Design for Manufacturability

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Course Number: ENGRG 7520
Course Name: Design for Manufacturability (Online)
Course Description:    A major portion of the costs and in turn the profitability of manufacturing organizations are affected by the quality of the design of their products. Building quality into the design will call upon engineers to systematically design a product and/or process so that it can be produced with lowest costs, rapid response time, and meet customers¿ expectations. This will require the integration of design, manufacturing, management, and economic principles. The course will address this overall integration and focus on the design for manufacturing aspects so as to provide faster time to market, productive utilization of equipment, faster delivery, improved quality, reduced cost, and effective continuous improvement. Students will be able to systematically design a product and/or process so that it can be produced with lowest costs, rapid response time, and meet customers¿ expectations. In doing so, they will be able to identify opportunity for design, address technical considerations of design & manufacturing, and make a business decision on feasibility of design.
Prerequisites:    None
Level: Graduate
Credits: 3
Format: Online
Program: MS in Engineering
MS in Integrated Supply Chain Management

Registration Instructions

NOTE: The information below is representative of the course and is subject to change.  The specific details of the course will be available in the Desire2Learn course instance for the course in which a student registers.

Additional Information

Course Rationale
This is a graduate level course in design for manufacturability. The course deals with all aspects of the product and process development process. There is no prerequisite for this course although it is helpful to have taken ENGRG 7550 Product Design and Development. It is also useful to have a basic understanding of manufacturing processes such as castings, forgings, sheet-metal forming, machining, welding, heat treat and plastics processing. You will need to know how to write a formal report for the term project. Having taken ENGRG 5000 Engineering Communications will be helpful for the formal report.

The course objective is to learn the product development process in stage-gate format. The stage-gate process is used by many companies in order to encourage rapid product development and to cull out the least promising projects before large sums of money are committed. Opportunities to use the principles taught in the course arise in all phases of engineering and scientific work, including technology development, new product design and development, process development, and manufacturing process improvement. Applications from various fields of engineering including chemical, mechanical, electrical, materials science, industrial, and more will be illustrated throughout the course.

Product development encompasses much more than conceiving and designing a product. It involves the preliminary assessment of the market for the product, the alignment of the product with the existing product lines of the company, and an estimate of the projected sales, cost of development, and profits. This course emphasizes the importance of the process of designing a product in hopes that students can apply the design for manufacturability practices and principles to their current and future job opportunities.

Course Outcomes
After successfully completing the course, you should have the capability to systematically design products and/or processes to get the lowest cost, quickest response time, and best-achieved customer expectations.

Upon completion of this course, you should be able to:

  • Identify opportunities for design.
  • Address technical considerations of design and manufacturing.
  • Make business decisions concerning the feasibility of a design.
  • Utilize DFM and Concurrent Engineering Principles on a "real life" project.

Unit Descriptions
No units for this course

Lesson Descriptions
Lesson descriptions blended with Lesson Commentaries

(Below is general overview provided in the course)

As you progress through the lessons, you will be able to identify certain characteristics of this course:

  • The commentary for each lesson contains a general overview and pertinent comments by your professor about that lesson. After reading the commentary, you should proceed to the Presentation link for that lesson. All units and lessons are listed in the Content area of the course.
  • Much of the presentation in each lesson is somewhat detailed and closely follows your textbook. This does not mean you won't have to read the textbook, since there is still significant material that you have to get directly from it.
  • Each lesson contains key figures, important charts, or graphics from the textbook.
  • The Engineering Design textbook has a large selection of resources via its references. Details for the references indexed in the Presentations for the various lessons are available in the Resources links for each lesson.
  • The Engineering Design textbook readings, commentary, presentations, and references form the core resources you will need for understanding the principles, goals, and the tools of design for manufacturability (DFM). These core resources will serve as the central base for comprehending applications in the vast field of design, manufacturing, and DFM. This field will become more familiar to you as you work through the homework, examinations, and projects of the course.
  • For your future benefit as well as grading in this course, assessments will measure how well you have learned DFM principles, goals, and tools. Assessment is conducted through homework (made up of quizzes, and unit/lesson related tasks), a final examination, and a major project. Some of these tasks, including the major project, will provide opportunities to apply the learned principles and tools to practical situations. Look periodically in the Course Calendar/Upcoming Events and/or the Announcements section of the course to keep abreast of scheduled tasks.
  • Each lesson includes both an assignment and a quiz to test you on key points of the lesson.
  • There is one examination in this course and one course project.

Exams: 13 quizzes 1 final exam

Activities and Assignments: 13 homework assignments & Term Project (broken into 6 subset tasks)

Group Assignments: 1

This project spans the length of the course and is intended to be a group effort. Groups will be assigned at the beginning of the semester. Each of the term project assignments leads to the final report. All dates are given in the course calendar. The term project has six parts, that encompasses each of the 13 lessons. This will encourage you to make thoughtful choices, get rid of poor topics, and avoid procrastination.

The term project will have valuable outcomes. First, it will be instructive for you to tie all of the lecture material to a practical exercise. Second, you will benefit from practicing the application of DFM to designs and from documenting the results in a written report.

Term project topics should be complex enough to allow for opportunities to apply DFM principles to parts fabrication and product assembly. They should include opportunities for using both off-the-shelf parts and designed parts. If you redesign an existing product, comparisons can be made between new and old. This is especially true if the existing product can be analyzed physically, or at least has been documented in the literature. Working engineers are encouraged to design or redesign a company product, existing or hypothetical.

I would like objective, specific goals for doing your DFM project. Don’t use terms like "reduce total number of fasteners." Use terms like "reduced fasteners from 300 hex bolt lengths and types to 50." Make the goal realistic and achievable.

A group discussion forum for this project will be available for discussing your progress and sharing feedback with others in the group.

The steps in the term project can be a useful guide in industry, too, especially after college experience under professorial guidance.

The final report should be one cohesive document. It must be a complete and thorough description of the design process that culminated in the presented design artifact. The final report must include adequate explanation, justification, and supporting information for all decisions that affected the outcome of the final design and the methods of producing it.

PARTICIPATION: Each interim project report and the final report must contain a statement on the cover page signed (electronically) by all team members warranting that every member of the team did his/her fair share to the satisfaction of the signatory, and a task assignment sheet (in the appendix) indicating which member was responsible for each report section.

Grading Information
The breakdown of points is as follows:

The final grade for the course is calculated from grades in homework (29.7%), quizzes (24.7%)  final exam (22.8%), and a term project (22.8%).

Grading Scale
Semester letter grades are assigned on the composite scores as follows:

A A- B+ B B-  
92 to 100 % 90 to 92 % 88 to 90 % 82 to 88 % 80 to 82%  
C+ C C- D+ D F
78 to 80% 72 to 78% 70 to 72% 68 to 70% 62 to 68% 0 to 62%

 

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