Production Management I

At the end of this course, the students should be able to: 1. state the types and principles of production processes; 2. apply basic materials management concepts; 3. develop group technology and cellular; 4. Explain the concepts of purchasing and implementation; 5. select appropriate interest rates and describe the methods of analysis; 6. discuss manufacturing methods in a range of industries; 7. visit manufacturing industries; 8. write a comprehensive report and communicate engineering knowledge gained during the visits; and 9. state the fundamentals of small-scale businesses and their industrial engineering roles.

Principles of production. Types of production processes. Development of Group technology and cellular systems. Materials management. Purchasing methods. Engineering Economy. Economic analysis of engineering projects. Selection of appropriate interest rates and methods of analysis, depreciation and tax considerations. Survey of manufacturing methods in a range of industries, textiles, timber, food, agriculture, etc. Plant visits. Overview of Some manufacturing industries such as cement, electronics, etc. Industrial computers and their applications. Small–scale businesses in Industrial and Production Engineering. IPE 532 : Production Management II (3 Units C: LH 45) Learning Outcomes At the end of this course, the students should be able to: 1. explain the fundamental principles of production planning and control and indicate how the knowledge of budgeting and cost control influences their outcome; 2. explain the meaning of forecasting, identify its types and show its importance; 3. determine forecast accuracy and interpret the result; 4. explain the principles of quality control and identify problems in quality improvement process; 5. explain and apply statistics and probability to quality control and management; 6. describe the basic concept of Total Quality management, the steps involved and its implementation; 7. perform process capability and specification studies; 8. explain the basic principles of reliability; 9. apply the principles of statistics and probability in characterising the reliability of an item or system; 10. explain the bathtub curve and its application; 11. determine the reliability of series and parallel systems; 12. explain basic concepts such as preventive ; and 13. corrective maintenance, maintainability and availability. Course Contents Production Planning and Control. Principles of control, Budgetary and cost control. Information Processing and Control. Forecasts. Principles of forecasting. Simple forecasting models and forecast accuracy. Schedulling Techniques. Sequencing n-jobs through n-machines. Quality Control. Quality Control Principles, Total Quality Concepts, economics of quality. process capability. Control Charts. Sampling systems. Inspection Systems. Quality Motivation and Training. Basic concepts of Reliability Engineering. Principles of reliability engineering, The Bathtub Curve. Failure rate analysis. Reliability of systems – Series and Parallel Systems, Maintenance – Preventive and Corrective. Maintainability and Availability. Minimum Academic Standards Equipment The required equipment and tools required for the Industrial and {Production engineering programme in accordance with the requirements of major laboratories are listed below. Note that accessories and consumables needed for effective use of these equipment are not listed but will be requested by the department that runs this curriculum when purchasing the equipment. Industrial and Production Engineering Laboratory Equipment 1. Induction Furnaces. 2. CNC machines 3.Lathe Machines. 4.Drilling Machines. 5.Hacksaw, Stolling, Cutting Machine. 6.Universal Gear Hobing Machine. 7.Sheet streaming, Bending, Rolling Machine. 8.Work Press Machines such as Eccentric press, punch press, Arbor press, Double Piller Type. 9.Screw presses. 10.Hammer mills. 11.Modern callipers and gauges. 12.Computer Workstations and Software. 13.Ergonomic Lab Workstations. Staffing Academic Staff The NUC guidelines on staff/student ratio of 1:15 for Engineering and Technology departments shall apply. However, there should be a minimum of six full-time equivalents of Staff in the department. There is need to have a reasonable number of Staff with doctoral degrees as well as sufficient industrial experience. With a minimum load of 15 Units per semester for students and a minimum of six full-time equivalent of staff in each programme, staff should have a maximum of 15 contact hours per week for lectures, tutorials, practical’s and supervision of projects. NUC requirement encourages all academic staff to have PhD degrees; hence appointment of academic staff is preferably to the Lecturer cadre. Only in exceptional cases are candidates with great promise appointed to Graduate Assistant and Assistant Lecturer positions for the purpose of being developed to the Lecturer cadre as registered PhD candidates. Academic Support Personnel Teaching Assistant/Demonstrators to help lecturers in the conduct of tutorials, practical’s and field work. This category of personnel is not expected to be regular staff as they are to be paid on the basis of approved hourly rate. Administrative Support Staff The services of the administrative support staff are indispensable in the proper administration of the departments and faculty offices. It is important to recruit very competent senior staff that are computer literate. Technical Support Personnel The services of technical support staff, which are indispensable in the proper running of laboratories and workshop/studios are required. It is important to recruit very competent senior technical staff to maintain teaching and research equipment. They are also to undergo regular training to keep them abreast of developments in equipment operation and maintenance. The minimum of academic staff to technical staff ratio of 5:1 should be maintained. Minimum Number of Staff Subject to the general standards specified by NUC; 1. there should be a minimum of two PhDs and four M.Eng degree holders full-time academic staff to mount the programme; 2. each workshop or laboratory should have an adequate number of staff with the right mix, such that each unit or section in that workshop or laboratory can run efficiently; and 3. there should be an adequate number of administrative staff of the appropriate caliber for the office of the Head of Department to run. Student/Staff Ratio The minimum staff-to-student ratio should be 1:15 from 200 level to 500 level. Library In addition to the university and faculty libraries, the programme must have a departmental library well equipped with specialised and modern books and journals in both physical and E-collections (E-Resources) of various types. Various field and research reports of the programme must also be available in the library for staff, students and researchers. The library must be connected to subscribed repository of: 1. Institutions (national and international); 2. Open access sources; 3. Professional Bodies’ E-learning platforms; and 4. Relevant international organizations; The library must also have adequate facilities for reading, lending services and reservation for specialised materials. It must have a dequate seating capacity for users up to 2,700. Other requirements include shelves (Main/Engineering Branch Library) , trolleys, reading chairs/tables. Computers, Printers, Scanners, Labelling machine, Catalogue cabinets, Kirk stand, cataloguing and classification tools, giant size staplers, cutter tables, library of congress subject heading, delivery decimal classification scheme, Universal decimal classification scheme. Classrooms, Laboratory, Workshops, Clinics and Offices The ICE programme shall adopt NUC recommendations for physical space requirement as presented below: Academic Size (m2) Head of Department’s Office 18.50 Professor’s Office 18.50 Tutorial Teaching Staff Space 13.50 Other Teaching Staff Space 7.00 Technical Staff Space 7.00 Science Staff Research Laboratory 16.50 Engineering Staff Research Laboratory 14.50 Seminar Space per student 1.85 Drawing Office Space (A.O. Board) (Per Student) 4.60 Drawing Office Space (A.I. Board) (Per Student) 3.70 Laboratory Space 7.50 Non-Academic Secretarial Space 7.00 Office Accommodation The requirements for office accommodation are: S/No Office No in Facilities Room 1. HOD/Professor 1 Table, chairs, A/C, filing cabinet, bookshelves, computer unit, Secretary and facilities. 2. Reader/ 1 Table, chairs, A/C, filing cabinet, bookshelves, Associate Professor computer unit. 3. Senior Lecturer 1 Table, chairs, A/C, filing cabinet, bookshelves, computer unit. 4. Lecturer I 2 5. Lecturer II 3