Internal Quality Assurance Cell
Course Plan – Theory with Laboratory Course
Programme & Department of
BE & Mechanical Engineering
Name of the Faculty, Dr V V Arun Sankar, the Students
Designation & Dept. Assistant Professor & Mechanical Engineering Academic Year, Semester &
2025-2026, V, A & B
Section
Course Code & Name 23MEP502 & Design for Manufacture and Assembly Lecture Hall No. M 402
1. COURSE OUTCOMES
On completion of the course, the students will be able to BT Level
CO1 implement DFMA in industry Ap/K3
CO2 identify selective assembly procedures Ap/K3
CO3 extract the nutshell of tolerancing theory Ap/K3
CO4 preform form design Ap/K3
CO5 develop tolerance charting Ap/K3
Mapping of COs with POs and PSOs
COs /
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
POs & PSOs
CO1 3 3 2 - - - - - - - - 1 3 -
CO2 3 3 2 - - - - - - - - 1 3 -
CO3 3 3 2 - - - - - - - - 1 3 -
CO4 3 3 2 - - - - - - - - 1 3 -
CO5 3 3 2 - - - - - - - - 1 3 -
Average 3 3 2 - - - - - - - - 1 3 -
1 – Slight, 2 – Moderate, 3 – Substantial
2. COURSE PLAN
UNIT I DFM APPROACH, SELECTION AND SUSTITUTION OF MATERIALS IN INDUSTRY
CO(s) BT Planned Actual
S. No. Topic Intended Learning Outcomes (ILOs)
Mapped Level Date Period Date Period
Department Vision and
Understanding the objectives and outcomes of the course and
Mission, Course Objectives,
1. relating with the Programme Outcomes and Vision and Mission - - 25.06.25 5
Course Outcomes and
of the department.
Programme Outcomes.
• Define the concept of Design for Manufacturing (DFM).
DFM approach, DFM
2. • List the key DFM guidelines. CO1 U 27.06.25 1
guidelines and standardization
• Recall the benefits of standardization in product design.
Group Technology, Value • Define group technology and its role in manufacturing.
3. CO1 U 28.06.25 3
Engineering • Identify the objectives of value engineering.
Comparison of materials on • Recall the criteria for comparing materials based on cost.
4. cost basis, Design for • Define Design for Assembly (DFA). CO1 U 30.06.25 3
assembly, DFA index • Identify the components of the DFA index.
• Define the Poka-Yoke principle.
Poka-Yoke principle and • Recall the purpose of tolerance analysis in mechanical
5. CO1 U 01.07.25 5
concept, Tolerance analysis design.
• List types of tolerance analysis methods.
Process capability and its • Define process capability.
6. metrics Cp and Cpk, Cost • Recall the meaning of Cp and Cpk indices. CO1 U 02.07.25 5
aspects • List the cost factors associated with poor process capability.
• Identify different types of feature tolerances.
Feature tolerance, Geometric
7. • Recall common geometric tolerance symbols. CO1 U 04.07.25 1
tolerance, Surface finish
• Define surface finish and its measurement units.
Review of relationship
8.
between attainable tolerance • Identify typical tolerance grades for various machining CO1 U 07.07.25 3
grades and different machining processes
processes
• List the methods used to calculate the cumulative effect of
9. Cumulative effect of tolerances CO1 U 08.07.25 5
tolerances.
• Recall the definitions of Sure Fit, Normal, and Truncated
Sure fit law, Normal law and laws.
10. CO1 U 09.07.25 5
Truncated law • Identify the application of these laws in assembly tolerance
analysis.
UNIT II SELECTIVE ASSEMBLY
CO(s) BT Planned Actual
S. No. Topic Intended Learning Outcomes (ILOs)
Mapped Level Date Period Date Period
Interchangeable and selective Recall the differences between interchangeable and selective
11. assembly
CO2 U 11.07.25 1
assembly.
Identify standard procedures used to determine group sizes in
12. Deciding the number of groups CO2 U 12.07.25 5
assembly classification.
