Vi Sem DPM Syllbus 08.12.2014 Final

GOVT.
TOOL ROOM & TRAINING CENTRE

SEMESTER: SIXTH
Course: DIPLOMA IN PRECISION MANUFACTURING
Syllabus -Theory and practical Subjects
SL. Contact
CODE SUBJECTS Hours/Week
Contact Hours/Semester
NO
1 DPM601 Advanced Manufacturing Technology 3 60
2 DPM602 Industrial Maintenance 3 60
3 DPM603 Process Engineering & Productivity 3 60
4 DPM604 Industrial Management 2 40

5 DPM605 Total Quality Management 2 40
Practical
6 DPM606 CNC Lab-II 28.5 570
7 DPM607 CAD/CAM Lab-II 3 60
8 DPM608 ISAP Lab 3 60
Scheme of Examination
Course: DIPLOMA IN PRECISION MANUFACTURING
SIXTH- SEMESTER
Scheme of Examination
Subjects Contact Exam. Internal Min
SI. Sub. Hours Duration Exam marks
Assessment Total
No Code per Max Min Max Min Marks for
Theory Week passing
Marks Marks Marks Marks
Advanced Manufacturing
1 DPM601 3 3 100 50 20 10 120 60
Technology
2 DPM602 Industrial Maintenance 3 3 100 50 20 10 120 60
Process Engineering &
3 DPM603 3 3 100 50 20 10 120 60
Productivity
4 DPM604 Industrial Management 2 3 100 50 20 10 120 60
5 DPM605 Total Quality Management 2 3 100 50 20 10 120 60
Practical
6 DPM606 CNC Lab-II 28.5 10 900 540 100 60 1000 600
7 DPM607 CAD/CAM Lab-II 3 3 100 50 20 10 120 60
8 DPM608 ISAP Lab 3 3 100 50 20 10 120 60
Total 47.5 1600 890 240 130 1840 1020
Govt.Tool Room & Training Centre Bangalore -10 VITH SEMESTER D.P.M. COURSE Page |1
ADVANCED MANUFACTURING TECHONOLOGY
SUBJECT CODE: DPM 601
Learning goals for ADVANCED MANUFACTURING TECHONOLOGY
On completion of this subject, the trainees will be able to:
 Principle and about EDM machine

 Die electric media
 Principle of Electrolyte and its system
 Principle of CM, Need for CM
 Need for USM, Equipment and process
 Principle of AJM, Need for AJM
 Need for WJM, WJM equipment and process
 Principle of LBM, Need for LBM
Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80
SPECIFIC INSTRUCTIONAL OBJECTIVES:
1. EDM:
- Introduction
- Principle, about machine
- Die electric, Spark generator
- Electrode (Types, Spark gap
- Electrode wear
- Electrode folders
- Electrode materials) Flushing mechanism
- Effect of parameters
- Advantages, Disadvantages and Applications.
2. WEDM:
- Introduction
- Principle, about machine and features
- Types of wires
- Types of material which can be wire cut
- Die electric media
- Machine parameters and Effect of parameters
- Simple programming examples for cut out parts
3. ELECTRO CHEMICAL MACHINING (ECM):

- Introduction
- Principle, Electrolyte and its system
- Types of electrolytes
- Faraday’s laws of electrolysis
- Experiment on electrolysis of copper on iron
- ECM equipment and process
4. CHEMICAL MACHINING (CM)

- Introduction
- Principle of CM, Need for CM
- Chemical blanking process
- Chemical milling process
- Difference between Chemical blanking and milling
- Machine parameters, Advantages
- Limitations and application of CM.
5. ULTRASONIC MACHINING:
- Introduction,
- Principle of USM,
- Need for USM, Equipment and process,
- Tool holders, Tool material,
- Machine parameters, Advantages,
- Limitations and application of USM.
6. ABRASIVE JET MACHINING:

- Introduction
- Principle of AJM, Need for AJM
- Equipment and process, AJM elements and their Influence
- Process parameters
7. WATER JET MACHINING:

- Principle of WJM,
- Need for WJM, WJM equipment and process,
- Machine parameters,
- Advantages, limitations and application of WJM.
8. LASER BEAM MACHINING:

- Introduction,
- Principle of LBM, Need for LBM,
- LBM equipment and process,
- Machine parameters, Types of LASER,
- LBM Operations,
- Advantages, limitations and application of LBM.
WEEKLY PLAN FOR
ADVANCED MANUFACTURING TECHNOLOGY
WEEK
CHAPTER TITLE CONTENTS OF TOPICS
NO
Introduction
Principle about machine
Die electric, Spark generator
1-3
EDM Electrode (Types, Spark gap,
Electrodes wear, Electrode folders
Electrode materials) Flushing mechanism
Effect of parameters
Advantages, Disadvantages and Applications.
Introduction
Principle about machine and features,
Types of wires
WEDM Types of material which can be wire cut,
4-6 Die electric media
Machine parameters and Effect of parameters
Simple programming examples for cut out parts
Advantages
Disadvantages and Applications.
Introduction
Principle, Electrolyte and its system
ECTRO CHEMICAL MACHINING (ECM) Types of electrolytes
8-10 Faraday’s laws of electrolysis
Experiment on electrolysis of copper on iron,
ECM equipment and process
Introduction
Principle of CM, Need for CM
CHEMICAL MACHINING (CM) Chemical blanking process
11-12 Chemical milling process
Difference between Chemical blanking and milling
Machine parameters, Advantages
Limitations and application of CM.
Introduction,
Principle of USM,
ULTRASONIC MACHINING:
Need for USM, Equipment and process,
13-14
Tool holders, Tool material,
Machine parameters, Advantages,
Limitations and application of USM.
Introduction
Principle of AJM, Need for AJM
ABRASIVE JET MACHINING:
Equipment and process, AJM elements and their Influence
15-16 Process parameters
WEEKLY PLAN FOR
ADVANCED MANUFACTURING TECHNOLOGY
WEEK
NO
Principle of WJM,
Need for WJM, WJM equipment and process,
WATER JET MACHINING:
17-18 Machine parameters,
Advantages, limitations and application of WJM.
Introduction,
Principle of LBM, Need for LBM,
LBM equipment and process,
19-20 LASER BEAM MACHINING:
Machine parameters, Types of LASER,
LBM Operations,
Advantages, limitations and application of LBM.
INDUSTRIAL MAINTENANCE
Learning goals for INDUSTRIAL MAINTENANCE

 Role of maintenance
 Restoration and manufacture of machine parts
 Accuracy measurements
 Methods for checking and control
 Rack and pinion
 Fits and tolerances between lead-screw and nut
 Lead screw repairs
 Spindle wear and their repairs
 Shanks and journal seats
 Concept of preventive maintenance
 Functions of the various sections of central maintenance workshop
SPECIFIC INSTRUCTIONAL OBJECTIVES
1. INTRODUCTION TO INDUSTRIAL MAINTENANCE

- Role of maintenance
- Maintenance management
- Restoration and manufacture of machine parts
- Planted maintenance activities
- Conclusion
2. MATERIAL FOR MACHINE PARTS AND HEAT TREATMENT OF STEEL

- Steels
- Heat treatment of steel
- Approximate determination of steel composition
- Cast iron
- Heat treatment (aging) of C.I castings
- Non-ferrous metals and other materials
- Materials for machine parts
- Hardness numbers
3. GUIDE SURFACES
- Accuracy of straight edges and surface plates
- Manufacture of standard surface plates
- Accuracy measurements
- Wear on guide surface and methods of determining the value of the wear
- Method for short guides
- Method for flat/prism long guides
- Method for long guides, beds, or plates
- Selection of repair method
- Scraper
- Guide characteristics and their control
- Universal bridge for controlling guide surface characteristics of flat and prism guides
- Drawing details
- Scheme for installing the bridge
- Methods for checking and control
- Universal bridge for controlling dove-tail type guide surface characteristics
- Drawing details
- Scheme for installing the bridge
- Repair methods for beds/guide surfaces
- Scraping of the guide surface
- Grinding of the guide surface
- Machining on planer or Plano-miller
- Modernization with low-friction slide ways
- Non- metallic guide way linings
- Anti-friction guide way elements
- Hydrostatic slide ways
- Aerostatic slide ways
- Auto-lubrication systems
4. GEAR TRANSMISSION
- Classification of the gears
- Gear transmission with parallel axes
- Intersecting axes gear transmission
- Non-parallel non-intersecting
- Rack and pinion
- Spur gear
- Calculations for teeth profile elements
- Accuracy control of gear milling
- Measurement from worn-out gear
- Gear milling
- Teeth edges chamfering
- Helical/spiral gear
- Helix angle and gear correction
- Calculations from measurements of used gears
- Practical example for straight bevel gear
- Bevel gear milling
- Worm and worm gear
- Bevel Gear
5. LEAD SCREW AND NUT

