6.

1 BASICS OF MANAGEMENT L T P 3 - RATIONALE Since the diploma holders are expected to take up middle level managerial positions, their exposure to basic management principles is very essential. Some topics like Structure of Organization, Leadership, Motivation, Ethics and Values, Customer Relationship Management (CRM), Legal Aspects of Business, Accident and Safety: Total Quality Management (TQM), Intellectual Property Rights (IPR) etc. have been included in the subject. DETAILED CONTENTS 1. Introduction: (14 hrs)

Definition and concept of Management, functions of management viz. planning, organizing, staffing, coordinating, controlling; Various areas of management: Human Resource Management (HRM): recruitment, training, retraining and compensation policies; Financial Management: payback period, Net Present Value (NPV), Internal Rate of Return (IRR), profitability ratio, cost benefit analysis; Materials Management: economic order quantity, re-order point, safety stock, Just-in-Time Technique of Materials Management; Marketing Management: necessity, advertisement, print media, electronic media, sales promotion 2. Structure of Industrial Organization (3 hrs)

Concept and structure of an organization, hierarchical management structure (top, middle and lower level management) and functional management structure. 3. Leadership Concept, importance, types and qualities of a good leader 4. Motivation (3 hrs) (3 hrs)

Concept and importance of motivation - drives and incentives, intrinsic and extrinsic motivation, brief about theories of motivation. 5. Ethics and Values (3 hrs)

Introduction, importance of attitude, values and ethical behaviour. Professional ethics its need and development 6. Customer Relationship Management (CRM) (5 hrs)

Need, various types of customers, customer satisfaction, life- long customer, Customer Satisfaction Index (CSI) and its significance 7. Legal Aspects of Business (7 hrs) a) Elementary knowledge of Income Tax, Sales Tax, Excise Duty, Provident Fund, Employees State Insurance Act. b) Labour welfare schemes, systems of wage payment, incentives

c) Salient features of Factory Act 1948 with special reference to health, safety and welfare measures, working hours, annual leave with wages, Payment of Wages Act 1936, Minimum Wages Act 1948 d) Intellectual Property Rights (IPR), concept, definitions, infringements related to patents, copyright, trademark 8. 9. 10 Introduction to Total Quality Management (TQM) and steps to achieve this. (2 hrs) MIS: Concept, importance and steps for its development (2 hrs) ill effect of drugs Knowing Drug Abuse. Type of Drugs used and their ill effects. Consequences of drug abuse. Symptoms and Prevention Rehabilitation (3 hrs) Importance of knowing traffic laws and safe driving Traffic rules Controlling road rage among young drivers Law regarding traffic Social responsibility towards injured in case of road accidents. (3 hrs)

11

Traffic Laws.

INSTRUCTIONAL STRATEGY It is observed that the diploma holders generally take up middle level managerial positions, therefore, their exposure to basic management principles is very essential. Accordingly students may be given conceptual understanding of different functions related to management. Some of the topics may be taught using question answer, assignment or seminar method. The teacher will discuss success stories and case studies with students, which in turn, will develop appropriate managerial qualities in the students. In addition, expert lectures may also be arranged from within the institutions or from management organizations. Appropriate extracted reading material and handouts may be provided. RECOMMENDED BOOKS 1. Principles of Management by Philip Kotler TEE Publication 2. Principles and Practice of Management by Shyamal Bannerjee: Oxford and IBM Publishing Co, New Delhi. 3. Financial Management by MY Khan and PK Jain, Tata McGraw Hill Publishing Co., 7, West Patel Nagar , New Delhi. 4. Modern Management Techniques by SL Goel: Deep and Deep Publications Pvt Limited , Rajouri Garden, New Delhi. 5. Management by James AF Stoner, R Edward Freeman and Daniel R Gilbert Jr. : Prentice Hall of India Pvt Ltd, New Delhi. 6. Essentials of Management by H Koontz, C O Daniel , McGraw Hill Book Company, New Delhi. 7. Marketing Management by Philip Kotler, Prentice Hall of India, New Delhi 8. Total Quality Management by DD Sharma, Sultan Chand and Sons, New Delhi. 9. Intellectual Property Rights and the Law by Dr. GB Reddy. 10. Service Quality Standards, Sales & Marketing Department, Maruti Udyog Ltd. 11. Customer Relationship Management: A step-by-step approach, Mohamed & Sagadevan Oscar Publication, Delhi 12. Customer Relation Management, Sugandhi RK, Oscar Publication, Delhi.

