Course Syllabus

 

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ME/MFG452/ISD528 (Advanced) Design for Manufacturability

Fall 2022 Course Syllabus

Contact Information

 

Instructor GSIs
Prof. Kazuhiro Saitou (he/him)
Email: kazu@umich.edu
Zoom Office hours:  Thurs 4-5pm

Vishnu Giri
Email: vigiri@umich.edu 
Zoom Office hours: Mon 5-6pm& Wed 1-2 pm

Sagar Singhal
Email: sagsngl@umich.edu 
Zoom Office hours: Tues 7-8pm & Fri 2-3pm
Passcode: qwerty

Lectures

  • In-person: Mon & Wed @ 10:30am-12:00pm in 165 Chrysler
  • Live streaming:  https://umich.zoom.us/j/97573773697 (passcode: W0lverines)
  • Recording: Available within 24 hours of live lectures at the lecture link in the schedule table below, or at the Panopto Video on this site.

Office hours

Information on Zoom office hours for the instructor and GSIs can be found above. 

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 success in hardware startups as well as global manufacturing enterprise.  The course topics include conceptual design for economical manufacturing and assembly, material and process selection, product platforms and families, manufacturing and assembly cost estimation, 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 (ideally SolidWorks).

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 slides (and video if taken asynchronously) 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: 1) One of the homework assignments with the highest missed points will be dropped from the calculation of the final course grade and 2)  Final letter grades will be curved based on ranking within the class. 

Homework Assignments

There are seven (7) homework assignments to be done individually. Students should upload their homework assignments as 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

  • Homework assignments (including Team Google Sheet and Team expectation agreement): No late submission will be accepted. One assignment with the highest missed points will be dropped. 
  • Project deliverables (excluding Team Google Sheet and Team expectation agreement): Any late submission will receive a scaled grade of  max{0, grade - 0.10*n*full_pts} , where n  is the number of days being late (as time-stamped by Canvas), grade is the raw grade for the late homework assignment, and full_pts is the full points for 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. 
  • Peer Evaluations: No late submission will be accepted.  If you do not submit, the system assumes you give full and equal evaluations to all team members.  

To be exempt from the policy, a  well-justifiable  technical, professional, medical, or family reasons accompanied by written proofs must  be submitted to the instructor. In particular, simply having the last-minute internet/software problem is not an acceptable reason to be late. 

Schedule (subject to change)

Lec # Date Topic Dues
1 08/29 Introduction; Manufacturing process overview (video only)
2 08/31 Fundamentals of product analysis
09/05 No lecture – Labor Day 
3 09/07 Product family design; Project overview (video only) Team Google Sheet
09/12 Special seminar on DFMPro Team expectations agreement
4 09/14 Design for manual assembly HW1 (Lec 2,3)
5 09/19 Design for automated assembly; Note; use this Zoom link for this lecture only with the same passcode
6 09/21 Process selection Proposal
7 09/26 Design for machining
8 09/28 Design for machining HW2 (Lec 4,5)
9 10/03 Design for sheet metalworking
10 10/05 Design for sheet metalworking HW3 (Lec 6,7,8) 
10/10 No lecture – project work day Interim presentation movie
10/12 Interim presentation
10/17 No lecture – Fall Study Break
10/19 No lecture – project work day HW4 (Lec 9,10)
11 10/24 Design for injection molding Interim report
12 10/26 Design for injection molding
13 10/31 Design for die casting Interim peer eval
14 11/02 Design for die casting HW5 (Lec 11,12)
15 11/07 Design for 3D printing (video only -- no in-person or Zoom )
16 11/09 Design for robustness HW6 (Lec 13,14)
17 11/14 Design for the environment
18 11/16 Design of product-service systems (PSS) HW7 (Lec 16)
11/21 No lecture – project work day
11/23 No lecture – Thanksgiving
11/28 No lecture – project work day HW8 (Lec 15; ISD528 only) 
11/30 No lecture – project work day Final presentation movie
12/05 Final presentation Day 1
12/07 Final presentation Day 2
12/12 Final report
12/13 Final peer eval 

 

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:

I, Kazuhiro Saitou, am committed to creating a learning environment for my students that is free of Prohibited Conduct, including gender-based and sexual harassment, sexual violence, retaliation, and a hostile environment based on discrimination and intimidation. I acknowledge the power differentials between instructors and students, and the prohibition of “Covered Relationships” (sexual, romantic, or dating) between instructors and students. To accomplish this, I pledge to the following:

  • I will conduct office hours with my door open. Students who wish to have confidential conversations with me may schedule a private meeting via Zoom or may ask to have a closed-door meeting. But this closed-door meeting must be made on your request in writing, even on the spot. I will never suggest a closed-door meeting myself because of the power dynamic.
  • I will document all pre-scheduled meetings between the instructor and the student via Google Calendar (or other software) and/or university email. Students who email to request an office hour appointment should expect to receive an email confirmation or a Google Calendar (or other software) invitation from me, or, upon my email confirmation and request, may send me a Google Calendar (or other software) invitation for this meeting. The purpose is to provide a permanent record of the meeting and to ensure that all class activities are documented and transparent. Students who choose to drop by for informal meetings are welcome to do so, but there will be no documentation provided. (See above for open-door policy.)
  • All individual meetings between instructor/student will take place at university venues. 
  • Off-campus meetings, trips or events must engage with course material. Off-campus meetings will not involve alcohol or take place at locations that serve alcohol. If the class goes out for a meal, it will be at a cafe or restaurant that does not serve alcohol. The location/day/time of any off-campus meetings between the instructor and students will be documented in Google Calendar (or other software).
  • I, the instructor, will conduct all individual communications using the University platforms of email, Canvas, Slack, or Piazza, with the caveat that we may use non-University platforms set up by students (such as GroupMe) only if they include all students in the class. There will be no instructor-student private communications on any non-University platforms, such as social media, GroupMe, personal phone numbers, What’s App, etc.
  • I, the instructor, offer to provide information to you about how to report sexual and gender-based misconduct, and am available to share information with the University at your request.  
    • People in certain roles are considered “Individuals with Reporting Obligations” (IROs) and are required to report suspected Prohibited Conduct to the Equity, Civil Rights and Title IX Office at the University of Michigan. I, your instructor, am an IRO. 
    • Submit a complaint about assault or harassment to the Equity, Civil Rights and Title IX Office at the University of Michigan (ECRT): Link to reporting at each of the three campuses can be found here. Please note that Title IX offices often distinguish between making a “report,” which does not launch an investigation, and filing a “complaint,” which does. This study, by Nicole Bedera, describes why there are so few investigations, even when survivors originally intend to report. We recommend this reading for anyone considering reporting, as a means to empower you through that process. Bedera’s study is called Settling for Less: How Organizations Shape Survivors’ Legal Ideologies Around College Sexual Assault. Dissertation the Department of Sociology, University of Michigan, 2021.
    • Report an assault through 911: Dialing 911 from your cell phone will take you to local police.  Dialing 911 from a campus phone will dial to the University police dispatch.
    • Report an assault to Local Police:  Ann Arbor Police Non-emergency Dispatch: 734-994-2911