Ver. 2005 Fall ver. 2.0

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Administrative Section

Introduction to the Course

Important Key Due Dates

Weekly Schedule of the Course

Learning Resources for this Course, this Semester

This is your latest, therefore the most current schedule. Last update: September 10, 2005 (Update history: September 2, 2005)

Please Read This! It Contains Vital Information about the Course as well as All the Assignments, Homework and Grades!

This is a combined Welcome Letter and Course Outline for both the live, as well as the distance learning class. Please read it carefully. You will find all essential course information here.

Please note, that this document will be updated during the semester. If anything is unclear please contact me.

PLEASE save the TREES! Please DO NOT Print this syllabus. Use this web site to read it in this electronic format; it will be updated during the semester. Thank you!

Welcome to MNE 601; The Live and the DL /Hybrid class: Manufacturing Systems Engineering

MnE 601 - Manufacturing Systems (3 credits). Modeling and control of large-scale systems with application to complex manufacturing systems including mathematically based modeling and control, and artificial intelligence-based methods.

Learn about Manufacturing Systems Engineering, as part of an integrated approach to Manufacturing Systems Modeling and Control, Process Design, and Service Systems Engineering, Total Quality Management, and Concurrent / Simultaneous Engineering, Incorporating New Process/service Innovation and Introduction (NPI&I), and Expert Systems, based on a set of analytical, quantitative and computational methods, tools and case studies.

This is a combined Welcome Letter and Course Outline for both the live, as well as the distance learning class. Please read it carefully. You will find all essential course information here.

This is an analytical, as well as practical course. This is what one of my recent graduate students wrote about IE655 Concurrent Engineering (the product design-oriented 'sister' course of the process and manufacturing systems engineering-focused MNE 601): 'Hi Prof., I did recommend your classes (IE673) and (IE655) to one of my friends at work, who is doing the M.S. in Engineering Management, and he is going to take them both. It has been a great learning experience. One of the things, I have to admit that if it wasn't for you, I would probably never learn how to design a web page, and think it is a complicated process. (thank you). Nirmin Nasef.'

Please note, that this document will be updated during the semester. If anything is unclear please contact me.

Paul G. Ranky, PhD, ASEE, IEE, PMI

Full Tenured Professor, Registered Chartered Professional Engineer
Department of Industrial and Manufacturing Engineering
NJIT, University Heights, NJ 07102 -1982

Email at NJIT: (Please note, that for reliability reasons I have added another email address: . Please use this and send again your email if you don't get an answer from me within 3 working days. I can read the account over the Internet anywhere where I have Internet access, therefore even if I am away at a conference we can still be in touch.)

Tel at home (in case of an emergency only, 24 hrs, but preferably during normal hours, ( i.e. 8.00 am to 10.00 pm) (201) 493 9561

Note, that my office is in ITC 2519 at NJIT, Newark Campus

My office hour for the Fall 2005 semester is Mondays 5-6 pm, and also by appointment in my office at NJIT (ITC 2519). Since most of you are working, if this is inconvenient for you please ask for an appointment by email, or by phone, and I'll be happy to see you as soon as I can. I am also pleased to stay longer after class if needs be to help with your coursework.

Find out more about the Professor’s past and current research work and background at:


Please read this new, shortened syllabus carefully. Having read and understood this syllabus please the following (you can copy paste the list below into your email for consistency):

