Hindusthan College of Engineering And Technology

Approved by AICTE, New Delhi, Accredited with ‘A’ Grade by NAAC

(An Autonomous Institution, Affiliated to Anna University, Chennai)
Coimbatore – 641 032
COURSE INFORMATION
1. Academic Year : 2018 – 19 (Odd)
2. Name of faculty : N.DHAYANANTHAN
3. Department : Mechanical Engineering
4. Programme : M.E., CAD/CAM Engineering
5. Class and semester : I year and First semester
6. Course code and title : 16CC1203/ COMPETITIVE MANUFACTURING SYSTEMS
7. Regulations : R2016
8. Core / Elective : Core
9. Contact hours : 45
10.Type of course : Theory
11.Number of credits :3
12.Course pre-requisites: (i) 16ME5201- CAD/CAM

13.Course learning objectives:

 To understand the principles of manufacturing and flexible manufacturing systems.

 To educate the students on Lean Green manufacturing systems.

 To familiarize the concept of Just in time for manufacturing the products.

 To understand the concepts of Green manufacturing systems.

 To impart the knowledge of Automation and production system techniques.

14.Course Syllabus:
UNIT I AUTOMATION AND PRODUCTION SYSTEMS 9
Production system facilities, support systems, automation and manual labor in production
CO1 systems, automation principles and strategies, manufacturing industries, products and
operations, Components and classifications of manufacturing systems.

UNIT II GROUP TECHNOLOGY & FLEXIBLE MANUFACTURING SYSTEMS 9

Part families, classification and coding, production flow analysis, group technology
CO2 applications and cellular manufacturing, Flexible manufacturing systems- components,
applications, benefits, planning and implementation.

UNIT III LEAN MANUFACTURING 9

CO3 Origin of lean production system, customer focus, muda (waste),Standards – 5S system,
Total productive maintenance, standardized work, man power reduction, overall efficiency,

1
 kaizen , common layouts, Jidoka concept, Poka-Yoke (mistake proofing),Worker
Involvement, quality circle activity, kaizen training, suggestion programmes, oshin planning
system (systematic planning methodology), lean culture.

UNIT IV JUST IN TIME 9

JIT – Definitions, approach, elements, effects, pull and push systems, KANBAN, MRP II,
CO4 quality management system, plant layout, product design, purchasing, implementation,
automation and benefits.

UNIT V GREEN MANUFACTURING 9

Impact of manufacturing in environment, role of manufacturing sector in national growth,
technological change and evolving risk, Principles of green manufacturing , green
CO5
manufacturing efficiency and its sustainability , green manufacturing strategies, motivation,
barriers, advantages and limitations, Standards for green manufacturing.
TOTAL: 45 PERIODS
15.Text book and Reference book:
T1- Groover M.P., “Automation, Production Systems and Computer Integrated Manufacturing”,
Third Edition, Prentice-Hall, 2007.
T2- Dr.Sadhu Singh, Computer Aided Design and Manufacturing, Khanna Publishers – Fifth
Edition.
R1- Pascal Dennis, “Lean Production Simplified: A Plain-Language Guide to the World's Most
Powerful Production System”, (Second edition), Productivity Press, New York, 2007.
R2- Jha.N.K. “Handbook of Flexible Manufacturing Systems ", Academic Press Inc., 1991.

Web Resources
1. http://www.tmssonline.com
2. http://www.tpslean.com
3. http://www.referenceforbusiness.com/management/Ex-Gov/Flexible-Manufacturing.html

2
16.Course plan:
No of Cum Text/ Reference
S.No Name of the topic
Hours Hours books
UNIT I – AUTOMATION AND PRODUCTION SYSTEMS

1 Production system facilities 1 1 T1,T2,R2

2 Support systems 1 2 T1,T2,R2
Automation and manual labor in production
3 1 3 T1,T2,R2
systems
4 Automation principles 1 4 T1,T2,R2
5 Automation strategies 1 5 T1,T2,R2
6 Manufacturing industries 1 6 T1,T2,R2
7 Products and operations 1 7 T1,T2,R2
8 Components of manufacturing systems 1 8 T1,T2,R2
9 Classifications of manufacturing systems. 1 9 T1,T2,R2
UNIT II – GROUP TECHNOLOGY & FLEXIBLE MANUFACTURING SYSTEMS
10 Part families 1 10 T1,T2,R2
11 Classification and coding 1 11 T1,T2,R2
12 Production flow analysis 1 12 T1,T2,R2
13 Group technology applications 1 13 T1,T2,R2
14 Cellular manufacturing 1 14 T1,T2,R2
15 Flexible manufacturing systems 1 15 T1,T2,R2
16 Components 1 16 T1,T2,R2
17 Applications and benefits 1 17 T1,T2,R2