SUGGESTED DISTRIBUTION OF MARKS Topic No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Total Time Allotted (hrs) 14 3 3 3 3 5 7 2 2 3 3 48 Marks Allotted (%) 30 08 08 08 05 10 10 05 05 05 06 100

6.2 RATIONALE

INDUSTRIAL SAFETY AND MAINTENANCE L T P 4 - 3

A diploma holder in Production Engineering is supposed to supervise erection, testing, repair and maintenance of machine tools. He/she should be aware of the devices used for vibration isolation. The diploma holders should also be aware of safety practices used in industry. Hence this subject. DETAILED CONTENTS 1 Accidents and Safety (12 hrs)

1.1 Classification of accidents: according to nature of injuries: fatal, temporary; according to event; according to place 1.2 Causes of accidents psychological, physiological and other industrial hazards 1.3 Effects of accidents 1.4 Accident prone workers 1.5 Action to be taken in case of accidents with machines, electric shock, road accident and fires. Erection and construction accidents 1.6 Safety consciousness 1.7 Safety procedures 1.8 Safety measures Dos and donts 1.9 Safety publicity 1.10 Safety measures during executions of engineering works 2. Erection (08 hrs)

Location, lifting and unloading of machines, use of tools, equipment such as pulleys, slings, cranes, rollers pinch bars Foundation factors, foundation bolts, grouting, leveling, vibration types self, excited and forced, vibration isolation materials viz. isolation wood/airpads, impact damper, vibration absorbers/dampers 3. Testing (08 hrs)

Alignment tests of lathe, drill, shaper, planer, milling machine by making use of dial gauge, mandrel, spirit level, straight edge, autocollimators, performance tests of lathe, drill, shaper 4. Maintenance (18 hrs)

Need of maintenance, people involved in maintenance, types of maintenance, stages in preventive maintenance, manpower planning for maintenance, economic aspects of maintenance, concept of repair complexity, maintenance down time Lubrication, desired characteristics of lubricants, lubricating devices, lubrication methods

5.

Repair

(10 hrs)

Wear and surface finish concept, surface plates, scrapers, manual scraping procedure, machining scraping, babbitting, metallising, chromium plating, cracks repairs weld deposition. Equipment Health Monitoring Tools 6. Environmental Engineering 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 Ecology Factors causing pollution Effects of pollution on human health Air pollution and Control Act Water pollution and Control Act Pollution control equipment Solid waste management Noise pollution and its control (08 hrs)

LIST OF PRACTICALS 1. 2. 3. 4. Alignment tests of lathe, drilling machine, shaper, milling machine by using dial gauge, spirit level and straight edge Preventive Maintenance: inspection of lathe, cleaning, dusting, dismantling tool post, inspecting after replacing worn out parts Lubrication: acquaintance with lubricating devices, oil cans, grease gun, and oil cups Repair manual scrapping of drill table, copper screw crack repair method INSTRUCTIONAL STRATEGY 1. 2. Students should be made aware of industrial laws and safety practices followed in industry. Industrial visit to process/manufacturing units should be made to demonstrate maintenance practices and tools along with the waste management and disposal practices

RECOMMENDED BOOKS 1. 2. 3. 4. 5. Industrial Maintenance by HP Garg, S Chand & Company, Delhi A Text Book of Reliability and Maintenance Engineering by A Manna, Prentice Hall of India, New Delhi Testing Machine Tools by G Schlosinger Vibration of Machine Tools by G Sweeney Industrial Maintenance Management by SK Srivastva, S Chand & Company, Delhi SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 3 4 5 6 Total Time Allotted (Hrs) 12 08 08 18 10 08 64 Marks Allotted (%) 20 10 10 30 15 15 100

6.3

INDUSTRIAL METROLOGY AND QUALITY CONTROL L T P 4 - 3

RATIONALE Diploma holders in this course are required to measure and inspect for ensuring quality of product. For this purpose, knowledge and skills about standards of measurement, limits, fits and tolerances, types of inspection and various measuring instruments and SQC is necessary. He/she must be aware of quality systems. Hence this subject. DETAILED CONTENTS 1. Inspection (14 hrs) 1.1 Introduction, units of measurement, standards for measurement and interchangeability, accuracy and precision 1.2 International, National and company standard, line and wavelength standards 1.3 Planning of inspection: What to inspect? When to inspect? Who should inspect? How to inspect? Where to inspect? 1.4 Types of inspection: Remedial, preventive and operative inspection, incoming, inprocess and final inspection 2. Measurement and Gauging (24 hrs)

2.2 2.3 3.