General Notes

  1. In this section we'll post notes that effect all students. This will save us all time. Please collaborate.
  2. Please note, that in case your email is not answered it means that my response wasn't delivered due to email address / account issues at your end, or perhaps at the NJIT end... Sorry, You have to fix your side, I'll fix my side. If everything fails, pls. call by phone (as above).
  3. Naturally my email at NJIT can fail too, as it has in the past. In this case either wait until NJIT resolves this, or call if urgent (you have my home telephone number above, in case of an emergency).
  4. Last year's statistics shows that over 70 percent of the questions asked by students about this course were actually answered in this combined Welcome Note/ Course Syllabus... so PLEASE READ THIS and try to beat last year's poor statistics... it saves time for all of us, most importantly for you!
  5. Due to the fact that I teach and supervise several students, I cannot confirm the receipt of your homework assignments.
  6. PLEASE set up your own web page, and/or use NJIT's web server, or your company's, or your own... submit your assignments electronically. I will NOT accept assignments on paper. Please make sure that your URL works before you send me an email with a URL in it so that I can click on it and directly link to your assignment(s). The best approach is to set up your own web page (NJIT offers you free web server space for this, please contact the NJIT Computer Help Desk, I cannot help with NJIT server details, I use other professional servers) and then add every assignment to this URL as you develop them. This will be an extremely valuable knowledge documentation method to share your knowledge, to learn, and a marketing resource when you apply for a job!
  7. WARNING! Make sure that your web page works fine! THERE ARE MANY web pages that do NOT LINK! Please make sure, that your URL does link well, directly from the email you send me to by email: (NOT via webCT!) to notify me of a new submission, else I won't be able to give you a grade... and everything will be delayed, which is bad for you as well as for me. (Never forget: Your success is my success too, and I am keen for both of us to succeed!)
  8. We plan to use the NJIT Highlander Account for this class. For us, this means, that in this class
  1. These are the steps my students suggested in the past to follow when uploading webpages to the NJIT server (Note: I use professional servers; I do not use the NJIT server, therefore if you need help please contact the NJIT computing helpdesk, and/or network with other students via the webCT chat groups):

    This is a good one, offered by Ashley (thanks!) Click to see it in .html

Last, but not least: ALWAYS test your uploaded assignment using your own, as well as somebody else's computer, to make sure, that everything works fine. (If you don't have a second, independent computer on the web, ask one of your classmates, or friends to check it for you, by sending him/her an email with a full URL in it, like this:

Also note, that besides the class discussions (live class), the eLearning pack CDs/ DVDs we have several examples covering the architecture of simple and complex web-pages. All of these are in open source, please study them!

As always,

Happy Learning,

Professor Paul G Ranky, PhD

Contents (MNE601) Manufacturing Systems Course Live and Distance Learning (DL, or eLearning, the same). Kindly note, that this class runs also in hybrid (or blended) mode (as defined by NJIT).


Welcome to MNE 601! If anything is unclear please call me or email me. I am here to help you!

In MNE 601 we discuss and learn a conceptual, as well as a practical approach to design lean, cellular, flexible and agile manufacturing systems and we work on manufacturing, assembly, etc. other process design focused assignments and projects. Techniques utilized and discussed in detail include manufacturing systems analysis and integration, needs analysis, process modeling, service system modeling, process risk analysis, collaboration and integration methods, rapid process prototyping, design of-, and for manufacturing / assembly and other systems, Computer Aided Manufacturing and expert systems. Relevant open source software is employed and made available to students in the form of a customized eLearning Pack. The course should be of interest to individuals concerned with integrated product/ process innovation and introduction to the market, maximizing quality, productive manufacturing / assembly, minimizing lead time, project development cost and time to market new products, manufacturing processes and/or services.

Narrative Description of the Course
An object oriented (i.e. modular product, process, service design) approach to the introduction of various integrated process (and product) design methods, tools, technologies and their management issues within a variety of small, medium and large enterprises for the purpose of reducing lead time, and cutting waste.

The purpose of integrating manufacturing systems engineering with product, process design (the subject of concurrent / simultaneous engineering) methods is to cut product and/or service process development lead time, to reduce waste, to reduce the number of costly product design changes focusing on the process side of integrated product/process design engineering to improve quality, and to create a lean workflow from concept to integrated product/process design, manufacture, assembly, maintenance and after-sales support, based on analytically established customer requirements, and process models.

The diagram below clearly illustrates the essence of this course. It is every company's aim to create products, processes and services that are required by customers, that are innovative, high quality, and can be introduced to the market at a competitive price. The diagram below clearly illustrates the extremely high cost of product design changes.