- Fits and tolerances between lead-screw and nut
- Lead screw repairs
- Thread wear up to 0.3mm
- Thread wear exceeding 0.3mm
- Manufacture of the lead screw
- Repairs of lead nut
- B1-metalling
- Pouring “stellon” compound
- Elimination of play
- Ball lead screw
- Construction of ball screw and nut
- Selection of ball screw
6. MACHINE SPINDLE
- General defects in the spindle unit
- Spindle wear and their repairs
- Shanks and journal seats
- Taper bore
- Threads
- Repair of keyways
- Manufacture of new spindle
- Manufacture of spindle from steel En8/En18
- Manufacture of spindle from steel En207
- Manufacture of spindle from steel En416
7. PREVENTIVE MAINTENANCE PLANNING

- Concept of preventive maintenance
- Condition based maintenance
- Corrective maintenance
- Scheduled preventive maintenance
- Repair cycle
- Inspection-I
- Small repair-S
- Medium repair-M
- Complete overhaul-O
- Annual and monthly preventive maintenance schedules
- Annual preventive maintenance schedule
- Monthly preventive maintenance schedule
- Main power planning
- Machine stoppage
- Norms for machine stoppage
- Maintenance costs
- Depreciation and machine life
8. LUBRICATION
- General purpose lubricants
- Lubricating instructions for operator
- Periodical replacement or addition of lubricant
- Annual lubrication replacement schedule
- Paint marks for lubricating points
- Regeneration of oils
- Storage of oils for regeneration
- Various oils available for regeneration
- Testing of used oils
- Process of regeneration
9. PLANNING OF MATERIALS AND STANDARD SPARES

- Planning of requirements for subsequent year
- Recommended welding electrodes, fasteners, etc.
- Spare parts stock rate
- Maximum and minimum stock of spare parts
10. ORGANISATION OF MAINTENANCE DEPARTMENT

- Functions and organization
- Control and co-ordination bureaus
- Equipment bureau
- Crane bureau
- Design bureau
- Maintenance centre for each shop
- Duties and functions
- Organization of maintenance centers
- Lubricants and spare parts store
- Sub-ordination of maintenance engineer
- Maintenance centre and machines
- Central maintenance workshop
- Central maintenance workshop and machines
- Functions of the various sections of central maintenance workshop
Reference books
1. Industrial Maintenance by; E.R H P Garg
Govt.Tool Room & Training Centre Bangalore -10 VITH SEMESTER D.P.M. COURSE P a g e | 10
WEEKLY PLAN FOR
WEEK
NO
Role of maintenance
1 INTRODUCTION TO INDUSTRIAL Maintenance management
MAINTENANCE Restoration and manufacture of machine parts
Planted maintenance activities
Conclusion
Steels
Heat treatment of steel
Approximate determination of steel composition
MATERIAL FOR MACHINE PARTS
Cast iron
2-3 AND HEAT TREATMENT OF STEEL
Heat treatment (aging) of C.I castings
Non-ferrous metals and other materials
Materials for machine parts
Hardness numbers
Accuracy of straight edges and surface plates
Manufacture of standard surface plates
Accuracy measurements
Wear on guide surface and methods of determining the
value of the wear
Method for short guides
Method for flat/prism long guides
Method for long guides, beds, or plates
Selection of repair method
Scraper
Guide characteristics and their control
Universal bridge for controlling guide surface characteristics
of flat and prism guides
GUIDE SURFACES Drawing details
Scheme for installing the bridge
4-6
Methods for checking and control
Universal bridge for controlling dove-tail type guide surface
characteristics
Drawing details
Scheme for installing the bridge
Repair methods for beds/guide surfaces
Scraping of the guide surface
Grinding of the guide surface
Machining on planer or Plano-miller
Modernization with low-friction slide ways
Non- metallic guide way linings
Anti-friction guide way elements
Hydrostatic slide ways
Aerostatic slide ways
Auto-lubrication systems
WEEKLY PLAN FOR
WEEK
NO
General purpose lubricants
Lubricating instructions for operator
Periodical replacement or addition of lubricant
Annual lubrication replacement schedule
LUBRICATION Paint marks for lubricating points
15-16
Regeneration of oils
Storage of oils for regeneration
Various oils available for regeneration
Testing of used oils
Process of regeneration
Planning of requirements for subsequent year
PLANNING OF MATERIALS AND STANDARD
Recommended welding electrodes, fasteners, etc.
17-18 SPARES
Spare parts stock rate
Maximum and minimum stock of spare parts
Functions and organization
Control and co-ordination bureaus
Equipment bureau
Crane bureau
Design bureau
Maintenance centre for each shop
ORGANISATION OF MAINTENANCE Duties and functions
19-20 DEPARTMENT Organization of maintenance centers
Lubricants and spare parts store
Sub-ordination of maintenance engineer
Maintenance centre and machines
Central maintenance workshop
Central maintenance workshop and machines
Functions of the various sections of central maintenance
workshop
PROCESS ENGINEERING & PRODUCTIVITY
Learning goals for PROCESS ENGINEERING & PRODUCTIVITY
 Understand the necessity of process requirement,
 Metal cutting process and materials
 Concept of gauges
 Tooling materials for plastics
 Tooling for NC machines
1. PROCESS ENGINEERING
- Introduction
- Initial data required for process planning
- Process Engineering records
- Terms used in process planning
- Standard time
- Machining allowance
- Selection of cutting variables
- Planning of operation sequence
- Main conditions in selecting the machining method
- Example of process sheet for turning, milling, grinding jobs
2. PROCESS OF METAL CUTTING