18 Planning and implementation. 1 18 T1,T2,R2

UNIT III – LEAN MANUFACTURING

19 Origin of lean production system 1 19 R1
20 Customer focus, muda (waste) 1 20 R1
21 Standards – 5S system 1 21 R1
22 Total productive maintenance 1 22 R1
23 Standardized work, man power reduction, 1 23 R1

3
 overall efficiency, kaizen
Common layouts, Jidoka concept, Poka-Yoke
24 1 24 R1
(mistake proofing)
25 Worker Involvement, quality circle activity 1 25 R1
26 Kaizen training, suggestion programmes 1 26 R1
Oshin planning system (systematic planning
27 1 27 R1
methodology), lean culture.
UNIT IV - JUST IN TIME
28 JIT – Definitions, approach, elements 1 28 T1,T2,R2
29 Effects, pull and push systems 1 29 T1,T2,R2
30 KANBAN 1 30 T1,T2,R2
31 MRP II 1 31 T1,T2,R2
32 Quality management system 1 32 T1,T2,R2
33 Plant layout 1 33 T1,T2,R2
34 Product design 1 34 T1,T2,R2
35 Purchasing, implementation 1 35 T1,T2,R2
36 Automation and benefits. 1 36 T1,T2,R2
UNIT – V GREEN MANUFACTURING
37 Impact of manufacturing in environment 1 37 R1
Role of manufacturing sector in national
38 1 38 R1
growth
39 Technological change and evolving risk 1 39 R1
40 Principles of green manufacturing 1 40 R1
Green manufacturing efficiency and its
41 1 41 R1
sustainability
42 Green manufacturing strategies 1 42 R1
43 Motivation, barriers 1 43 R1
44 Advantages and limitations 1 44 R1
45 Standards for green manufacturing. 1 45 R1
Total No. of lecture hours: 45

17.Weightage of unit contents:

Factors considered,
4
 F1 Number of periods allotted for teaching the unit and weightage per hour is equal to 1 and
represented as number of hours per weightage
F2 Usefulness of the content matter of the unit in the student’s learning point of view and its
weightage is equal to 1 if useful otherwise zero
F3 Usefulness of the content matter of the unit in understanding other units of the same
subject and its weightage is equal to 1 if useful otherwise zero
F4 Usefulness of the content matter of the unit in understanding other subjects prescribed
for the programme and its weightage is equal to 1 if useful otherwise zero

Topic F1 F2 F3 F4 A1 A2
Unit- I AUTOMATION AND PRODUCTION SYSTEMS (Weightage) (%)
Production system facilities, support systems. 1 1 1
Automation and manual labor in production
1 1 1
systems, automation principles and strategies.
9 18 23.37
Manufacturing industries, products and
operations, Components and classifications of 1 1 1
manufacturing systems.
Unit – II GROUP TECHNOLOGY & FLEXIBLE MANUFACTURING SYSTEMS
Part families, classification and coding, production
1
flow analysis.
Group technology applications and cellular
1 14 18.18
manufacturing. 9
Flexible manufacturing systems-components,
applications, benefits, planning and 1 1 1
implementation.
Unit – III - LEAN MANUFACTURING
Origin of lean production system, customer focus,
1 1
muda (waste), Standards – 5S system.
Total productive maintenance, standardized work,
man power reduction, overall efficiency, kaizen, 1 1 1 16 20.77
common layouts, Jidoka concept. 9
Poka-Yoke (mistake proofing), Worker
Involvement, quality circle activity, kaizen training,
1 1
suggestion programmes, oshin planning system
(systematic planning methodology), lean culture.
Unit – IV - JUST IN TIME 15 19.48
JIT – Definitions, approach, elements, effects, pull 9
1 1
and push systems.
KANBAN, MRP II, quality management system. 1

5
Plant layout, product design, purchasing,
1 1 1
implementation, automation and benefits.
Unit- V – GREEN MANUFACTURING
Impact of manufacturing in environment, role of
manufacturing sector in national growth, 1 1 1
technological change and evolving risk.
Principles of green manufacturing, green 14 18.18
9 1
manufacturing efficiency and its sustainability.
Green manufacturing strategies, motivation,
barriers, advantages and limitations, Standards for 1
green manufacturing.
Total 77 100
A1 – Total weightage
A2 – % of Weightage

18. Mapping syllabus with Bloom’s Taxonomy LOT and HOT:

Lower Order Thinking
Students are expected to Recall the information through Recognizing,
R Remembering
listing, describing, retrieving, naming, finding
Students are expected to Explain an ideas or concepts through
U Understanding
Interpreting, summarizing, paraphrasing, classifying, explaining
Students are expected to Use the information in another familiar
Ap Applying
situation through Implementing, carrying out, using, executing
Higher Order Thinking
Students are expected to Break the information into parts to explore
A Analysing understandings and relationships through Comparing, organizing,
deconstructing, interrogating, finding
Students are expected to Evaluate the Justifying a decision or course of
E Evaluating
action through Checking, hypothesizing, experimenting, judging
Students are expected to Generate new ideas, products, or ways of
C Creating viewing things through Designing, constructing, planning, producing,
inventing.