This is typical without understanding the process side of concurrent engineering... Note, that in the IE655 class we'll learn concurrent product design methods, and in MNE 601 we focus on the manufacturing systems and process aspects, methods, tools and technologies, that will lead us to innovate our manufacturing processes, and minimize the number, and therefore the cost of changes during the entire lifecycle of a product. (As can be seen, despite what accountants claim, one cannot reduce waste without attacking BOTH the PRODUCT DESIGN, as well as the MANUFACTURING SYSTEMS side of our engineering activities...)


Furthermore, as illustrated below, it is important to understand, that Concurrent Engineering, combined with Total Quality Management, and Project Management offers major product life-cycle cost reductions.

As you study the graph below, consider the following:

In engineering systems the term 'life-cycle cost' means the sum of all the costs, both recurring as well as non-recurring, related to product, structure, system, process, IT, and/or service during its life span. (A typical life-cycle is illustrated below.)

As you can see from this graph, life-cycles typically start by identifying a customer need, a requirement, a want, a desire, and/or a sound business opportunity, and end with product/process retirement, conversion, re-engineering, recycling and eventual disposal activities. (Note, that in the case of a modern, environmentally friendly concurrently engineered product/process design system, 85-90% of products are eventually re-used and recycled.)

Since by understanding the underlying drivers and processes of concurrent engineering, the opportunities for saving valuable product/process design and development cost and time are huge, the aim is obviously close to 100% re-use and re-cycling, and as we will discuss this issue in the course, there are already good examples for achieving this goal...)

Besides others, the graph below underlines the fact, that manufacturing systems engineering in integration with concurrent engineering economic studies, process-by-process cost and gain assessments are essential part of the big picture, because they help to analyse and compare alternatives in virtual environments, costing a lot less than real-world experimentation on the shop floor when the product/process is already in full swing production and the commited costs are already high.

We can furthermore see, that the greatest savings occur at the acquisition phase, in other words around the basic idea to detailed design transition phase. This is why a factory with a future will have to understand and master concurrent engineering and NPI&I methods and apply them at all stages of the business to be able to successfully compete. Note, that very often a new manufacturing process triggers new product designs, therefore it is crucial to understand manufacturing systems engineering for any viable design.

As a good example, think of hydro-forming as a manufacturing process, and manufacturing system creating new product designs. As an other example look at the way we cut stone with laser, rapid prototype and rapid manufacture by spraying metal onto a plastic shell, or the way we process plastic cylinder heads for automotive engines, and many other aspects of engineering. The key is, that if you don't understand manufacturing systems and processes, YOU CANNOT BE A GOOD DESIGNER. Period!

It is also important to recognize, that as shown below, the commited cummulative life-cycle cost curve increases rapidly during the basic product/process idea to detailed design transition phase. In general typically 80% of life-cycle costs are 'locked in' at the end of this phase and at the beginning of the 'release design to manufacturing' phase by the decisions made during the requirements analysis, preliminary and detailed design phases. As illustrated by the cummulative, actual life-cycle cost curve, only about 20% of actual costs occur during the acquisition phase, in other words around the basic idea to detailed design transition phase, with about 80% being occured at the product construction, operation phase.

As a conclusion, as shown below, the concurrently engineered NPI&I activity must understand the potential for product / process life-cycle savings in all processes, with their requirements and risks involved, their time and cost demands, and then simulate these issues in advanced virtual environments, and take decisions as early as possible to avoid dead-end paths and costly changes! (Note, that this statement is true for every product/process, IT, and service product development activity!)



It is interesting to see, that the above illustrated principles apply to all manufacturing and design industries, as well as to IT and service environments too. As an example, in the IT industry the opportunities for savings are enormous, due to the fact that over 85% of IT projects fail (1990-2002 figures), costing over 56 billion (!) USA dollars, the US economy only!

Using concurrent engineering and NPI&I methods this amazing level of failure can be reduced significantly (as a reference only 10-15% of engineering projects fail). The major challenge though is to convince IT professionals to actually learn, understand and then apply these methods during their everyday work, versus jump into code-writing... as many of them do even now...

