[edit] ME 455/655 – Design for Manufacturing

[edit] Prerequisites:

The student must have passed with a C or better the following courses:  ME 301, 306, and 404.  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:

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

[edit] References:

See the Library Reserves.<o:p></o:p>

[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 404 (or concurrent enrollment), or consent of instructor.  The primary objectives of this course are to develop in the student:

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

[edit] Homework:

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, homework is designed to help the student understand the material, not to create “busy work”.

• Homework should be professional quality (clear, concise, correct, and conscientious).
• Homework will be collected once a week and returned to the students the following lecture.
  
• The homework should be submitted with a standard cover sheet (see website).
• Homework is due at the BEGINNING of class.  No late assignments will be given credit, 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.  Out of class tutorials may be offered to augment students’ existing capabilities.

[edit] Weighting for Grade:

[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):

1. Engineers shall hold paramount the safety, health, and welfare of the public in the performance of their professional duties.
2. Engineers shall perform services only in areas of their competence.
3. Engineers shall continue their professional development throughout their careers, and should provide opportunities for the professional and ethical development of engineers under their supervision.
4. 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.
5. Engineers shall build their professional reputation on the merit of their services and shall not compete unfairly with others.
6. Engineers shall associate only with reputable persons or organizations.
7. Engineers shall issue public statements only in an objective and truthful manner.
8. 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.

Week	Lecture	Day	Topic	Reading	Today's Tie
1	1	08.01.10 (R)	Introduction: Course, Design for Manufacturing (large) (small)	Chapter 1, 2
2	2	08.01.15 (T)	Design for Assembly (large) (small) Last day to add or register for a class	Chapter 12,Boothroyd Project 1 Rules Template Rule Example In-Class
	3	08.01.17 (R)	No Class - Summers at Michelin/NIST meeting all day
		08.01.18 (F)	Trip to Greenville Auto Show: Meet by the "Six Degrees of Freedom" statue on the east side of the EIB building. Buy your tickets on-line ($3.50) at: www.motortrendautoshows.com/greenvl/ NOTE: if you purchase online using the passcode (CLEMSON), then you will receive a free subscription to MotorTrend.
3	4	08.01.22 (T)	Design for Assembly (large) (small)	Chapter 12, Boothroyd
	5	08.01.24 (R)	Design for Assembly (large) (small) Worksheet for Example	Chapter 12, Boothroyd Rules Example 2.1 Rules Example 2.2 Rules Example 2.3
	6	08.01.29 (T)	DFA and Fixture Design (large) (small)	Chapter 12 Change (Ch. 5) In-Class-2
	7	08.01.31 (R)	Fixture Design and Injection Molding (large) (small)	Chapter 3; Chang 5 ME 655 Term Project In Class 03
	8	08.02.05 (T)	Injection Molding (overview) (large) (small)	Chapter 3 In Class 04
	9	08.02.07 (R)	Injection Molding (large) (small)	Chapter 4 Project 2 Evaluation Form
	10	08.02.12 (T)	Injection Molding (large) (small) Guest Lecturer: Dr. Farhad Ameri	Chapter 4 Chapter 5 Project 2 Evaluation Form
	11	08.02.14 (R)	Casting (large) (small)	Chapter 5, 6
	12	08.02.19 (T)	Casting (large) (small) Guest Lecturers: Mr. Beshoy Morkos and Mr. Ajit Kanda	Chapter 7
	13	08.02.21 (R)	Casting (large) (small)	Chapter 7
	14	08.02.26 (T)	Die Casting Guest Lecture (Stuart Miller) (large) (small)	Chapter 7
	15	08.02.28 (R)	Sheet Metal (large) (small)	Chapter 8, 9
	16	08.03.04 (T)	Clemson Test
	17	08.03.06 (R)	Sheet Metal (large) (small)	Chapter 10
	18	08.03.11 (T)	Sheet Metal (large) (small)
	19	08.03.15 (R)	Sheet Metal (large) (small)
	20	08.03.18 (T)	SPRING BREAK
	21	08.03.20 (R)	SPRING BREAK
	22	08.03.25 (T)	Material Selection (large) (small)	Chapter 13
	23	08.03.27 (R)	Summers is a big old sickie
	24	08.04.03 (T)	Reverse Engineering (large) (small)	Otto and Wood - Handout
	25	08.04.05 (R)	Reverse Engineering	Otto and Wood
	26	08.04.08 (T)	Reverse Engineering	database
	27	08.04.12 (R)	Lean Manufacturing	notes
	28	08.04.17 (T)	ME 655 Presentations
	29	08.04.19 (R)	OPEN