Model–I: Group tolerances of
13. mating parts equal
Define the assumptions used in Model-I for group tolerance. CO2 U 14.07.25 3
Model–II: Total and group Identify how Model-II differs from Model-I in tolerance
14. tolerances of shaft
CO2 U 15.07.25 5
distribution.
List methods used to control axial play in shaft-bearing
15. Control of axial play CO2 U 16.07.25 5
arrangements.
Datum Systems: Grouped datum Recall different types of grouped datum systems used in
16. systems and its types
CO2 U 18.07.25 1
geometric dimensioning and tolerancing.
Two and three mutually
Recall the function of two- and three-plane datum systems in
17. perpendicular grouped datum CO2 U 21.07.25 3
planes component positioning.
Grouped datum system with
Recall typical features used in grouped datum systems such as
18. spigot and recess, pin and hole, CO2 U 22.07.25 5
and tongue-slot pair spigot-recess, pin-hole, and tongue-slot.
Computation of translational and Apply geometric and dimensional parameters to compute
19. rotational accuracy
CO2 Ap 23.07.25 5
translational accuracy in mechanical assemblies.
UNIT III TRUE POSITION TOLERANCING THEORY
CO(s) BT Planned Actual
S. No. Topic Intended Learning Outcomes (ILOs)
Mapped Level Date Period Date Period
20. Comparison between co–ordinate 25.07.25 1
and convention method of feature
location tolerancing and true
position tolerancing
Comparison between co–ordinate Identify and Define coordinate and conventional methods of CO3 U
and convention method of feature feature location tolerancing.
21. location tolerancing and true
26.07.25 5
position tolerancing
Recall the definition and significance of zero true position
22. Zero true position tolerance CO3 U 28.07.25 3
tolerance.
23. Virtual size concept Define the concept of virtual size in geometric tolerancing. CO3 U 29.07.25 5
24. Floating and fixed fasteners Apply the concept of fixed and floating fasteners to select 30.07.25 5
CO3 Ap
25. Floating and fixed fasteners appropriate configurations in assemblies. 01.08.25 1
26. Projected tolerance zone Recall the purpose of a projected tolerance zone in GD&T. CO3 U 04.08.25 3
Functional gauges – Paper layout
27. gauging
Define functional gauges and paper layout gauging. CO3 U 05.08.25 5
28. Compound assembly – Examples Define compound assembly and identify its characteristics. CO3 U 06.08.25 5
UNIT IV FORM DESIGN OF CASTINGS AND WELDMENTS
CO(s) BT Planned Actual
S. No. Topic Intended Learning Outcomes (ILOs)
Mapped Level Date Period Date Period
Redesign of castings based on
29. parting line considerations
18.08.25 3
Apply knowledge of parting line selection to redesign cast
CO4 Ap
Redesign of castings based on components for easier mold fabrication and ejection.
30. parting line considerations
19.08.25 5
31. Minimizing core requirements Explain the purpose and function of cores in casting processes. CO4 U 20.08.25 5
Redesigning cast members using
32. weldments
22.08.25 1
Use weldment principles to replace or redesign complex castings
CO4 Ap
Redesigning cast members using with fabricated welded structures.
33. weldments
25.08.25 3
Explain the purpose and significance of welding symbols in
34. Use of welding symbols CO4 U 26.08.25 5
engineering drawings.
Design considerations for plastic
35. component manufacturing
29.08.25 1
Describe how material properties of plastics affect component
CO4 U
Design considerations for plastic design and selection.
36. component manufacturing
30.08.25 1
Design considerations for plastic
37. component manufacturing
01.09.25 3
UNIT V TOLERANCE CHARTING
CO(s) BT Planned Actual
S. No. Topic Intended Learning Outcomes (ILOs)
Mapped Level Date Period Date Period
Tolerance Charting Technique:
Explain the purpose and steps involved in tolerance charting for
38. Operation sequence for typical CO5 U 02.09.25 5
shaft type of components shaft-type components
Preparation of process drawings Prepare process drawings that accurately represent each step of
39. for different operations
CO5 Ap 03.09.25 5
manufacturing operations for a given component.