Of course, the root cause is to convince many (not all) computing and information sciences professors to change the way they teach IT, information sciences and computer programming... but this is outside the scope of this class... Nevertheless any fool can see that even if we just save 10% of the $ 56 billion, we can gain $ 5.6 billion every year; not an ignorable sum... the potential savings of course are at least 80% of the 85% failure, therefore we really talk about saving 80% of $ 56 billion = $ 44.8 billion USA Dollars in the USA only... world-wide this figure is estimated to be several times this value... imagine how many hungry kids we could fed out of this money... now you feel the pressure; amazing but true!

As seen below, the Design for Manufacturing (DFM) / Concurrent Engineering (CE) software market is forecast to grow very agressively not only in the mechanical (like the automotive) but also in the electrical, and electro-mechanical industries.

This is because the electronics industry recognises the significant cost saving, quality improvement, and time-to-market reduction opportunities with advanced manufacturing systems and CE.

As an example, at a recent Design for Manufacturability conference in San Diego, CA, USA, the electronic engineering community expressed their views, that 'DFM / CE solutions have emerged to help designers to cope with process variability reductions and yield increase' (... hope you recognize the link here with what we teach in Total Quality Management, IE673, and IE 655).

As EE Times, the industry newspaper for electronic engineers and technical management (by United Business Media, USA) reports in their June 14, 2004 issue, 'taking one of the boldest steps yet to merge design with manufaturing, Magma Design Automation Inc., USA announced an integrated solution...' Furthermore, IBM and academic research partners are working on methodologies for manufacturing-driven design rule exploration, physical verification, design rule checking (DRC), and other hot CE topics... As Vasilios Gerousis, Chief Scientist at Infineon Technologies AG put it: 'Design and process parameters need to be adjusted at the same time'; a clear success for concurrent / simultaneous engineering principles!

The graph below illustrates the above planned, industry-driven, drastic electronic design DFM/CE software growth rate.


In order to lead the above outlined plan, our students are prepared for this challenge and are educated to respond to the rapidly growing employment opportunities in the field of concurrent / integrated product / process and service system design and engineering management.

In the IE655 course they learn several well established product design-focused methods in-depth. In MNE 601 we focus on the process side of our business, such as process-focused quality function deployment, requirements analysis, collaborative manufacturing system (and service) process modeling, process failure mode and risk analysis methods, PLM (Product Lifecycle Management), NPI & I (New Product Innovation and Introduction), and others, including methods, tools and technologies in the product / process / service system design field, covering the following:

The course is supported by a comprehensive eLearning package (same for both live and distance learning students) with a textbook, some printed material, and several web-browser readable, open source 3D interactive multimedia CD-ROMs/ DVD-ROMs. It includes real-world research and industrial case studies on CD-ROMs/ DVD-ROMs, as well as open source, professional active code and spreadsheets, that the students can customize when developing their assignments with their own data.

To summarize, the methods taught in this course are relevant not just to innovative design, manufacture, test and quality control of products, but to a large variety of services too, because they reduce development costs, and improve working capital management, by offering powerful methods and software tools.

Upon completing this program of study the candidates will be able to understand Concurrent/ Simultaneous Engineering, and related total quality engineering management methods and tools.

Note, that besides the above, in this semester we'll specifically focus on cellular, flexible, lean manufacturing, assembly and disassembly systems, multi-lifecycle engineering, and total quality engineering management aspects.

Why is the course needed?
There are many methods and solutions to innovate and develop new products and processes, to cut down waste and to improve an organization, a design office, a manufacturing enterprise, or a product. One major discipline is Concurrent Engineering (CE), supported by strong MANUFACTURING SYSTEMS ENGINEERING INPUT. (This is why we have to understand manufacturing systems to be able to design good products.) (CE is also widely known as Simultaneous, or Parallel Engineering.)

Concurrent Engineering represents a structured, logical framework which supports a systematic approach to the integrated, concurrent design of products and their related processes, including manufacture and support.

This method is intended to ensure that developers consider all elements of the product life cycle from conception through to final disposal, and re-engineering / recycling, including quality, cost schedule and user requirements. In contrast to the old, conventional, or sequential product design method, Concurrent Engineering focuses on customer satisfaction, on teamwork as well as on Design for Manufacturing, Design for Assembly, Quality and Total Lifecycle issues.

