Course Syllabus

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ME452/ISD528: (Advanced) Design for Manufacturability

Spring 2021 Course Syllabus

Contact Information

Instructor GSI

Prof. Kazuhiro Saitou (he/him)

Email: kazu@umich.edu

Phone: 734-763-0036

Zoom Office hours:  Thurs @5-6pm

Sagar Singhal (he/him)

Email: sagsngl@umich.edu 

Phone: n/a

Zoom Office hours:  Mon @ 8-9pm and Tues @ 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 11:59pm on the previous day of the scheduled lecture dates. 

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

Course Description

This course discusses fundamentals of Design for Manufacturing (DFM), a set of a process, tools, and methods for enhancing the ease of manufacturing and assembly in product design.  DFM reduces the time and cost for product development and is seen by many as one of the keys for successful hardware startups.  The course topics include conceptual design for economical manufacturing and assembly, material and process selection, product platforms and families, design guidelines for manufacturing and assembly, robust parameter design, design for the environment, and design of product-service systems. 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 software.

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 %

Note: final letter grades will be curved based on ranking within the class. 

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. Unless otherwise instructed, the process of arriving at the final answers should be explained in all homework problems.  

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

A late homework assignment, presentation, or report will receive a scaled grade of max{0, (1-0.25*n)*grade}, where n is the number of days being late and grade is the raw grade of the late homework assignment.  The days are counted starting the midnight in Michigan: for example, n = 1 between 12:00am and 11:59pm on the first day after the due date, n = 2 between 12:00am and 11:59pm on the second day after the due date, etc., according to the time stamp of the submission recorded on Canvas. The scaled grade is 0 for n >= 4.  To be exempt from this policy, a well-justifiable technical, professional, medical, or family reasons accompanied by a written proof must be submitted to the instructor.

Schedule (subject to change)

Lec # Date Topic Dues
1 05/04 Introduction; Manufacturing process overview
2 05/05 Fundamentals of product analysis
3 05/06 Product family design
4 05/11 Design for manual assembly; Project overview HW1 (Lec 2,3), Teams in Google Sheet *
5 05/12 Design for automated assembly
6 05/13 Material and process selection
7 05/18 Design for machining HW2 (Lec 4,5), Proposal
8 05/19 Design for machining
9 05/20 Design for sheet metalworking
10 05/25 Design for sheet metalworking HW3 (Lec 6,7,8)
11 05/26 No lecture – project work day Interim presentation movie
12 05/27 Design for injection molding HW#4 (Lec 9,10)
13 06/01 Design for injection molding Interim report, peer eval
14 06/02 Design for die casting
15 06/03 Design for die casting HW5 (Lec 12,13)
16 06/08 Design for robustness
17 06/09 Design for 3D printing HW6 (Lec 14,15)
18 06/10 Design for the environment
19 06/15 Design of product-service systems (PSS) HW7 (Lec 16)
20 06/16 No lecture – project work day HW8 (Lec 17; ISD528 only)
21 06/17 No lecture – project work day Final presentation movie
06/21 Final report, peer eval

     * Google will ask you to request permission for edit to the document owner (kazu) for the first time. 

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 Well-Being

Students may experience stressors that can impact both their academic experience and their personal well-being. These may include academic pressure and challenges associated with relationships, mental health, alcohol or other drugs, identities, finances, etc.

If you are experiencing concerns, seeking help is a courageous thing to do for yourself and those who care about you. If the source of your stressors is academic, please contact me so that we can find solutions together. For personal concerns, U-M offers the following resources:

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