2.1 Study of various measuring instruments like: Callipers, micrometers, dial indicators, surface plate, straight edge, try square, protactors, sine bar, clinometer, gear tooth vernier, comparators-mechanical and electrical. Slip gauges, tool room microscope, profile projector, talysurf. Limit gauges: Plug, ring, snap, taper, thread, height, depth, form, feeler, plate, wire and their applications for linear, angular, surface, thread and gear measurements, gauge tolerances. Measurement of Surface finish Terminology of surface roughness concept of primary texture and secondary texture. Factors affecting surface finish, CLA, RMS and RA values. Principles of operation of Talysurf. Error, calibration of measuring instruments (20 hrs)

Statistical Quality Control 3.1 3.2 3.3 3.4 3.5

Quality control, SQC, functions of quality control, quality cost, factors affecting quality of product. Basic statistial concepts, emperical distribution and histograms, frequency, mean, mode, standard deviation, normal distribution, binomial and poisson (No mathematical derivations) Introduction to control charts, namely X, R, P and C charts and their simple applications. Sampling plans, selection of sample size, method of taking samples, frequency of samples Inspection plan format and test reports (06 hrs)

4.

Standards And Codes 4.1 4.2 4.3 National and International Codes ISO-9000, concept and its evolution and implications Quality Control tools

LIST OF PRACTICALS 1. Exercise on use of vernier calliper 2. Exercise on use of micrometer 3. Exercise on use of height gauge 4. Exercise on use of combination set 5. Exercise on use of bevel protractor 6. Exercise on use of sine bar and slip gauges for measuring taper 7. Use of dial indicator for measuring taper 8. Measurement of thread characteristic using thread micrometer 9. Measurement of all elements of gears by using gear tooth vernier 10. Use of tool makers microscope 11. Use of comparators 12. Use of profile projector 13. Verify that when random samples are taken from a universe with a certain percentage of defectives same percentage tends to appear in random samples by using Shewarts plastic kit box. 14. Plot frequency distribution for 50 turned components 15. To plot X-R charts for given samples 16. To plot p-chart for given samples 17. To plot c-chart for given samples INSTRUCTIONAL STRATEGY 1. 2. 3. 4. Role of National Physical Laboratory (NPL) in standardization and calibration should be clearly explained. While dealing with theory, the respective measuring instruments should be demonstrated. Stress should be laid on correct use of measuring instruments Visit to quality control department of any one manufacturing unit should be made.

LIST OF RECOMMENDED BOOKS 1. Production Engineering Estimating and Costing by. M. Adithon and B.S. Pabla; Konark Publisher, New Delhi. 2. Inspection Quality Control and Reliability by SC Sharma; Khanna Publishers, Delhi. 3. Engineering Metrology by R.K.Jain : Dhanpat Rai and Sons, Delhi. 4. Satistical Quality Control by M. Mahajan SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 3 4 Total Time Allotted (Hrs) 14 24 20 06 64 Marks Allotted (%) 20 40 30 10 100

6.4

MACHINE DESIGN L T P 4 - -

RATIONALE A diploma holder in this course is required to assist in the Design and Development of Prototype and other components. For this, it is essential that he is made conversant with the principles related to design of components and machine and application of these principles for designing. The aim of the subject is to develop knowledge and skills about various aspects related to design of machine components. DETAILED CONTENTS 1. Introduction 1.1 Design Definition, Type of design, necessity of design 1.1.1 1.1.2 1.1.3 1.2 Comparison of designed and undesigned work Design procedure Characteristics of a good designer (08 hrs)

Design terminology: stress, strain, factor of safety, factors affecting factor of safety, stress concentration, methods to reduce stress concentration, fatigue, endurance limit. 1.2.1 General design consideration 1.2.2. Codes and Standards (BIS standards) Engineering materials and their mechanical properties : 1.3.1 Properties of engineering materials: elasticity, plasticity, malleability, ductility, toughness, hardness and resilience. Fatigue, creep, tenacity, strength 1.3.2 Selection of materials, criterion of material selection

1.3

2.

Design Failure 2.1 2.2

(04 hrs)

Various design failures-maximum stress theary, maximum strain theory Design for tensile, compressive and torsional loading. (10 hrs)

3.

Design of Shaft 3.1 3.2

3.3 3.4 4.