We further illustrate this concept with Peter Rayson's GICCA enterprise lifecycle curve (Technology Innovation Centre, University of Central England, Birmingham, UK).

As it can be seen from the figure below, it is essential to understand that none of the Concurrent Engineering or CIM (Computer Integrated Manufacturing) methods work in practice unless they are applied to all levels of the enterprise, that they are introduced gradually and that they are managed by people who understand and support them. (In order to promote this thought CIM, or Computer Integrated Manufacturing is now often referred to as the lean, or agile, or adaptive, manufacturing and design system, preferably implemented in a digital factory (more on this topic in a web-article...).

It is furthermore obvious from the table below, that the extended enterprise (with a future) must focus on all aspects of product / process and service system innovation and introduction to the international marketplace.

This process needs knowledgeable and empowered individuals who understand the importance of enterprise knowledge management, exactly the professionals industry needs, and this course aims to develop!

Note, that various views and angles of this complex topic is addressed by Ranky in this Concurrent / Simultaneous Engineering course (IE655), in his Total Quality Management class (IE673), and also in his Project Management (IE) and Lean, Flexible Automation classes (MNE).


In broader terms, the aims of CE, or integrated lean, or agile, or adaptive, design and manufacturing systems are very clear: getting rid of waste, reducing the number of costly changes, integrating product and process engineering better, focusing on high quality at low cost, offering product data management (PDM) within all the companies involved in the product creation and manufacturing processes, organizing our knowledge in our minds, focusing on new innovative opportunities driven by the customer and integrating the

In other words, CIM (Computer Integrated Manufacturing), Total Quality Management, Engineering Project Management and Concurrent Engineering address the whole enterprise, including humans and machines, the business systems, product design, process planning, manufacturing planning, the shop floor, packaging and maintenance, for several life-cycles, via the internal, as well as the external supply chains.

For Whom is the Course Designed?

Graduate / Master of Science programs in (MNE) Manufacturing Systems Engineering, in IE (Industrial Engineering), in EM (Engineering Management), as well as an elective course for Graduate Mechanical Engineering, Graduate Computing Science and Graduate Environmental Engineering, and Biomedical Engineering students. Note, that students with science background can take this course too. We follow a modular approach that makes the topic very adaptable to a variety of different environments. This approach has been successfully tested and run for several years at NJIT as well as on a consulting basis at large companies and software houses, such as Rolls-Royce, IBM, GM, Ford, Raytheon, and others.

Furthermore, the course is aimed at graduate research students, professional engineers and managers working in industry, wishing to learn about new, integrated design and manufacturing methods, tools and technologies, and management methods, for the purpose of improving products and services, and to learn how to innovate in a cost effective and productive way.

Note, that if you have taken the IE673, Total Quality Management course with me, you will find this course to be an integrated part of our advanced project management, total quality and new product/process/service creation approach.

Live as well as Distance and Hybrid (blended) Learning (eLearning) Students purchase their educationally priced, customized eLearning Packs from the NJIT Bookstore (PLEASE ask for the FAll 2005 MNE601 eLearning Pack. The pack changes every semester, therefore you need the current version. Both Live, as well as eLearning (DL) students get the same type of eLearning Pack from the bookstore). Every eLearning Pack is different, because it is customized, and this semester includes the following:

  • The eLearning Packs will give us a great opportunity to work on projects in collaboration with the Four Selected Companies (also in your eLearning Pack). PLEASE NOTE, that each eLearning pack is different, nevertheless the methods we use are the same. Each student should therefore uses one eLearning pack. Also note, that you will need a multimedia PC (approx. 500 MHz, with a CD drive and 800x600 resolution screen min.), a link to the Internet and email, as well as a recent version (not older than yr. 1998) version of MS-Excel in your machine. PLEASE NOTE, that as a student of NJIT, you are entitled to educational software and hardware discounts, some free software, and site licenses, therefore make sure that you take advantage of the huge discounts and opportunities offered. (See NJIT's bookstore, as well as contact NJIT's computing help desks and the njit website for further details).

