IE (ME) 312 PRODUCT DESIGN AND

MANUFACTURING PROCESSES

COURSE INTRODUCTION

Course Instructor
Prof. Edward C. De Meter
Dept. of Industrial & Manufacturing Engineering
The Pennsylvania State University
 MANUFACTURED PRODUCT

Definition: A product whose attributes

have been created or enhanced by
human activity

Manufacturing accounts for roughly

20% to 30% of the total value of all
economic activity world wide1
 NON-MANUFACTURED PRODUCTS

Oil Field Drilling Rig Crude Oil Corn Harvesting Combine

Iron Ore
Corn
Iron Ore Mine

Raw materials and agricultural crops are not

considered manufactured products
 MANUFACTURED PRODUCTS

Iron Ore

Steel Mill
Steel Blooms

Crude Oil Oil Refinery

Petro-chemicals

Processed materials such as steel and

petro-chemicals are
 MANUFACTURED PRODUCTS

Canned Corn

Food Processing Plant

So are processed foods

 MANUFACTURED PRODUCTS

Nail

Automobile Engine

Discrete Product: A mechanical or electro-

mechanical part or assembly
 MANUFACTURED PRODUCTS

Product Specification: A description of product attributes

along with their acceptable ranges of variation

Recipe necessary to insure functionality

 MANUFACTURING PROCESS
WIP Specifications
MANUFACTURING
PROCESS
Machine Tool
Tools
Utilities
Consumables
Labor Finished Product
Work-in-Process Methods

An activity that transforms the properties of raw materials and/or

Work-In-Process (WIP) for the purpose of increasing their
functionality and value

For mechanical parts, this implies the transformation of:

Shape
Surface Texture
Mechanical Properties (Bulk or Surface)
Surface Coating

The transformation is done in accordance with WIP specifications

 PROCESS ENGINEERS

Process engineers are responsible for the design, analysis,

implementation, and troubleshooting of mfg processes

Mechanical engineers are the #1 discipline hired as process

engineers for plants that fabricate mechanical products
 VERIFICATION PROCESS
Specifications

VERIFICATION
PROCESS
Machine Tool
Tools
Utilities
Consumables
Measured Product
Wip/Finished Attributes
Labor
Product Methods

An activity that measures the attributes of a WIP or finished product

Attributes are compared to specifications

Manufacturing processes are altered in the case of unacceptable

deviations
 QUALITY CONTROL ENGINEERS

Quality Control Engineers are responsible for the design and

implementation of verification processes

Mechanical engineers are the #1 discipline hired as quality control

engineers for plants that fabricate mechanical products
 COURSE OBJECTIVES

Students will learn:

Critical relationships between product specification, product

fabrication, and product verification

Factors that drive manufacturing lead time and manufacturing

cost

Design issues that significantly affect product manufacturability

Science, engineering, and critical thinking that must be applied to

the commercial manufacture of products
 COURSE TOPICS
Product Specification and Measurement
In-class lecture coverage and assigned readings on:
materials
bulk mechanical properties
surface hardness
surface topography
Video lecture coverage and assigned readings on Geometric
Dimensioning & Tolerancing
Assigned readings on geometric error metrology
GD & T assignments and metrology labs
 COURSE TOPICS
Manufacturing Processes
In-class lectures and assigned readings on:
machining processes
casting processes
bulk deformation processes
sheet metal processes
joining processes
powder metal processes

Manufacturing process labs and demonstrations

 CLASS CONDUCT

Class meetings will be used for topic lectures and

pop quizzes

Laboratories will be used for:

Manufacturing Experiments and Demonstrations

Quality Control Experiments
Study of GD & T and geometric error metrology
 CLASS CONDUCT
Extra Credit Team Assignments
GDT Assignment III
Metrology Lab 4
Credit to be added to your lab grade
 CLASS CONDUCT
EXAMS
Two midterm exams to be held in the late
evening
Noncumulative final exam
GD&T Q & A Sessions
Two sessions to be held in the evening
Complete information on the exams and
Q & A sessions can be found in the
Exam and Review Session folder on-line
 CLASS CONDUCT
Course Study, Assignment, and Exam
Schedule
All assignment dates and due dates for
reading, video study, GDT assignments,
laboratory assignments, and exams can be
found in the syllabus
 REQUISITES
Pre-requisites
EMCH 213 & EMCH 210H or EMCH 210

Co-requisites
MATSC 259 or ESC 414M

(Courses Must be Passed with a D or better)

 TEXTS
Kalpakjian, S. and S. Schmid, Manufacturing
Processes for Engineering Materials, 5th Edition,
Prentice Hall, NJ, 2010

Electronic copies of lecture notes and other

documents will be provided via ANGEL
 READING ASSIGNMENT
Kalpakjian
I. Introduction (complete by Thursday)