Tolerance worksheets and Use tolerance worksheets to allocate and record dimensional
40. centrality analysis with examples
CO5 Ap 08.09.25 3
tolerances for multi-step manufacturing processes.
Design features to facilitate Summarize key design modifications that improve machinability,
41. machining
CO5 U 09.09.25 5
such as chamfers, radii, and tool clearance.
Define datum features and their role in establishing part
42. Datum features CO5 U 10.09.25 5
references during manufacturing and inspection.
Differentiate between functional datums and manufacturing
43. Functional and manufacturing CO5 U 12.09.25 1
datums
Describe the steps involved in designing a mechanical
44. Component design CO5 U 13.09.25 3
component with manufacturing feasibility in mind.
Machining considerations,
45. redesign for manufacture with CO5 Ap 15.09.25 3
examples Apply machining principles to identify design features that
Machining considerations, increase manufacturing difficulty, cost, or time.
46. redesign for manufacture with CO5 Ap 16.09.25 5
examples
3. Teaching Learning Methodology
* TL Methodology Planned Actual
Course
S. No. Session Outcome Learning Space (Min. one Period/
Outcomes
methodology / CO) Month & Week Date
Duration
1 CO1 implement DFMA in industry Lecture Hall ICT Usage July 2nd week 21
2 CO2 identify selective assembly procedures Lecture Hall ICT Usage July 4th week
3 CO3 extract the nutshell of tolerancing theory Lecture Hall ICT Usage Aug 2nd week
4 CO4 preform form design Lecture Hall ICT Usage Sep 1st week
Lecture Hall and ICT Usage and
5 CO5 develop tolerance charting CAD Lab Activity based Sep 3rd week
learning
*Methods: Industrial Expert Lecture, ICT usage, +Field Visit, Guest Lecture, Tutorial, Online Quiz, Hands-on training, Activity based learning, Assignment,
Seminar, Mini projects, etc.,
4. Text Book(s): (As per AC Book)
Sl. No. Author(s) Title of the Book Publisher Year of Publication
1. Harry Peck Designing for Manufacture Pitman Publications, First Edition 1973
Gerhard Pahl Engineering Design – A Systematic Springer Science and Business
2. 2021
Wolfgang Beitz Approach Media, Third Edition
5. Reference Books: (As per AC Book)
Sl. No. Author(s) Title of the Book Publisher Year of Publication
Design for Manufacture: Principles and Independently Published, First
1. Henry W Stoll 2024
Practices Edition
Productivity Press, Second
2. David M Anderson Design for Manufacturability 2020
Edition
Applications of Design for Manufacturing
3. Ancuta Carmen Pacurar Intech Open, First Edition 2020
and Assembly
Materials Selection for Design and
4. Joseph Datsko CRC Press, First Edition 2020
Manufacturing
6. Web URLs
1. www.apriori.com/design-for-manufacturability/
2. www.gdandtbasics.com/true-position
3. www.home.iitk.ac.in/~anupams/ME251/tolerances_tables.pdf
7. Assessment Items
Proposed
Cognitive Process
Date of
Mark Split up CO Distribution (%) K Levels
Assessmen
Distribution in Percentage
t
Part C
Sections/ Total
Part A Part B (for CO1 CO2 CO3 CO4 CO5 K1 K2 K3 K4 K5 K6
Tests Marks
MBA)
CIA - 1 20 80 - 100 58 26 16 - - 20 60 20
CIA - 2 20 80 - 100 - - 20 40 40 20 60 20
Assignment-I 100 - 100 40 40 20 - - - 80 20
Assignment-II 100 - 100 20 40 40 - 80 20
ESE 20 80 100 25 50 25 - - 30 60 10
Course Faculty Course Coordinator HoD