    Reading for a degree... A few words about 'reading for a degree'... for hundreds of years, academics all over the world emphasized the importance of reading for a degree. Here is a short list of excellent resources that will help you to deepen your understanding in the subject area of this course. Although your eLearning Pack of this course is sufficient to master the topic and get an 'A', please read more on the subject if you can (the NJIT library has hundreds of excellent resources in this field):

    Academic Calendar

    Please look up the accurate dates on the NJIT website

    Schedule: This semester is the equivalent of 15 weeks of study. You have to complete and submit 6 assignments (see them below in detail). There is no final examination, the course is assessed based on the 6 assignments. The schedule and deadlines for all assignments are below. All assignments should be in electronic format. If there is something not clear, please email, or call, or make an appointment and see me (as specified above). There is a limited number of rework options (typically one per assignment) to assure that you do your best and learn the most, and of course get the fair grade for your efforts. I am keen to help, but I need your help to be able to help you. Your hard work is the best help for all of us!

    Class 1 Introduction and overview of the course as well as the subject: Manufacturing systems engineering within an integrated framework of Total Quality, Concurrent / Simultaneous Engineering and IT framework. All of our discussions have a manufacturing systems engineering design and management focus.

    Student Activities (this is what you should do to get an 'A' in this class, and most importantly learn the subject):

    1. Read this syllabus. Know your deadlines, and what is needed and by when.
    2. Review your eLearning Pack companies. Who are they? What are they doing? How can they help you with your new product / process innovation? You must work with them... the boss says so...
    3. Review all other resources in your eLearning Pack. See what you have and how do the resources relate to the study program in this class. There are CDs supporting each assignment, and there is a book too. Look at them and see what they cover.
    4. Start to read the book offered in the eLearning Pack. Most assignments are supported by Chapters in the book. Look at it as a useful resource helping you with assignments and methods.
    5. To prepare for the first assignment (Assignment 0, since this is the zero stage) invent a new product/process that you will develop (virtually) with the collaborative companies (the 4 companies in your eLearning Pack). Think of something that you are already familiar with. As examples think of the hydroforming process (a great method to bend tubes, designers should know), or 4-axis turning using computer controlled machine tools, or a smart hospital bed that is networked to the Internet, or a new cell phone (see an old model in 3D; need Quicktime to play this! Whilst holding down the mouse move your cursor left and right to activate the 3D object; enjoy!) which has camera, email, web-access, music, video, a new smart humanoid robot that will iron shirts, or clean the house, and the car, or a digital hub in your house, or telematics solutions for your car, or smart appliances in the kitchen, etc. There are plenty of opportunities! Just think and invent. Can think BIG, don't have to implement it all!
    6. Also start to work with the Video Lectures you have in your eLearning Pack (see above). These will set your mind set and help you to understand the subject.

    Class 2 Manufacturing Systems Engineering Methods, Tools and Technologies. Focus on integrating design and manufacturing processes for the purpose of cutting waste, and improving quality.

    Submit by the End of This Week! (note, that 'End of Week', for all cases means Friday, 5.00 p.m. of that week)! Assignment No. 0: Design your Own Manufacturing System Design Challenge with the 4 Collaborative Companies in your eLearning Pack (1 page Executive Summary) This is a short electronic presentation by each student entitled: 'My manufacturing system design challenge, my collaborative companies, and my plans for collaborating with them in order to develop, innovate, manufacture/assemble, and bring to market my new manufacturing cell, or system design'. Please address briefly all these issues. You can change the focus later as you develop the project, but you'll need my approval to go ahead. This is why I need the single page executive summary emailed to me. (This is also a good time to start to set up your webpage...) Also, include your project Title, Author (Name, Class, Date, your eLearning Pack serial number and the collaborative companies you have ( a MUST!). I will respond to this by email, comment and hopefully accept your plans.

    Class 3 Manufacturing systems engineering in the research and development world = Video Lectures

    Submit by the End of This Week!

    Project/ Assignment No.1: Manufacturing Systems Engineering Video Lectures (Relevant eLearning Pack Resource: work through the DVDs, as described above: Label 1, 2, and 3.)