Type of shaft, shaft materials, Type of loading on shaft, standard sizes of shaft available Shaft subjected to torsion only, determination of shaft diameter (hollow and solid shaft) on the basis of : Strength criterion Rigidity criterion Determination of shaft dia (hollow and solid shaft) subjected to bending Determination of shaft dia (hollow and solid shaft) subjected to combined torsion and bending . Design of Key (06 hrs)

4.1 4.2 4.3 4.4 5.

Types of key, materials of key, functions of key Failure of key (by Shearing and Crushing). Design of key (Determination of key dimension) Effect of keyway on shaft strength. (Figures and problems). Design of Joints (20 hrs)

Types of joints - Temporary and permanent joints, utility of various joints 5.1 Temporary Joint: 5.1.1 5.1.2 5.2 Knuckle Joints Different parts of the joint, material used for the joint, type of knuckle Joint, design of the knuckle joint. (Figures and problems). Cotter Joint Different parts of the spigot and socket joints, Design of spigot and socket joint.

Permanent Joint: 5.2.1 Welded Joint - Welding symbols. Type of welded joint, strength of parallel and transverse fillet welds. 5.2.2 Strength of combined parallel and transverse weld. 5.2.3 Riveted Joints. : Rivet materials, Rivet heads, leak proofing of riveted joint caulking and fullering. 5.2.4 Different modes of rivet joint failure. 5.2.5 Design of riveted joint Lap and butt, single and multi riveted joint.

6.

Design of Flange Coupling (08 hrs) Necessity of a coupling, advantages of a coupling, types of couplings, design of muff coupling, design of flange coupling. (both protected type and unprotected type). Design of Screwed Joints 7.1 7.2 7.3 (08 hrs)

7.

Nature of loads on nut and bolts, types of failure of nut and bolts. Initial stresses due to screwing up, stresses due to combination of different loads. Design of power screws (press, screw jack, screw clamp).

Note : The paper setter should provide all the relevant data for the machine design numerical in the question paper. Drawing of any two designed components to be made using CAD. INSTRUCTIONAL STRATEGY 1. Use moulds of various parts/components. 2. Presentation should be arranged for various topics. RECOMMENDED BOOKS 1. 2. 3. 4. 5. Machine Design by R.S. Khurmi and JK Gupta, Eurasia Publishing House (Pvt.) Limited, New Delhi. Machine Design by V.B.Bhandari, Tata McGraw Hill, New Delhi. Engineering Design by George Dieter; Tata McGraw Hill Publishers, New Delhi. Mechanical Engineering Design by Joseph Edward Shigley; McGraw Hill, Delhi. Machine Design by Sharma and Agrawal; Katson Publishing House, Ludhiana.

6. 7. 8.

Design Data Handbook by D.P. Mandali, SK Kataria and Sons, Delhi. Machine Design by A.P.Verma; SK Kataria and Sons, Delhi Machine Design by AR Gupta and BK Gupta ; Satya Parkashan, New Delhi. SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 3 4 5 6 7 Total Time Allotted (Hrs) 08 04 10 06 20 08 08 64 Marks Allotted (%) 12 06 16 10 32 12 12 100

6.5 RATIONALE

CNC MACHINES AND AUTOMATION 3 L T P - 3

Diploma holders are required to supervise and handle specialized machines and equipment like CNC machines. For this purpose, knowledge and skills about NC machines, part programming in NC machines and tooling for CNC machines are required to be imparted for enabling them to perform above functions. This subject aims at development of knowledge and skills about CNC machines, tools, equipment and use of high tech machines for increased productivity and quality. DETAILED CONTENTS

1.

Introduction

(06 hrs)

Basic concepts of NC, CNC & DNC, adoption controls, advantages & disadvantage of CNC Machines, Application of CNC Machines, difference between conventional & CNC Machines, Profitable applications of CNC Machines.

2.

Construction of CNC Machines

(12 hrs)

Machine control unit, NC control, PLC control, its advantages & disadvantages, Application aid limitations of PLC machines, Axis designate of CNC machines, special constructional requirement of CNC machines, slide ways, bolt screw & nut assembly, Lubrication & cooling of CNC machines, Spindle & spindle motors, axis drives motor, Swarf removal & safety provision of CNC machines, Feedback mechanism in CNC machines.

3.

Tooling of CNC Machines (06 hrs) Introduction, various cutting tools for CNC machines, Work holding devices, automatic tool changer. Control System (08 hrs)

4.

Open & close loop control system, fundamental problem in control: Accuracy, resolution, repeatability, instability, response & damping, type of position control: Point to point Straight line Continuous

5.

Part Programming

(08 hrs)

Part programming and basic concepts of part programming, NC words, part programming formats, simple programming for rational components, part programming using conned cycles, subroutines and do loops, tool off sets, cutter radius compensation and wear compensation

6.