- Introduction
- Cutting tool materials
- Carbon tool steel
- High speed steel
- Cemented carbides
- Ceramics
- Diamonds
- UCON
- CBN
- Principles of metal cutting
- Orthogonal and oblique metal cutting
- Comparison of orthogonal and oblique cutting
- Type of chips
- Nomenclature of single point cutting tool
- Tool signature
- Tool life and tool failure
- Factor affecting tool life
- Machinability
- Machinability index
- Cutting fluids
- Purposes of cutting fluids
- Properties of cutting fluids
- Types of cutting fluids
- Materials for multi point cutting tools
- Problems on tool life and tool failure
3. GAUGE DESIGN
- Introduction
- Types of gauge
- Snap gauge
- Plug gauge
- Ring gauge
- Receiver gauge
- Gap gauge
- Radius or fillat gauge
- Taylor's principle
- Maximum and minimum metal limits
- Gauge allowance and tolerance
- Materials for gauges
- Simple problems on gauges
4. PLASTIC AS TOOLING MATERIALS

- Introduction
- Plastics commonly used as tooling materials
- Merits and demerits of plastic tooling
- Plastics tooling techniques
- Repair of plastic tools
- Safety precaution of plastic tooling material
5. TOOLING FOR N.C.MACHINES

- Introduction
- Spindling tooling for machining centers,
- Shell mill adaptor
- Collet chucks and extensions
- End mill adaptor
- Morse taper adaptor
- Boring bars
- Tooling for N.C. turing machines
- Qualified tooling
- Preset tooling
Reference Books:
1) Production Engineering Design by Dr. Surendrakumar & Dr.Umesh chandra Satya Prakashan - New
Delhi
2)Tool Engineering and Design by G.R.Nagpal Khanna publishers
WEEKLY PLAN FOR
WEEK
NO
- Introduction
- Initial data required for process planning
- Process Engineering records
- Terms used in process planning
- Standard time
- Machining allowance
- Selection of cutting variables
1-5 PROCESS ENGINEERING - Planning of operation sequence
- Main conditions in selecting the machining
method
- Example of process sheet for turning, milling,
grinding jobs
- Introduction
- Cutting tool materials
- Carbon tool steel
- High speed steel
- Cemented carbides
- Ceramics
- Diamonds
- UCON
- CBN
- Principles of metal cutting
- Orthogonal and oblique metal cutting
- Comparison of orthogonal and oblique
cutting
6-10 PROCESS OF METAL CUTTING - Type of chips
- Nomenclature of single point cutting tool
- Tool signature
- Tool life and tool failure
- Factor affecting tool life
- Machinability
- Machinability index
- Cutting fluids
- Purposes of cutting fluids
- Properties of cutting fluids
- Types of cutting fluids
- Materials for multi point cutting tools
- Problems on tool life and tool failure
- Introduction
- Types of gauge
- Snap gauge
11-12 GAUGE DESIGN - Plug gauge
- Ring gauge
- Receiver gauge
WEEKLY PLAN FOR
WEEK
NO
- Gap gauge
- Radius or fillat gauge
- Taylor's principle
- Maximum and minimum metal limits
13-14 GAUGE DESIGN - Gauge allowance and tolerance
- Materials for gauges
- Simple problems on gauges
- Introduction
- Plastics commonly used as tooling
PLASTIC AS TOOLING materials
- Merits and demerits of plastic tooling
15-18 MATERIALS - Plastics tooling techniques
- Repair of plastic tools
- Safety precaution of plastic tooling
material
- Introduction
- Spindling tooling for machining centers,
- Shell mill adaptor
- Collet chucks and extensions
- End mill adaptor
19-20 TOOLING FOR N.C.MACHINES - Morse taper adaptor
- Boring bars
- Tooling for N.C. turing machines
- Qualified tooling
- Preset tooling
INDUSTRIAL MANAGEMENT
Learning goals for INDUSTRIAL MANAGEMENT
 Understand the estimation and costing procedure in industries
 Know the actual costing process and calculation of selling prices
 Understand the depreciation of equipments, plants and to know the different methods of calculating depreciation
 Know the procedure for calculating material cost of various components
 Understand the procedure for estimation of various shops
 Know the labour wages and incentives
 Know about basics of financial management
 Understand the concepts of project planning and breakeven analysis
INDUSTRIAL MANAGEMENT (THEORY)
1. INTRODUCTION TO ESTIMATION AND COSTING
- Estimation - Definition, Importance and Aims

