updated tonight

[edit] Course Contact

[edit] Prerequisites

The student must have passed with a C or better the following courses: ME 301, 306, and 312. Under limited circumstances, the student may be concurrently enrolled in ME 404 based upon professor discretion.

[edit] Special Accommodations

If special accommodations are required for the student, please see the professor so that proper arrangements may be made.

[edit] Textbooks

[edit] Required

Poli, C., (2001), Design for Manufacturing:  A Structured Approach, Butterworth-Heinemann, Boston, MA: ISBN 0-7506-7341-9. online-Google Books

[edit] Suggested

Boothroyd, G., Dewhurst, P., Knight, W., (2002), Product Design for Manufacture and Assembly, CRC Press, : ISBN 082470584X, 9780824705848. (online-Google Books (partial)

[edit] References

See the Library Reserves.

[edit] Course Description

Concepts of product and process design for automated manufacturing are considered. Topics include product design for automated manufacturing, inspection and assembly, using automation, industrial robots, knowledge-based systems and concepts of flexible product manufacture. Preq: ME 301, 306, and 312 (or concurrent enrollment), or consent of instructor. The primary objectives of this course are to develop in the student:

  • To show students the relationships between part design and its manufacturability.
  • To teach students methods of DMF and DFA.
  • To provide students team instruction through project experiences.

[edit] Assignments

This course is structured to build upon the student's experiences, encourage the student to discover new material independently, and foster a habit of self-critique. To do this, assignments are designed to help the student understand the material, not to create busy work.

  • Assignments should be professional quality (clear, concise, correct, and conscientious).
  • Design Rules should be turned online to the following e-mail id: and The e-mail should contain the subject "ME55/655"
  • The Design Rules should be submitted with a standard cover sheet.
  • Assignments are due at the BEGINNING of class. Late assignments will be given credit after a 10% reduction for each day late, however late work may be submitted for corrections.
  • Ethical behavior and professional standards are expected in this class. All work submitted is to be that of the individual

student unless cooperative effort is authorized in specific instances. The College of Engineering and Sciences Honor Code will be observed.  Refer to your student handbook regarding University policies on academic dishonesty.

[edit] Computer Usage

Word processing, spreadsheet, Internet, and mathematical computation utilities will be used by the students throughout the course.

[edit] Weighting for Grade

Description ME 455 Weighting ME 655 Weighting
In-class Activities 20% 15%
Reverse Engineering Project 20% 15%
Design for Assembly Project 15% 15%
Design for Manufacturing Project 15% 15%
DFX Guidelines 30% 20%
Term Project 20%
Total 100% 100%

[edit] Graduate/Undergraduate

This course will be taught at an accelerated pace, corresponding with a graduate level course. Students are encouraged to work in pairs on the projects. Undergraduates and graduates will be evaluated on separate scales. Additional assignments will be given to the graduate students to test deeper understanding of the material.

[edit] The Engineer's Creed

As a Profession Engineer, I dedicate my professional knowledge and skill to the advancement and betterment of human welfare. I pledge:

  • to give the utmost of performance
  • to participate in none but honest enterprise
  • to live and work according to the laws of man and the highest standards of professional conduct
  • to place service before profit, the honor and standing of the profession before personal advantage, and the public welfare above all other considerations

In humility and with need for Divine Guidance, I make this pledge.

[edit] Engineering Ethics (The Canons)

  • Engineers shall hold paramount the safety, health, and welfare of the public in the performance of their professional duties.
  • Engineers shall perform services only in areas of their competence.
  • Engineers shall continue their professional development throughout their careers, and should provide opportunities for the professional and ethical development of engineers under their supervision.
  • Engineers shall act in professional matters for each employer or client as faithful agents or trustees, and shall avoid conflicts of interest or the appearance of conflicts of interest.
  • Engineers shall build their professional reputation on the merit of their services and shall not compete unfairly with others.
  • Engineers shall associate only with reputable persons or organizations.
  • Engineers shall issue public statements only in an objective and truthful manner.
  • Engineers shall consider environmental impact in the performance of their professional duties.

[edit] Tentative Schedule

This schedule is subject to change. Students are responsible for being aware of such changes.

Questions should be directed to the professor: Joshua D. Summers [1]

[edit] Project Images

[edit] Design for Assembly - Prototype Images

Week Day Topic Reading
1 2010.01.07 Introduction: Course, Design for Manufacturing (large) (small) * Chapter 1 and Chapter 2 of Poli
2 2010.01.12 Design for Assembly (large) (small) * Chapter 12 (Poli)
2 2010.01.14 Design for Assembly (large)(small) * Chapter 12 (Poli)
3 2010.01.19 Design for Assembly (large)(small) Assembly Textbook Chapter
3 2010.01.21 Design for Assembly (large) (small) (in class example)
4 2010.01.26 Design for Assembly/Poka Yoke/Fixtures (large) (small)
4 2010.01.28 Fixtures (large) (small) * Chapter 3 (Poli)
5 2010.02.02 Fixtures and Injection Molding (large) (small) * Chapter 3 (Poli)
  • Chapter 4 (Poli)
5 2010.02.04 Injection Molding (large) (small) Chapter 5 (Poli)
6 2010.02.09 Injection Molding (large) (small) Chapter 5 (Poli)
6 2010.02.11 Injection Molding (large) (small) Chapter 5 (Poli)
7 2010.02.16 Injection Molding (large) (small) Chapter 5 (Poli)
7 2010.02.18 Casting (large) (small) Chapter 6 (Poli)
8 2010.02.23 Casting (large) (small) Chapter 6 (Poli)
8 2010.02.25 Die Casting (Sen) (large) (small) Chapter 7 (Poli)
9 2010.03.02 Stamping (large) (small) Chapter 8 (Poli)
9 2010.03.04 Stamping (Sen) (large) (MAPP Test) Chapter 8 (Poli)
10 2010.03.09 Stamping (Sen) (large) (small) Chapter 8 (Poli)
10 2010.03.11 Stamping (Sen) (large) (small) Chapter 8 (Poli)
11 2010.03.16 SPRING BREAK
11 2010.03.18 SPRING BREAK
12 2010.03.23 Stamping (Sen) (large) (small)
12 2010.03.25 Reverse Engineering(Sen) (large) (small) Chapter 6 (Otto & Wood)
13 2010.03.30 Reverse Engineering (Sen) (large) (small) Chapter 6 (Otto & Wood)


13 2010.04.01 Reverse Engineering In-Class Exercise(Sen) (worksheet) Chapter 6 (Otto & Wood)
14 2010.04.06 Lazy Parts Indicators(Sen) (large) (small)
14 2010.04.08 Lean Manufacturing (Palmer II) (large) (small)
15 2010.04.13 Lean Manufacturing (Palmer II)
15 2010.04.15 Lean Manufacturing (Palmer II)
16 2010.04.20 Term Paper Presentations (ME 655)
16 2010.04.22 Term Paper Presentations (ME 655)
Taillight Fixture Lunar Tweel Hub (NASA) Six Pack Holder Shredder
Lunar Spring Tweel Cannolli Filling Machine Golf Ball Sorter for Packaging
Six Pack Holder Shredder Golf Ball "Testing Device" Cannolli Filling Machine
Dropping System for Quenching Taillight Fixture Lunar Tweel (NASA)

[edit] Design for Manufacturing - Prototype Images

Ryobi Molding 1 Ryobi Molding 2 Headlight Casing 1
Headlight Casing 2 Headlight Casing 3 Headlight Casing 4
Radiator Fan Back Rest 1 Back Rest 2
Back Rest 3
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