Common Problems in CNC Machines

(04 hrs)

Common problems in mechanical, electrical, pneumatic, electronic and PC components of NC machines, diagnostic study of common problems and remedies, use of on-time fault finding diagnosis tools in CNC machines

7.

Industrial Automation

(04 hrs)

Meaning of automation, need of automation, different types of automation, advantages/disadvantages of automation, Components of automated system, programmable logic controllers - introduction and use, concept of FMS. LIST OF PRACTICALS 1 2. 3. Study the constructional details of CNC lathe. Study the constructional details of CNC milling machine. Study the constructional details and working of: 4. Automatic tool changer and tool setter Multiple pallets Swarf removal Safety devices

Develop a part programme for following lathe operations and make the job on CNC lathe and CNC turning center. Plain turning and facing operations Taper turning operations (internal and external) Thread cutting operations ( internal and external) Operation along contour using circular interpolation. job

5. Develop a part programme for the following milling operations and make the on CNC milling 6. 7. Plain milling Slot milling Contouring Pocket milling

Preparation of work instruction for machine operator Preparation of preventive maintenance schedule for CNC machine.

8. Demonstration through industrial visit for awareness of actual working of FMS in production. 9. 10. Use of software for turning operations on CNC turning center. Use of software for milling operations on machine centres.

INSTRUCTIONAL STRATEGY This is highly practice-based course. Efforts should be made to develop programming skills amongst the students. During practice work, it should be ensured that students get opportunity to individually perform practical tasks.

RECOMMENDED BOOKS

1. CNC Machines Programming and Applications by M Adithan and BS Pabla; New

Age International (P) Ltd., Delhi. 2. Computer Aided Manufacturing by Rao, Kundra and Tiwari; Tata Mc Graw Hill, New Delhi. 3. CNC Machine by Bharaj; Satya Publications, New Delhi. SUGGESTED DISTRIBUTION OF MARKS Topic No. 1 2 3 4 5 6 7 Total Time Allotted (Hrs) 06 12 06 08 08 04 04 48 Marks Allotted (%) 12 28 12 16 16 08 08 100

6.6 RATIONALE

PROJECT WORK L T P - - 10

The practical training cum project work is intended to place students for project oriented practical training in actual work situations for the stipulated period with a view to: i) Develop understanding regarding the size and scale of operations and nature of field work in which students are going to play their role after completing the courses of study. Develop understanding of subject based knowledge given in the class room in the context of its application at work places. Develop first hand experience and confidence amongst the students to enable them to use and apply polytechnic/institute based knowledge and skills to solve practical problems in the world of work. Develop special skills and abilities like interpersonal skills, communication skills, attitudes and values.

ii) iii)

iv)

This practical training cum project work should not be considered as merely conventional industrial training in which students are sent at work places with minimal supervision. This experience is required to be planned and supervised on regular basis by the polytechnic faculty. For the fulfillment of above objectives, polytechnic may establish close linkage with 8-10 relevant organization for providing such an experience. It is necessary that each organisation is visited well in advance and activities to be performed by students are well defined. The chosen activities should be such which are of curricular interest to students and of professional value to industrial/field organisations. Each teacher is expected to supervise and guide 5-6 students. Effort should be made to identify actual field problems as project work for the students. Project selected should not be too complex which is beyond the level of the students. The placement of the students for such a practical cum project work should match with the competency profile of students and the project work assigned to them. Students may be assessed both by industry and polytechnic faculty. The suggested performance criteria is given below : (1) (2) (3) (4) (5) (6) (7) (8) (9) Punctuality and regularity Initiative in learning/working at site Level/proficiency of practical skills acquired Ability of solve live practical problems Sense of responsibility Self expression/communication skills Interpersonal skills/Human Relation Report Writing Skills Viva Voce

The projects given to students should be such for which some one is waiting for solution. Some of the suggested project activities are given below: 1. 2. 3. 4. Projects connected with repair and maintenance of machines . Estimating and costing projects. Design of jigs / fixtures. Projects related to quality control.

5. 6. 7. 8. 9. 10.

Project work related to increasing productivity. Projects relating to installation, calibration and testing of machines. Projects related to wastage reduction. Project, related to fabrication. Energy efficiency related projects. Projects related to improving an existing system Students are required to prepare working drawings of the projects and will prepare the estimate, material lists as required, and carry out market survey etc. Students will specify various processes involved in the project

Note: 1. 2.