- Qualities and functions of an Estimator
- Source of errors in estimation
- Constituents of Estimation
- Costing - Definition and Aims
- Standard cost and its Advantages
- Difference between estimation and costing
- Advantages of efficient costing
1. ELEMENTS OF COST
- Elements of cost- material, labour, expenses
- Material - Direct material, indirect material and examples
- Calculation of Material cost
- Labour - direct, indirect labour and examples
- Calculation of labour cost
- Expenses - direct, indirect expenses and examples
- Classification of expenses - factory, administrative, selling and distribution expenses and examples
- Fixed and variable expenses and examples
- Components of cost - prime cost, factory cost, office cost, total cost
- Selling price
- Block diagram to show the relationship between elements and components of cost
- Simple problems on above
- Allocation of on-cost - methods and simple problems
3. INDIRECT EXPENSES AND DEPRECIATION
- Indirect expenses - depreciation, obsolescence, inadequacy, idleness, repair and maintenance

- Depreciation - causes, methods of calculating depreciation
4. MENSURATION AND ESTIMATION OF MATERIAL COST

- Area of regular plane figures
- Volume and surface area of solids (formulae only)
- Estimation of material costs of tool elements and total cost of tool.
- Mechanical Estimation
- Estimation in machine shop - Definition of cutting speed, feed, depth of cut
- Estimation of time for various operations like Turning, Knurling, Facing, Drilling, Boring, Reaming, Threading,
Tapping, Milling, Grinding, Shaping and Planning
- Estimation in sheet metal shop - Sheet material and gauge number, Select suitable formula for Estimation
5. WAGES AND INCENTIVES
- Definition of wages, normal wages, real wages, living wages, fair wages
- Minimum wages, methods of wage payment
- Incentives - definition of incentive, types of incentives, examples
- Characteristics of a good wage and incentive systems
- Standard time - work measurement
- Bonus system - collective bonus system, group bonus system
6. INTRODUCTION TO FINANCIAL MANAGEMENT
- Definition of terms such as assets, liabilities, current and long term assets and liabilities, capital, income, expenses,
gain
- Working capital - definition - net and gross working capital - factors affecting working capital.
- Maintenance of accounts through journal ledger, cash book, balance sheet.
- Transaction with bank - credits, payments overdraft, current account, securities.
-
7. PROJECT PLANNING AND BREAK EVEN ANALYSIS

- Concept of project work.
- Project planning like market survey, project capacity, selection of site, plant
Layout, product design, drawing, specification, material requirement operation planning,
- Break even analysis - break event chart, diagram to illustrate break event point, Simple problems on break even
analysis
8. OPERATION RESEARCH
- Game theory: definitions- strategy, saddle point, two person zero sum game, dominance property, problems
- Transportation problem: NW corner rule, Least cost method (simple problems)
- Assignment problem (balanced problems only)
REFERENCE BOOKS
1. Mechanical estimation and costing- T.R.Banga and S.C.Sharma

