Production Engineering
Level 4 Syllabus
S.No. Category Sub-category Weight-age
1. Automation and Numerical Control - Basic principles
of automation, Extending the capabilities of
2
conventional machines through improved devices and
manipulators, basic principles of numerical control
2. CNC Machining - CNC, DNC and Machining Centres;
Methods of coding and programming; APT
2
Automation, CNC programming; Adaptive control; Economics of
1. Machines and numerical control
Robotics 3. Robotics - Introduction to Robotics: Synthesis of
elements with movability constraints; Elements of
robot anatomy; Hydraulic, pneumatic and electrical
manipulators; End-effectors and their design; 2
Controllers with microprocessors or fluidics; Robot
Sensors; Applications of industrial robots; Economics of
robotics.
1. Statistical Process Control - Quality control, Quality
Assurance Variation in process, Factors, control charts,
variables XR and Xσ , - Attributes P, C and U-Chart 2
Establishing and interpreting control charts process
capability, Quality rating, Short run SPC.
2. Acceptance Sampling -Lot by lot sampling types,
2. Quality Control probability of acceptance in single, double, multiple
and Reliability sampling plans, OC curves, Producer’s risk and
consumer’s risk. AQL, LTPD, AOQL, Concepts Design of 2
single sampling plan, standard sampling plans for AQL
and LTPD, Use of standard sampling plans, Sequential
sampling plan.
3. Experimental Design and TAGUCHI Method-
Fundamentals, factorial experiments, Fundamentals,
factorial experiments, random design, Latin square 1
design, Taguchi method, Loss function, experiments,
S/N ratio and performance measure, Orthogonal array.
4. Reliability and its Prediction - Life testing, Failure
characteristics, Meantime to failure, maintainability
and availability, reliability, system reliability, OC curves,
reliability improvement techniques, Reliability testing 1
techniques, Pareto analysis. MTBF MTTF, System
reliability, OC curve Availability and Maintainability,
Reliability Improvement techniques
5. Failure Data Analysis - Real time distribution, 1
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Production Engineering
Level 4 Syllabus
exponential, normal, log normal, gamma and weibull,
reliability data requirements, Graphical evaluation.
1. Elements of Machine tools - Types and capabilities
of various machine tools. General purpose, and special
purpose machine tools, Design of machine tool
structures:-Design of bed & columns- Materials of
construction, Profiles, Static and dynamic stiffness.
Designing for strength and rigidity. Methods of
enhancing rigidity. Design of machine tool bed cross-
section like lathe bed. Design of simple machine tool
columns like pillar drill column etc. on the basis of
strength and rigidity, Machine tool guide ways -
Materials of construction, Classification of guide ways,
Types of sideways, Clearance adjustment and wear
compensation techniques, Fundamentals of hydrostatic
2
guide ways. Design of guide ways for wear and
stiffness, Design of mechanical drives, Design of belt
drives - Design of belts, belt materials, belt types:-
specification and selection, types of pulleys and design
of pulleys, Design of gear drives - Types of gears,
3. Machine Design - materials, application, and selection. Design of spur
II gears - Design on the basis of beam strength (W. Lewis
equation), Design on the basis of wear and fatigue
(Buckingham's Equation) Design of chain drives- Types
of chains and sprockets. Principles of designing
sprockets and roller chains. Design of chain drives-
Types of chains and sprockets. Principles of designing
sprockets and roller chains
2. Design of Speed and Feed boxes - Stepped and 2
Stepless speed outputs, selection of spindle speed
ranges, construction of structural, speed, gearing &
deviation diagrams, layout of speeds on arithmetic and
geometric progression, kinematic advantages of
geometric progression series, selection of values of
common ratio. Steeples drives : Mechanical stepless
drives − single disc, double disc and cone disc
transmissions, speed regulation by epicyclic gear train,
positive infinitely variable drives (PIV drives) − Kopp’s ,
Meander and Svetozarav’s drives. Feed boxes:
Quadrant change gear mechanism, speed boxes with
gear cone and sliding key, Norton gear drive, Meander
gear drives, gear boxes with clutched drive, Schopke
drive and Ruppert drive. Design of gear boxes for feed
and speeds having 2−3 stages and 4−12 speeds.
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Production Engineering
Level 4 Syllabus
3. Design of Power Screws, Clutches and Bearings -
Design of power screws: Materials of construction.
Power screw profiles and selection, design of machine
tool power screws based on strength, buckling and
stiffness, power requirements and efficiency, mounting
of power screws, Elementary treatment on ball
recirculating power screws. 04 Design considerations,
materials of clutch plates & linings. Running conditions-
wet & dry, Design of plate clutches. Single and
multiplate clutches involving design of clutch plates,
springs & operating lever, Bearing materials & their
characteristics. Types of bearings- selection & 3
application. Design of ball & roller bearings – Bearing
designation (ISI, ISO, SAE, and SKF). Calculation of
equivalent load, cubic mean load, static & dynamic
load bearing capacities. Selection of ball & roller
bearing from handbook. Mounting & maintenance of
bearings, Design of journal bearings – Terminology.
Theory of lubrication, bearing characteristic Number,
Sommerfeld Number, calculations involving bearing
dimensions, clearance, coefficient of friction, heat
generated, and heat dissipated and power lost in
friction. Mounting & maintenance of bearings
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