PI PRODUCTION AND INDUSTRIAL ENGINEERING
Section 1: Engineering Mathematics
Linear Algebra: Matrix algebra, Systems of linear equations, Eigen values and eigen
Calculus: Functions of single variable, Limit, continuity and differentiability, Mean
value theorems, Evaluation of definite and improper integrals, Partial derivatives,
Total derivative, Maxima and minima, Gradient, Divergence and Curl, Vector
identities, Directional derivatives, Line, Surface and Volume integrals, Stokes, Gauss
and Green’s theorems.
Differential equations: First order equations (linear and nonlinear), Higher order linear
differential equations with constant coefficients, Cauchy’s and Euler’s equations,
Initial and boundary value problems, Laplace transforms, Solutions of one
dimensional heat and wave equations and Laplace equation.
Complex variables: Analytic functions, Cauchy’s integral theorem, Taylor series.
Probability and Statistics: Definitions of probability and sampling theorems,
Conditional probability, Mean, median, mode and standard deviation, Random
variables, Poisson, Normal and Binomial distributions.
Numerical Methods: Numerical solutions of linear and non-linear algebraic
equations Integration by trapezoidal and Simpson’s rule, single and multi-step
methods for differential equations.
Section 2: General Engineering
Engineering Materials: Structure and properties correlation;engineering materials
(metals, ceramics, polymers and composites) – properties and applications; stress-
strain behavior of metals and alloys;iron-carbon phase diagram, heat treatment of
metals and alloys, its influence on mechanical properties.
Applied Mechanics: Engineering mechanics – equivalent force systems, free body
concepts, equations of equilibrium; trusses; strength of materials – stress, strain and
their relationship; failure theories, Mohr’s circle(stress), deflection of beams, bending
and shear stress, Euler’s theory of columns.
Theory of Machines and Design: Analysis of planar mechanisms, cams and
followers; governors and fly wheels; design of bolted, riveted and welded joints;
interference/shrink fit joints; design of shafts, keys, spur gears, belt drives, brakes and
clutches; pressure vessels.
Thermal and FluidsEngineering: Fluid mechanics – fluid statics, Bernoulli’s equation,
flow through pipes, equations of continuity and momentum, capillary action,
contact angle and wetting; thermodynamics – zeroth, first and second law of
thermodynamics, thermodynamic system and processes, calculation of work and
heat for systems and control volumes; air standard cycles; heat transfer –
basicapplicationsof conduction, convection and radiation.
Section 3: Manufacturing Processes I
Casting: types of casting processes and applications; patterns – types and
materials; allowances; moulds and cores – materials, making, and testing; casting
techniques of cast iron, steels and nonferrous metals and alloys; analysis
ofsolidification andmicrostructure development; design of gating and riser; origin of
Metal Forming: Stress-strain relations in elastic and plastic deformation; concept of
flow stress; hot and cold working – forging, rolling, extrusion and wire drawing; sheet
metal working processes – blanking, bending and deep drawing; ideal work and
slab analysis;origin of metal workingdefects.
Joining of materials: Principles of fusion welding processes(manual metal arc, MIG,
TIG, plasma arc, submerged arc welding processes)–different heat sources (flame,
arc, resistive, laser, electron beam), and heat transfer and associated losses, flux
application, feeding of filler rod; Principles of solid state welding processes (friction,
explosive welding, ultrasonic welding processes); Principles of adhesive, brazing and
soldering processes; Origins of welding defects.
Powder processing: Production of metal/ceramic powders, compaction and
sintering of metals and ceramic powders.
Polymers and Composites: Plastic processing – injection, compression and blow
molding, extrusion, calendaring and thermoforming; molding of composites.
Section 4: Manufacturing Processes II
Machine Tools and Machining: Basic machine tools like centre lathe, milling
machine, and drilling machine – construction and kinematics; machining processes
- turning, taper turning, thread cutting, drilling, boring, milling, gear cutting, thread
production, grinding; geometry of single point cutting tools, chip formation, cutting
forces, specific cutting energy and power requirements, Merchant’s analysis; basis
ofselection of machining parameters; tool materials, tool wear and tool life,
economics of machining, thermal aspects of machining, cutting fluids,
machinability; Jigs and fixtures – principles, applications, and design
Non-traditional Manufacturing: Principles, applications, effect of process
parameters on MRR and product quality of non-traditional machining processes –
USM, AJM, WJM, AWJM, EDM and Wire cut EDM, LBM, EBM, PAM, CHM, ECM.
Computer Integrated Manufacturing: Basic concepts of CAD – geometric modeling,
CAM – CNC and robotics – configurations, drives and controls, Group Technology
and its applications – CAPP, cellular manufacturing and FMS.
Section 5: Qualityand Reliability
Metrology and Inspection: Limits, fits, and tolerances, gauge design,
interchangeability, selective assembly; linear, angular, and form
measurements(straightness, squareness, flatness, roundness, and cylindricity) by
mechanical and optical methods; inspection of screw threads and gears; surface
finish measurement by contact and non-contact methods;tolerance analysis in
manufacturing and assembly.
Quality management: Quality – concept and costs; quality assurance; statistical
quality control, acceptance sampling, zero defects, six sigma; total quality
management; ISO 9000.
Reliability and Maintenance: Reliability, availability and maintainability; distribution
of failure and repair times; determination of MTBF and MTTR, reliability models;
determination of system reliability; preventive maintenance and replacement.
Section 6: Industrial Engineering
Product Design and Development: Principles of good product design, tolerance
design; quality and cost considerations; product life cycle; standardization,
simplification, diversification, value engineering and analysis, concurrent
engineering;comparison of production alternatives.
Work System Design: Taylor’s scientific management, Gilbreths’s contributions;
productivity – concepts and measurements; methodstudy, micro-motion study,
principles of motion economy; work measurement –time study, work sampling,
standard data, PMTS; ergonomics; job evaluation, merit rating, incentive schemes,
and wage administration.
Facility Design: Facility location factors and evaluation of alternate locations; types
of plant layout and their evaluation; computer aided layout design techniques;
assembly line balancing; materials handling systems.
Section 7: Operations research and Operations management
Operation Research: Linear programming – problem formulation, simplex method,
duality and sensitivity analysis; transportation and assignment models; network flow
models, constrained optimization and Lagrange multipliers; Markovian queuing
models; dynamic programming; simulation – manufacturing applications.
Engineering Economy and Costing: Elementary cost accounting and methods of
depreciation; break-even analysis, techniques for evaluation of capital investments,
financial statements, time-cost trade-off, resource leveling.
Production control: Forecasting techniques – causal and time series models, moving
average, exponential smoothing, trend and seasonality; aggregate production
planning; master production scheduling; MRP and MRP-II; routing, scheduling and
priority dispatching; Push and pull production systems, concept of JIT
manufacturing system; Logistics, distribution, and supply chain management;
Inventory – functions, costs, classifications, deterministicinventory models, quantity
discount; perpetual and periodic inventory control systems.
Project management – PERT and CPM.