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)