    Typical Mistakes: Why am I loosing grade points in this assignment?

    Classes 4, 5 and 6

    Manufacturing system process modeling. QFD (Quality Function Deployment); Requirements Analysis is discussed with 3D Virtual Reality examples. (Note, that we are first dealing with the "Product Planning Stage QFD diagram/ matrix. i.e. the very first one (this is worked out in the Requirements Analysis CD in the Concurrent Engineering book with an Excel template) and then carry on with the manufacturing system requirements analysis too! This is new, not worked out for you; you have to invent it... but I help you with an Excel template)

    Student Activities:

    1. Carry on reading the book offered in the eLearning Pack.
    2. Based on the CORA CD: The CORA CD educates a requirements analysis method and offers examples and solutions, as well as active code-tools for you to execute (in the form of MS Excel templates). You should understand this and based on the MS-Excel Template, develop your own Requirements Analysis solution for the manufacturing system requiremets of the product you are developing, with the 4 collaborative companies. As outlined in Assignment 0).
    3. Study the QFD / Requirements Analysis method and the 3D objects. Consider the requirements analysis aspects when designing your new product, and then the processes too.

    Class 7

    QFD (Quality Function Deployment) / Requirements analysis is discussed with 3D Virtual Reality examples as a Concurrent Engineering methodology. Focus on the Assignment this week! We like professional quality assignments!

    Submit by the End of Week 8! Assignment No.2: Manufacturing system process model based on examples in the textbooks, eBooks and as discussed in the class.

    Assignment 3: QFD1 (Quality Function Deployment; Component Oriented MAnufacturing System Requirements / Needs Analysis) In terms of assignment development method, please follow the CORA CD-ROM in your Learning Pack. (Relevant eLearning Pack Resource: Requirements analysis CD-ROM inside the CE book, as described above)

    When developing the QFD1 matrix for a product try to put down all customer requirements for the WHAT’s side, prioritize them, then create the HOW’s, this is the "engineers’ voice", then the HOW MUCH’s, which will give you the parameter ranges for satisfactory data and then develop the rest of the correlation and the comparative quality models on the right hand side of the matrix. The crucial thing is that in the report you should explain what you have done and why?

    Please note, that the best assignments show evidence that the student has worked through the learning material provided on CD-ROMs and the book. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided on the CDs into your assignment; nevertheless never forget to credit the source of such objects in the bibliography.

    Project/ Assignment No.3:
    QFD1 (Quality Function Deployment; Component Oriented Manufacturing System Requirements / Needs Analysis)

    Typical Mistakes: Why am I loosing grade points in this assignment?

    Class 8

    FMEA: The Failure Mode and Effect Analysis, or Process Failure Risk Analysis methodology and its use in manufacturing systems. What can go wrong during manufacturing processes? How can we avoid it? Interactive FMEA modeling / Disassembly Failure Risk Analysis modeling. Note, that we'll disassemble real products and design a simplified disassembly manufacturing system for it. It will be fun! Take a few screwdrivers to take old phones, PCs etc. apart... I'll get these old products don't worry.

    Class 9

    Design For Manufacturing, Quality, Assembly. We'll focus on the manufacturing / assembly side of DFA, DFM, DFQ, etc.

    Submit by the End of This Week! Assignment No.4: Manufacturing / Demanufacturing, Disassembly Process Failure Mode and Effects / Failure Risk Analysis

    The student’s main task is to pay attention to the multimedia presentations, to take notes on every important issue, item, principle, and example, to interact with the tutor (on Email, Fax, Telephone, etc.) and the class members (on Email, Fax, Telephone, etc.) and fully understand the topics covered.

    Student Activities and relevant eLearning Pack Resources

    1. Carry on reading the CE book offered in the eLearning Pack.
    2. The printed textbook has the basic FMEA diagram (Figure 3.2). Look at the BOM file of the product (Bill Of Material) and gradually build up elements to subassemblies and parts, products.
    3. Then analyze each important failure mode. In case you choose to deal with a larger system, such as an automobile, or tank, etc. deal with larger objects only in the BOM /DBOM file, else you’ll spend your life on it? Nevertheless the "trick" is to find the critical subsystems that might fail, and then find out why they might fail?
    4. Furthermore, the textbook covers: KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE, methods and the role of Quality Circles too. These are great ideas, principles, and methods. Understand them well and deploy them in your new product / process designs!