2. Estimation and costing – by Acharya and Narang
3. Industrial Organisation and Engineering Economics by Banga and Sharma
4. Mechanical Estimation by Malhotra
5. Operations research by S D Sharma
6. Operations research by Phaneesh
WEEKLY PLAN FOR
WEEK NO CHAPTER TITLE CONTENTS OF TOPICS

Estimation - Definition, Importance and Aims
Qualities and functions of an Estimator
INTRODUCTION TO ESTIMATION AND Source of errors in estimation
1-3 COSTING Constituents of Estimation
Costing - Definition and Aims
Standard cost and its Advantages
Difference between estimation and costing
Advantages of efficient costing
Elements of cost- material, labour, expenses
Material - Direct material, indirect material and examples
Calculation of Material cost
Labour - direct, indirect labour and examples
Calculation of labour cost
Expenses - direct, indirect expenses and examples
Classification of expenses - factory, administrative, selling and
ELEMENTS OF COSTS
distribution expenses and examples
4-6
Fixed and variable expenses and examples
Components of cost - prime cost, factory cost, office cost, total
cost
Selling price
Block diagram to show the relationship between elements and
components of cost
Simple problems on above
Allocation of on-cost - methods and simple problems
Indirect expenses - depreciation, obsolescence,
INDIRECT EXPENSES AND DEPRECIATION inadequacy, idleness, repair and maintenance
7-9
Depreciation - causes, methods of calculating depreciation
Area of regular plane figures

Volume and surface area of solids (formulae only)
Estimation of material costs of tool elements and total cost of
tool.
MENSURATION AND ESTIMATION OF Mechanical Estimation
MATERIAL COST Estimation in machine shop - Definition of cutting speed, feed,
10-13
depth of cut
Estimation of time for various operations like Turning, Knurling,
Facing, Drilling, Boring, Reaming, Threading, Tapping, Milling,
Grinding, Shaping and Planning
Estimation in sheet metal shop - Sheet material and gauge
number, Select suitable formula for Estimation
WEEKLY PLAN FOR

Definition of wages, normal wages, real wages, living
wages, fair wages
Minimum wages, methods of wage payment
WAGES AND INCENTIVES Incentives - definition of incentive, types of incentives,
14-16 examples
Characteristics of a good wage and incentive systems
Standard time - work measurement
Bonus system - collective bonus system, group bonus
system
Definition of terms such as assets, liabilities, current and
long term assets and liabilities, capital, income, expenses,
INTRODUCTION TO FINANCIAL gain
MANAGEMENT Working capital - definition - net and gross working capital
17-18 - factors affecting working capital.
Maintenance of accounts through journal ledger, cash
book, balance sheet.
Transaction with bank - credits, payments overdraft,
current account, securities.
Concept of project work.
Project planning like market survey, project capacity,
PROJECT PLANNING AND BREAK EVEN
selection of site, plant
ANALYSIS Layout, product design, drawing, specification, material
requirement operation planning,
Break even analysis - break event chart, diagram to
19-20 illustrate break event point, Simple problems on break
even analysis
Game theory: definitions- strategy, saddle point, two
person zero sum game, dominance property, problems
OPERATION RESEARCH Transportation problem: NW corner rule, Least cost
method (simple problems)
Assignment problem (balanced problems only)
TOTAL QUALITY MANAGEMENT
1. OVERVIEW OF TQM
- Definition of TQM
- Definition of quality and its characteristics
- TQM concepts
- Deming’s philosophy
- Principles of TQM
- Benefits of TQM
- TQM organization
2. LEADERSHIP
- Characteristics of TQM leaders
- Role of TQM leadership
- Continuous process improvement
- The PDSA (Plan-Do-Study-Act) cycle
- Six sigma (6σ) quality
3. QUALITY MANAGEMENT TOOLS
- Nominal group technique
- Affinity diagram
- Inter relationship diagram
- Tree diagram
- Matrix diagram
- Activity network diagram
4. STATISTICAL PROCESS CONTROL
- Seven quality control tools
- Process Capability
- Defect v/s defective
5. FUNDAMENTAL STATISTICS AND PROBABILITY DISTRIBUTIONS
- Measures of central tendency- mean mode, median, standard deviation Problems
- Definition and Properties of Probability
- Poisson distribution- simple problems
- Binomial distribution -simple problems
- Normal distribution- simple problems
6. DESIGNS FOR SIX SIGMA
- Tools for concept and design development
- Design optimization
- Design verification
7. RELIABILITY AND LIFE TESTING
- Definitions of Reliability, Life testing and Redundancy
- Failure rate curve
- MTBF, MTTR, MTTF (simple problems)
- Systems reliability – series and parallel configuration
- Improvement factor
REFERENCE BOOKS
1. Total Quality Management by NVR Naidu

