Course Syllabus

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ME452/ISD528: (Advanced) Design for Manufacturability

Fall 2020 Course Syllabus

Contact Information

Instructor GSI

Prof. Kazuhiro Saitou (he/him)

Email: kazu@umich.edu

Phone: 734-763-0036

BlueJeans Office hours:  Thurs @ 4:30-6pm

Vardhaman Chougule (he/him)

Email: vmandc@umich.edu  

Phone: n/a

BlueJeans Office hours:  Mon and Tue @ 5-6pm

Lectures: There will be no live on-line session. The new lecture recordings will be posted on Canvas (https://umich.instructure.com/) by 5:00pm on Tuesdays and Thursdays.

Office hours: Select the BlueJeans link from the menu on the left. On this page, you will see the Virtual Office Hours recurring meeting. To join, simply click the Join button

Course Description

This course discusses fundamentals for enhancing the ease of manufacturing and assembly in product design.  The topics includes conceptual design for economical manufacturing and assembly, material and process selection, product platforms and modular design, and design guidelines for manufacturing and assembly, Taguchi methods for robust design, and design for additive manufacturing. The homework and course project emphasize the application of these concepts to example parts and products.

Prerequisites: Senior/graduate standing in Mechanical Engineering, Automotive Engineering, or Program in Manufacturing.  Learners are expected to have basic knowledge in common mass manufacturing processes, and familiarity with a CAD program.

Course Learning Goals

  • Understand the impact of design on the ease of manufacturing and assembly
  • Apply the platforming strategy to design a family of products with reduced manufacturing cost
  • Select manufacturing processes that are compatible with desired characteristics of a part.
  • Understand the cost models and key cost drivers for manufacturing and assembly processes
  • Apply redesign guidelines for improving the ease of manufacturing and assembly
  • Balance the performance-cost tradeoff in applying the redesign guidelines
  • Apply Taguchi robust design method for balancing the performance-cost tradeoff
  • Understand the principles of design for the environment
  • Understand the pros and cons of product-service system
  • Complete a redesign project for improving the ease of manufacturing and assembly of an existing product

Course Materials

Required: Lecture video, lecture slides, and other materials posted on Canvas.

Suggested: The course lecture notes have been developed from a variety of sources and created such that a textbook is NOT required. If you prefer a reference book, several are listed below.

  • Ulrich, S. Eppinger, 2012, Product Design and Development, 6th ed., McGrow Hill, ISBN: 978-0-07-802906-6.
  • Ashby, 2010, Materials Selection in Mechanical Design, 4th ed., Elsevier, ISBN: 978-1-85-617663-7.
  • Boothroyd, P. Dewhurst, W. Knight, 2011, Product Design for Manufacturing and Assembly, 3rd ed., CRC Press, ISBN: 978-1-4200-8927-1.
  • Hanson, 2017, Industrial 3D Printing For Dummies®, Proto Labs Special Edition, John Wiley & Sons, ISBN: 978-1-119-38696-4.

Grading (total 100%)

40 %
50 %
10 %

Homework Assignments

There are eight (8) homework assignments to be done individually. Students should upload their homework assignments as scanned PDF files to their Assignments folders on Canvas by the indicated due dates.  You are allowed and encouraged to work with other students on the homework assignments; however, each student must complete all calculations and write-up on your own. Verbatim copying of another student's work is NOT allowed.  Please do not use the online communication tools to check answers with other students!  You may not consult homework solutions from a previous term unless they are made available in a publicly accessible form by the instructor.  It is our course policy and at the directions of the College of Engineering Honor Code to review all submitted work to check for potential violations.  When identified, credible allegations will be submitted for an Honor Code referral.  The use of non-University of Michigan websites and services including but are not limited to Chegg, Course Hero, Slater, Khan Academy will constitute a violation of course policy and result in an Honor Code referral.  

Project

The course project is on analyzing an existing product of your choice and redesign it with enhanced manufacturability by applying various methods discussed in the lectures.  It will be done by a team of 4-5 students with the following deliverables:

The details of the project deliverables are provided separately here. The grade of each project deliverable will be assigned in proportion to its relative points.

Teams should upload their presentations as a movie file (mp4 or mov) to their Assignments folders on Canvas by the indicated due dates.  See this page for one way to create a presentation movie. The reports should be uploaded as PDF files to their Assignments folders on Canvas by the indicated due dates.

Peer Evaluation

Since the team activities are an essential part of this course, you will be asked to submit two peer evaluations using CATME system in the middle of and at the end of the semester, in order to evaluate the participation of each team member (including yourself) to the project activities.  If you do not submit peer evaluations, the system assumes you give full and equal evaluations to all team members.  

Policy on Late or Missed Assignments

Late homework assignments, presentations, and reports will not be accepted unless you have made prior arrangements with the instructor (a well justifiable medical, professional, and family reason is needed with a proof).

