Mekelle University

Ethiopian Institute of Technology - Mekelle

School of Mechanical and Industrial Engineering
Manufacturing Engineering Chair
Course code MaEng 4231 ECTS Credits 5 Credit Points

Course Title Design for Manufacturing Contact hour 2lec+3titor+5home

study
B.Sc. in manufacturing Engineering Machining Technology
Degree Program Pre-requisites ,Forming Technology
Foundry Technology
Class year Fourth year Status of Course Compulsory
Minimum of 90%
Weldegebrial K. attendance during lecture
Lecturer Attendance Req hours & 100% during
tutorial classes
Technical assistance

Course Objectives & Competences to be Acquired

After the completion of this course, the students will be able to:
 Identify and classify modern manufacturing operations, including their capabilities, limitations,
and how to design for lowest cost
 Explains how designers influence manufacturing schedule and cost.
 Learn how to analyze products and be able to improve their manufacturability and lower costs.
 Explain the relationship between customer desires, functional requirements, product materials,
product design, and manufacturing process selection.
 Examine a product and determine how it was manufactured and why.
 Explain the importance of human-factors in manufacturing and assembly, and how it relates to
design
 Describes how and why value stream analysis is used to lower manufacturing costs.
 Identify the advantages and disadvantages of hard (inflexible) and soft (flexible) manufacturing
automation.
 Explain the advantages and disadvantages of discrete-event simulation and how it is used to reduce
manufacturing costs
Course Description
This course covers the knowledge, skills and attitudes required for Concepts of Design for Manufacturing
(DFM); Role of DFM in product specification and standardization, Methods of material, shape and process
selections, Design rules for manufacturing and assembly processes, Design for quality and reliability,
Approach towards robust.

1
Weeks Day 1 activity Day 2activity
1 CHAPTER -1: INTRODUCTION TO DFM
1.1Need identification and problem definition 1.3Embodiment design
1.2Concept generation and evaluation 1.4 Design philosophy
steps in design process
- general design rules for
 Mode of delivery : Lectures manufacturability

2 1.5Materials 1.7Case study –I

Selection of materials for design developments in material technology assignments,
Criteria for material selection worksheets,
Material selection interrelationship with process selection
Process selection charts
1.6Selection of shapes

Mode of Tutorial
3 CHAPTER -2: SELECTION AND DESIGN OF MANUFACTURING PROCESS
2.1Review of manufacturing processes Case studies–II
2.2Design for casting Worksheet
2.3Design for bulk deformation processes assignments,
 Mode of delivery : Lectures Tutorials and assignments worksheets,
Mode of Tutorial
4 2.4Design for sheet metal forming processes Case studies–III
2.5Design for machining assignments,
2.6Design for powder metallurgy worksheets,
 Mode of delivery Lectures, Tutorials and worksheets Mode of Tutorial
5 2.7Design for polymer processing Case studies–IV& V
2.8Co-selection of materials and processes assignments,
2.9Case, III, IV and V worksheets,
 Mode of delivery Lectures, Tutorials and worksheets Feedback given on test 1
Test1 for chapter 1&2 10 % Mode of Tutorial
6 CHAPTER -3: DESIGN FOR ASSEMBLY Case studies–VI
3.1Review of assembly processes assignments,
3.2Design for welding worksheets,
3.3Design for brazing and soldering Mode of Tutorial
 Mode of delivery Lectures, Tutorials
7 3.4Design for adhesive bonding Case studies–VII
3.5Design for joining of polymers assignments,
3.6Design for heat treatment worksheets,
3.7Case-studies – VI, VII and VIII Mode of Tutorial
 Mode of delivery Lectures, Tutorials
8 CHAPTER -4: DESIGN FOR RELIABILITY AND QUALITY Case-study IX
4.1Failure mode and effect analysis assignments,
4.2Design for quality worksheets,
4.3Design for reliability
Mode of Tutorial
Mode of delivery Lectures, Tutorials
 Mode of delivery Lectures, Tutorials
9 4.4Approach to robust design Case-study IX
4.5Design for optimization assignments,
4.6Case-study IX worksheets,
 Mode of delivery Lectures, Tutorials

2
 Mode of Tutorial
10 CHAPTER -5: DFM WITH RESPECT TO COST MANAGEMENT Tutorial
5.1The machines and processes used Feedback given on
5.2The materials used project 1
5.3The form of the materials
 Mode of delivery Lectures, Tutorials
11 5.4The quantity being manufactured Case-study X
5.5The dimensional tolerances and strength
 Mode of delivery Lectures, Tutorials Mode of Tutorial
12 5.6The design and shape Feedback given on test 2
5.7The desired quality of the final product
5.8Case - study X
 Mode of delivery Lectures, Tutorials
Test 2, 10 %
13 CHAPTER -6: Tutorial
DESIGN FOR ENVIRONMENT
 Mode of delivery Lectures, Tutorials
14 Continue from ch-6 Tutorial
DESIGN FOR ENVIRONMENT Project2 work 20%
 Mode of delivery Lectures, Tutorials
15 Feedback given on project 2
16
Evaluation methods
Tests and quizzes ------------------------ 20%
Case – studies/Projects ----------------- 30%
Group Assignments ---------------------- 10 %
Final examination ----------------------- 40%
References
1. M. F Ashby and K. Johnson, Materials and Design - the art and science of material selection in
product design, ButterworthHeinemann, 2003.
2. G. Dieter, Engineering Design - a materials and processing approach, McGraw Hill, NY, 2000.
3. M. F Ashby, Material Selection in Mechanical Design, ButterworthHeinemann, 1999.
4. T. H Courtney, Mechanical Behavior of Materials, McGraw Hill, NY,2000.
5. K. G Swift and J. D Booker, Process selection: from design to manufacture, London: Arnold, 1997.
6. S. S. Rao, Engineering Optimization: theory and practice, John Wiley,NY, 1996.
7. G. Boothroyd, P. Dewhurst and W. Knight, Product Design for Manufacture and Assembly, John
Wiley, NY: Marcel Dekkar, 1994.
8. J. G. Bralla, Handbook for Product Design for Manufacture, McGrawHill, NY, 1998.
9. Houldcroft, Which Process – an introduction to welding and related processes and guide to their
selection, Cambridge, Abington Pub.,1990

Prepared by Course instructor: _______________________________ _________________________

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Approved by Chair head: _______________________________ _________________________

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Endorsed by TQA Focal Person: _______________________________ _________________________

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