2. Total Quality Management By S D Ramachandra
3. Statistics by Mahajan
4. Statistics by Raj Mohan –volume 1 & 2
WEEKLY PLAN FOR
TOTAL QUALITY MANAGEMENT

Definition of TQM
Definition of quality and its characteristics
TQM concepts
1-3 OVERVIEW OF TQM
Deming’s philosophy
Principles of TQM
Benefits of TQM
TQM organization
Characteristics of TQM leaders
LEADERSHIP Role of TQM leadership
4-6 Continuous process improvement
The PDSA (Plan-Do-Study-Act) cycle
Six sigma (6σ) quality
Nominal group technique
Affinity diagram
QUALITY MANAGEMENT TOOLS Inter relationship diagram
7-9
Tree diagram
Matrix diagram
Activity network diagram
Seven quality control tools
STATISTICAL PROCESS CONTROL
10-12 Process Capability
Defect v/s defective
Measures of central tendency- mean mode,
median, standard deviation Problems
FUNDAMENTAL STATISTICS AND PROBABILITY
Definition and Properties of Probability
13-15 DISTRIBUTIONS
Poisson distribution- simple problems
Binomial distribution -simple problems
Normal distribution- simple problems
Tools for concept and design development
DESIGNS FOR SIX SIGMA
16-18 Design optimization
Design verification
Definitions of Reliability, Life testing and
Redundancy
Failure rate curve
RELIABILITY AND LIFE TESTING
19-20 MTBF, MTTR, MTTF (simple problems)
Systems reliability – series and parallel
configuration
Improvement factor
CNC- LAB - 2
Contact Hrs./Week: 28.5 Contact Hrs. / Semester: 570
EX CONTENTS WEEK NO
NO
01 CNC milling. 1-5
1.1 2d drawings using 2d tool paths.
1.2 Exercises.
1.3 Solid models preparation using Master cam.
1.4 Exercises.
1.5 Mini project
02 CNC lathe. 6-11
2.1Exercises (combined operations)
03 CNC EDM. 11-16
3.1 Electrode preparation.
3.2 Process sheet preparation for electrode and work piece.
3.3 Job dialing and job clamping,
3.4 Datum setting.
3.5 CNC EDM programming.
3.6 Exercises
04 Process planning sheet preparation for milling and lathe. 17-22
4.1 Exercises
CAD - CAM –LAB - 2
Contact Hrs./Week:3 Contact Hrs. / Semester: 60
EX NO CONTENTS WEEK NO
01 Surface modeling: 1-5
1.1 Objectives
1.2 Surface modeling procedure
1.3 Surface terms
1.4 Surface types
1.5 Surface trim
1.6 Fillet surface and its types
1.7 Surface blend and its types
1.8 Example demo on above topics( Exe-1,2)
02 Wireframe tool path 6-10
03 Surface tool paths 11-12
3.1 Demo example on surface tool paths
04 DNC concept. 13-15
05 Assignment: Exercise on surface modeling 16-18
06 Assignment: Exercise on surface tool path 19-20
INFORMATION SEARCH ANALYSIS AND PRESENTATION - LAB
Contact Hrs./Week:3 Contact Hrs. / Semester: 60
1. TOPIC ANALYSIS:
a)PART : WRITTEN COMMUNICATION
- Write research papers and articles.
b). PART: ORAL COMMUNICATION
- Transparency Based Presentation
c). OTHER ORAL COMMUNICATION ACTIVITIES.