6
Unit – I AUTOMATION AND PRODUCTION SYSTEMS (Weightage 23.37%)
Sl.No Name of the Topic Process verb Types of thinking
Understanding
1 Production system facilities, support systems. Explain
CO1
Automation and manual labor in production systems, Understanding
2 Explain
automation principles and strategies. CO1
Manufacturing industries, products and operations,
Applying
3 Components and classifications of manufacturing Apply
CO1
systems.
R U Ap A E C Total
Type of thinking in Nos 2 1 3
Weightage,% 15.58 7.79 23.37%
Unit – II GROUP TECHNOLOGY & FLEXIBLE MANUFACTURING SYSTEMS (Weightage 18.18%)
Sl.No Name of the Topic Process verb Types of thinking
Part families, classification and coding, production Applying
1 Apply
flow analysis. CO2
Group technology applications and cellular Applying
2 Apply
manufacturing. CO2
Flexible manufacturing systems-components, Understanding
3 Explain
applications, benefits, planning and implementation. CO2
R U Ap A E C Total
Type of thinking in Nos 1 2 3
Weightage,% 6.06 12.12 18.18%
Unit – III LEAN MANUFACTURING (Weightage 20.77%)
Sl.No Name of the Topic Process verb Types of thinking
Origin of lean production system, customer focus, Understanding
1 Classify
muda (waste), Standards – 5S system. CO3
Total productive maintenance, standardized work,
Understanding
2 man power reduction, overall efficiency, kaizen, Describe
CO3
common layouts, Jidoka concept.
Poka-Yoke (mistake proofing), Worker Involvement,
quality circle activity, kaizen training, suggestion Applying
3 Apply
programmes, oshin planning system (systematic CO3
planning methodology), lean culture.
R U Ap A E C Total
Type of thinking in Nos 2 1 3

Weightage,% 13.84 6.92 20.77%

Unit – IV JUST IN TIME (Weightage 19.48%)

Sl.No Name of the Topic Process verb Types of thinking
JIT – Definitions, approach, elements, effects, pull and Understanding
1 Define
push systems. CO4

7
 Understanding
2 KANBAN, MRP II, quality management system. Explain
CO4
Plant layout, product design, purchasing, Applying
3 Calculate
implementation, automation and benefits. CO4
R U Ap A E C Total
Type of thinking in Nos 2 1 3
Weightage,% 12.98 6.49 19.48%
Unit- V – GREEN MANUFACTURING (Weightage 18.18%)
Sl.No Name of the Topic Process verb Types of thinking
Impact of manufacturing in environment, role of Understanding
1 manufacturing sector in national growth, Classify
CO5
technological change and evolving risk.
Principles of green manufacturing, green Understanding
2 Explain
manufacturing efficiency and its sustainability. CO5
Green manufacturing strategies, motivation, barriers,
Applying
3 advantages and limitations, Standards for green Apply
CO5
manufacturing.
R U Ap A E C Total
Type of thinking in Nos 2 1 3
Weightage,% 12.12 6.06 18.18%

R U AP A E C TOTAL
UNIT 1 2 1 23.37%
UNIT 2 1 2 18.18%
UNIT 3 2 1 20.77%
UNIT 4 2 1 19.48%
UNIT 5 2 1 18.18%
TOTAL 100%
Lower Order Thinking 100%
Higher Order Thinking 0%

19.Expected outcome of the course:

Upon successful completion of this course, the student will be able to:
CO1 Students can understand the concept of various Production and flexible manufacturing systems.
CO2 Enhance the ability of students to create GT code for a given product and differentiate the different
types of products.

CO3 Create capability to manufacture different products with minimum defects using lean principles.
8
 CO4 Able to prepare a well planned schedule for production in industries.
CO5 Student can understand the concepts of Just in time and Green Manufacturing approach.