    Please keep this in mind: We are interested in seeing that you understand the methods... we don't want you to spend your entire life on these assignments... you follow...Please note, that the best assignments show evidence that the student has worked through the learning material provided on CD-ROMs and in the book. Therefore feel free to incorporate digital images, text and even video clips or 3D VR objects provided on the CDs into your assignments; nevertheless never forget to credit the source of such objects in the bibliography.

    Project/ Assignment No.4: Manufacturing / Demanufacturing, Disassembly Process Failure Mode and Effects / Failure Risk Analysis

    Typical Mistakes: Why am I loosing grade points in this assignment?

    Class 10

    Design For Manufacturing, Quality, Assembly, KANRI, KAISEN, MUDA, MURA, MURI, POKA-YOKE, the role of Quality Circles, and other methods discussed with 3D Virtual Reality examples and classroom exercises. Rapid prototyping methods and solutions (Part 1).

    Based on the Rapid Prototyping CD-ROM: Focus on the engineering related challenges/ questions in this CD. Try to answer 10 selected questions of your choice! Incorporate these answers into the Assignment below!

    Class 11

    Design for Demanufacturing, disassembly, Virtual Product Disassembly over the web, and other methods discussed with 3D Virtual Reality examples and classroom exercises. Rapid prototyping methods and solutions (Part 2). Networked Concurrent Engineering systems in digital collaborative factories. Discussion on network modeling methods and tools. PLM (Product Lifecycle Management), NPI & I (New Product Innovation and Introduction).

    Student Activities:

    1. Carry on reading the book offered in the eLearning Pack.
    2. Based on the Rapid Prototyping CD-ROM: Focus on the engineering related challenges/ questions in this CD.
    3. Try to answer 10 selected questions of your choice! Incorporate these answers into the Assignment below!

    Submit by the End of This Week! Assignment No.5: Rapid Prototyping Manufacturing Processes and Rapid Manufacturing Systems

    Typical Mistakes: Why am I loosing grade points in this assignment?

    Class 12 (Don't worry, it's almost over...)

    Manufacturing systems engineering team management methods and issues. The TOPS method (The Ford Motor Company). Virtual teaming methods over the Internet. A 3D Virtual Reality web-based method and code is discussed in detail. Manufacturing database management. Manufacturing knowledge based expert systems.

    Student Activities:

    1. Carry on reading the book offered in the eLearning Pack.
    2. Based on the Rapid Proto CD: study collaborative teamwork opportunities. (This section links from the documentation methods chapter and has a series of important principles, that you can work with).
    3. Based on the web: Search for TOPS (Team Oriented Problem Solving) and team management issues on the web!
    4. Search for New Product Innovation and Introduction (NPI & I) methods, tools and technologies over the Internet. Try to collect at least 10 URLs with a short explanation of the method they cover.

    Classes 13, 14 and 15 (Note, that Classes 13, 14 and 15 are kept for Assignment related project improvements and presentations)

    Submit This Week! Assignment No. 6: Project Presentations in Class (Note, in order to get an 'A' you MUSt present your project in class!)

    5.00 pm, December 12, 2005: ABSOLUTELY THE LAST DAY TO SUBMIT any new assignments, or reworked assignments! All submissions MUST be electronic, via email / web.

    Schedule and due dates: As above. The total course duration is the equivalent of 15 weeks of study. Students will be required to complete each assignment. Assignments totaling 120% max. Grade "A" for this class requires min. 92% total. PLEASE note, that you must submit Assignments 0, 1, 2 and 3 by week 7, else you cannot get an 'A' for the class. (I am forced to declare this to make sure, that you don't slip... )

    It is over! Congratulations! You can now analyze and improve many products and services!


    PLEASE save the TREES! Please DO NOT Print this syllabus. Use this web site to read it in this electronic format; it will be updated during the semester. Thank you!