- Meetings
- Group Discussion
- Debates
Note:
1) Topics selected for part one ‘A’ and part two ‘A’ are to be separate and it is left to the students choice.
2) The output of part one ‘A’ activity is well documented written report, which will be evaluated at the time of examination.
3) The output of part two ‘ A’ activity is the production of transparencies which the student will use at the time of
presentation in the examination.
2. INTRODUCTION:
The average engineer walking out of education institution is surprised by the amount of non- technical work he or she
faces in the real world (the number of meetings , presentations , debates etc) .
Further many cannot find appropriate jobs , because employer’s complain that students lack these key skills.
This course attempts to provide a slice of that kind of practical training in a form that may be used in classroom settings.
This course is NOT a course that is taught to the students in the manner that conventional courses are taught. In this
course the emphasis will shift from teacher --- oriented --- methods to students
Oriented methods.
INFORMATION SEARCH ANALYSIS AND PRESENTATION - LAB
3. OBJECTIVE:
1) This course provides an ideal opportunity to acquire skills in learning -- to – learn which is very essential for his
professional growth later on.
2) To inculcate information skills into students i.e to let the students acquire information skills on their own initiative and
drive . these skills would be a lifelong asset to him or her --- in fact they grow with age.
3) Another main objective of this course is to develop written communication skills in students.
4) Another important objective of this course is to develop oral communication skills in students.
4 . ACTIVITIES:
1) WRITE RESEARCH PAPERS AND ARTICALS: RESEARCH SOURCE OF INFORMATION
a) People
- Print media
- News Paper
- Maganises
- Journals
b) Electronic information
- CD
- INTERNET
Student’s projects can be done individually or in groups of not more than five depending on the theme subject.
5. TRANSPARENCY BASED PRESENTATION
- Preparation
- Information gathering
- Transparency design using power point.

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GOVT.

TOOL ROOM & TRAINING CENTRE

2 DPM602 Industrial Maintenance 3 60

3 DPM603 Process Engineering & Productivity 3 60

4 DPM604 Industrial Management 2 40

8 DPM608 ISAP Lab 3 60

Course: DIPLOMA IN PRECISION MANUFACTURING

SUBJECT CODE: DPM 601

Learning goals for ADVANCED MANUFACTURING TECHONOLOGY

On completion of this subject, the trainees will be able to:

 Principle and about EDM machine

SUBJECT CODE: DPM 601

Contact Hrs. /Week: 4 Contact Hrs. / Semester: 80

SPECIFIC INSTRUCTIONAL OBJECTIVES:

3. ELECTRO CHEMICAL MACHINING (ECM):

4. CHEMICAL MACHINING (CM)

6. ABRASIVE JET MACHINING:

7. WATER JET MACHINING:

8. LASER BEAM MACHINING:

ADVANCED MANUFACTURING TECHNOLOGY

ADVANCED MANUFACTURING TECHNOLOGY

SUBJECT CODE: DPM 602

Learning goals for INDUSTRIAL MAINTENANCE

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60

SPECIFIC INSTRUCTIONAL OBJECTIVES

1. INTRODUCTION TO INDUSTRIAL MAINTENANCE

2. MATERIAL FOR MACHINE PARTS AND HEAT TREATMENT OF STEEL

5. LEAD SCREW AND NUT

7. PREVENTIVE MAINTENANCE PLANNING

9. PLANNING OF MATERIALS AND STANDARD SPARES

10. ORGANISATION OF MAINTENANCE DEPARTMENT

SUBJECT CODE: DPM 603

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60

Learning goals for PROCESS ENGINEERING & PRODUCTIVITY

On completion of this subject, the trainees will be able to:

 Understand the necessity of process requirement,

 Metal cutting process and materials

 Tooling materials for plastics

 Tooling for NC machines

Contact Hrs. /Week: 3 Contact Hrs. / Semester: 60

SPECIFIC INSTRUCTIONAL OBJECTIVES:

2. PROCESS OF METAL CUTTING

4. PLASTIC AS TOOLING MATERIALS

5. TOOLING FOR N.C.MACHINES

SUBJECT CODE: DPM 604

Learning goals for INDUSTRIAL MANAGEMENT

On completion of this subject, the trainees will be able to:

 Understand the estimation and costing procedure in industries

 Know the actual costing process and calculation of selling prices

 Know the procedure for calculating material cost of various components

 Understand the procedure for estimation of various shops

 Know the labour wages and incentives

 Know about basics of financial management

 Understand the concepts of project planning and breakeven analysis

Contact Hrs. /Week: 2 Contact Hrs. / Semester: 40

SPECIFIC INSTRUCTIONAL OBJECTIVES:

1. INTRODUCTION TO ESTIMATION AND COSTING

- Estimation - Definition, Importance and Aims

3. INDIRECT EXPENSES AND DEPRECIATION

- Indirect expenses - depreciation, obsolescence, inadequacy, idleness, repair and maintenance

4. MENSURATION AND ESTIMATION OF MATERIAL COST

5. WAGES AND INCENTIVES

6. INTRODUCTION TO FINANCIAL MANAGEMENT