Schedule (subject to change)

Lec # Date Topic Dues
1 09/01 Introduction; Manufacturing process overview
2 09/03 Fundamentals of product analysis
3 09/08 Product family design
4 09/10 Design for manual assembly Teams*
5 09/15 Design for automated assembly HW1 (Lec #2,3)
6 09/17 Material and process selection
7 09/22 Design for machining HW2 (Lec #4,5)
8 09/24 Design for machining Proposal
9 09/29 Design for sheet metalworking HW3 (Lec #6, 7,8)
10 10/01 Design for sheet metalworking
11 10/06 No lecture – project work day Interim presentation movie
12 10/08 Interim presentation (YouTube)
13 10/13 Design for injection molding HW#4 (Lec#9,10), Interim report, peer eval
14 10/15 Design for injection molding
15 10/20 Design for die casting HW5 (Lec #13,14)
16 10/22 Design for die casting
17 10/27 Design for robustness HW6 (Lec #15,16)
18 10/29 Design for 3D printing
19 11/03 Design for the environment HW7 (Lec #17)
20 11/05 Design of product-service systems (PSS)
21 11/10 State of the art HW8 (Lec #18; ISD528 only)
22 11/12 No lecture – project work day
23 11/17 No lecture – project work day
24 11/19 No lecture – project work day
25 12/01 No lecture – project work day Final presentation movie
26 12/03 Final Presentation (YouTube)
27 12/08 No lecture – project work day Final report, peer eval

* GSI will announce the link to a Google Doc

Course Add/Drop Policy

Courses are added and dropped in Wolverine Access.  Please refer to ME ASO for the specific dates or to the College of Engineering Bulletin found here: https://bulletin.engin.umich.edu/academic-calendar-and-deadlines/undergraduate-deadlines/

Honor Code

All students in the class are presumed to be decent and honorable, and all students in the class are bound by the College of Engineering Honor Code. You may not seek to gain an unfair advantage over your fellow students; you may not consult, look at, or possess the unpublished work of another without their permission; and you must appropriately acknowledge your use of another’s work.  Any violation of the honor policies appropriate to each piece of course work will be reported to the Honor Council, and if guilt is established penalties may be imposed by the Honor Council and Faculty Committee on Discipline. Such penalties can include, but are not limited to, letter grade deductions or expulsion from the University. If you have any questions about this course policy, please consult the course instructor.  For more information about the Standards of Conduct, Honor Code, and Statement of Student Rights and Responsibilities, please consult the following resource: https://bulletin.engin.umich.edu/rules/

Diversity, Equity, and Inclusion

I consider this classroom to be a place where you will be treated with respect, and I welcome individuals of all ages, backgrounds, beliefs, ethnicities, genders, gender identities, gender expressions, national origins, religious affiliations, sexual orientations, ability – and other visible and nonvisible differences. All members of this class are expected to contribute to a respectful, welcoming and inclusive environment for every other member of the class.  I am dedicated to helping each of you achieve all that you can in this class. I may, either in lecture or smaller interactions, accidentally use language that creates offense or discomfort. Should I do this, please contact me and help me understand and avoid making the same mistake again. 

Accessibility/Accommodations

The University of Michigan and the Mechanical Engineering Department are committed to providing equal opportunity for participation in all programs, services, and activities.  Requests for accommodations by persons with disabilities may be made by contacting the Services for Students with Disabilities (SSD) Office located at G-664 Haven Hall. If you think you need an accommodation for a disability, please let me know at your earliest convenience, preferably at the beginning of the term, or at least two weeks prior to the need of accommodation (test, projects, etc.)  Some aspects of this course, the assignments, the team  activities, and the way the course is usually taught may be modified to facilitate your participation and progress.  As soon as you make me aware of your needs, we can work with the Services for Students with Disabilities (SSD) office to help us determine appropriate academic accommodations.  SSD (734-763-3000; http://ssd/umich.edu) typically recommends accommodations through a Verified Individualized Services and Accommodations (VISA) form.  Any information you provide is private and confidential and will be treated as such.

Student Mental Health and Well-being

University of Michigan is committed to advancing the mental health and wellbeing of its students. If you or someone you know is feeling overwhelmed, depressed, and/or in need of support, services are available. For help, contact Counseling and Psychological Services (CAPS) at (734) 764-8312 and https://caps.umich.edu/ during and after hours, on weekends and holidays, or through its counselors physically located in schools on both North and Central Campus. You may also consult University Health Service (UHS) at (734) 764-8320 and https://www.uhs.umich.edu/mentalhealthsvcs, or for alcohol or drug concerns, see www.uhs.umich.edu/aodresources.  For a listing of other mental health resources available on and off campus, visit: http://umich.edu/~mhealth/.

University of Michigan Policy & Procedures on Student Sexual & Gender-Based Misconduct & Other Forms of Interpersonal Violence

The University of Michigan supports its educational mission by fostering a community based on civility, dignity, diversity, inclusivity, education, equality, freedom, honesty, and safety. Consistent with these values, the University is committed to providing a safe and non-discriminatory learning, living, and working environment for all members of the University community. The University does not discriminate on the basis of sex or gender in any of its education or employment programs and activities. Please consult the following website for policy details and related support resources: https://studentsexualmisconductpolicy.umich.edu/content/policy-statement

Title IX Statement

Title IX makes it clear that violence and harassment based on sex and gender is a Civil Rights offense subject to the same kinds of accountability and the same kinds of support applied to offenses against other protected categories such as race, national origin, etc. If you or someone you know has been harassed or assaulted, you can find the appropriate resources here:

  • UM Sexual Assault and Prevention Center (SAPAC) 24-hour confidential crisis line: (734) 936-3333 * http://sapac.umich.edu/

Course Summary:

Course Summary
Date Details Due