20.Mapping course outcome with Bloom’s Taxonomy LOT and HOT:

R U Ap A E C
CO1  
CO2  
CO3  
CO4  
CO5  

21.Mapping Course outcome with graduate attributes:

Graduate attributes Descriptions
Apply the knowledge of mathematics, science, engineering
PO1 Engineering knowledge fundamentals, and an engineering specialization to the solution of
complex engineering problems.
Identify, formulate, research literature, and analyze complex
engineering problems reaching substantiated conclusions using first
PO2 Problem analysis
principles of mathematics, natural
sciences, and engineering sciences.
Design solutions for complex engineering problems and design system
Design/development of components or processes that meet the specified needs with
PO3
solutions appropriate consideration for the public health and safety, and the
cultural, societal, and environmental considerations.

Use research-based knowledge and research methods including

Conduct investigations of
PO4 design of experiments, analysis and interpretation of data, and
complex problems
synthesis of the information to provide valid conclusions.
Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to
PO5 Modern tool usage
complex engineering activities with an understanding of the
limitations.
Apply reasoning informed by the contextual knowledge to assess
PO6 The engineer and society societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice

Understand the impact of the professional engineering solutions in

Environment and
PO7 societal and environmental contexts, and demonstrate the knowledge
sustainability
of, and need for sustainable development.
Apply ethical principles and commit to professional ethics and
PO8 Ethics
responsibilities and norms of the engineering practice.
9
 Function effectively as an individual, and as a member or leader in
PO9 Individual and team work
diverse teams, and in multidisciplinary settings.
Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able
PO10 Communication
to comprehend and write effective reports and design documentation,
make effective presentations, and give and receive clear instructions.
Demonstrate knowledge and understanding of the engineering and
Project management and management principles and apply these to one’s own work, as a
PO11
finance member and leader in a team, to manage projects and in
multidisciplinary environments
Recognize the need for, and have the preparation and ability to engage
PO12 Life-long learning in independent and life-long learning in the broadest context of
technological change.

To design, analyze and apply knowledge in complex engineering problems with time effective
PSO 1
software solutions.
To understand the relevance of engineering practices with society and environment and
PSO2 become an ethical team oriented effectively communicating individual with managerial skills
and sustained learning ability.

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
CO1 3 1 2 2 1 1 1 2 2 2 2
CO2 3 2 2 2 1 1 2 2 2 2
CO3 2 2 1 1 3 2 2 1 2 2 2 2
CO4 3 1 1 2 1 1 1 1 1 3 3
CO5 2 3 3 3 2 3 1 3

3 High level 2 Moderate level 1 Low level

22.Mapping with programme educational objectives:

Programme educational objectives:
1. Graduates able to apply technical expertise and skills to face Industrial challenges.
2. Graduates able to design create and innovate economically, environment-friendly and
technically feasible products with social acceptance.
3. Graduates able to exhibit professionalism in their profession with good communication,
ethics and entrepreneurship skills to meet the social challenges.

Course PEO1 PEO2 PEO3

Moderate Moderate
COMPETITIVE MANUFACTURING SYSTEMS High level
level level

3 High level 2 Moderate level 1 Low level

10
 23.Course assessment methods:
Monthly test: 15 Marks
Objective To Identify What Students Have Learned and also to identify students strength and
weakness
Product Answer scripts
Frequency Monthly
Format Part –A 6 x 2= 12Marks
Part –B 2 x 14=28Marks
Part – C 1 x 10 = 10 Marks
Total marks= 50
Duration : 1 Hour and 30 Minutes
Evaluation Based on answer given in the scripts
criteria Pass mark – 50%
Minimum pass percentage: 75% to be fixed for attainment level
If not, remedial action will be taken.

Assignment: 5 marks
Objective To enhance students' understanding of a particular reading
Product Hand written assignment/tutorial sheets
Frequency After completing one unit
Format Important questions from each units
Evaluation Based on rubrics
Criteria No. of assignments: 3
Submit on or before the date of submission

11
 Attendance: 5 marks
Objective To make all students to attend the class throughout the course
Product Record of class work
Frequency All working days
Format Record of class work format
Evaluation Based on attendance earned by the students

Criteria Marks will be awarded according to attendance percentage of students.

91 and above 5.0
86 – 90 4.0
81 – 85 3.0
75 – 80 2.0
Less than 75 0

End semester exam: 75 marks

Objective To assess the each student’s knowledge of the course
Product Result analysis
Frequency Semester
Format Part –A 10 x 2= 20 marks
Part –B 5 x 14= 70 marks
Part – C 1 x 10 = 10 Marks
Total marks= 100
Duration : 3 Hours
Evaluation Based on answer given in the scripts
criteria Minimum pass percentage: 75%
If not, remedial action will be taken.

Faculty in-charge HOD/MECH DEAN

ADVISOR

12