Pierpaolo CARLONE | Production and Quality Management Systems

cod. 0612600022

PRODUCTION AND QUALITY MANAGEMENT SYSTEMS

	0612600022
	DIPARTIMENTO DI INGEGNERIA INDUSTRIALE
	EQF6
	INDUSTRIAL ENGINEERING AND MANAGEMENT
	2020/2021

PERCORSO IN COMMON

	OBBLIGATORIO
	YEAR OF COURSE 2
	YEAR OF DIDACTIC SYSTEM 2018
	SECONDO SEMESTRE

TEACHING UNITS

	SSD	CFU	HOURS	ACTIVITY	TYPE OF ACTIVITY
	ING-IND/16	9	90	LESSONS	COMPULSORY SUBJECTS, CHARACTERISTIC OF THE CLASS

PROFESSORS

	PIERPAOLO CARLONE T Curriculum
	VINCENZO SERGI Curriculum

	Objectives
	THE COURSE PROVIDES THE FUNDAMENTAL CONCEPTS AND METHODOLOGICAL TOOLS FOR THE ANALYSIS OF CONVENTIONAL TECHNOLOGICAL PROCESSES USED FOR THE PRODUCTION OF METAL AND NON-METAL PRODUCTS THROUGH PLASTIC DEFORMATION AND CHIP REMOVAL AS WELL AS GUIDELINES TO DESCRIBE, EVALUATE AND INTERPRET THE VARIABILITY IN THE EXPERIMENTAL AND INDUSTRIAL FIELD. KNOWLEDGE AND UNDERSTANDING. AT THE END OF THE COURSE, THE STUDENT KNOWS: - SUBTRACTIVE MANUFACTURING PROCESSES: CUTTING MECHANISM, TURNING, MILLING, DRILLING, RECTILINEAR CUTTING PROCESSES, GRINDING; - CONSERVATIVE PROCESSING PROCESSES: FORGING AND MOLDING, ROLLING, DRAWING, EXTRUSION; - STATISTICAL ANALYSIS OF THE PROCESSES AND MANAGEMENT OF QUALITY METHODS APPLIED KNOWLEDGE AND UNDERSTANDING AT THE END OF THE COURSE, THE STUDENT IS ABLE TO: - CHOOSE THE MOST APPROPRIATE MANUFACTURING PROCESS TO CREATE SURFACES MEETING THE SPECIFIC DESIGN REQUIREMENTS - CALCULATE FORCE AND POWER REQUIRED FOR PROCESSING AND EVALUATE THE FEASIBILITY OF PROCESSING WITH CERTAIN EQUIPMENT AND MACHINES - SELECT TOOLS AND EQUIPMENT TO PERFORM A SPECIFIC PROCESS -MONITORING THE PERFORMANCES OF A MANUFACTURING PROCESS AND THE QUALITY OF ITS PRODUCTS. AUTONOMY OF JUDGMENT BEING ABLE TO IDENTIFY THE MOST APPROPRIATE PROCESSES TO CREATE SURFACES MEETING THE SPECIFIC DESIGN REQUIREMENTS AND THE MOST APPROPRIATE TOOLS FOR QUALITY CONTROL. COMMUNICATION SKILLS BEING ABLE TO DESCRIBE, IN WRITTEN FORM, IN A CLEAR AND CONCISE WAY AND ORALLY PRESENT THE OBJECTIVES USING TECHNICAL-SCIENTIFIC LANGUAGE, THE PROCEDURE AND THE RESULTS OF THE PERFORMED ELABORATIONS. LEARNING SKILLS BEING ABLE TO APPLY THE KNOWLEDGE ACQUIRED IN CONTEXTS DIFFERENT FROM THOSE PRESENTED DURING THE COURSE, AND TO DEEPEN THE TOPICS COVERED USING MATERIALS OTHER THAN THOSE PROPOSED.

THE COURSE PROVIDES THE FUNDAMENTAL CONCEPTS AND METHODOLOGICAL TOOLS FOR THE ANALYSIS OF CONVENTIONAL TECHNOLOGICAL PROCESSES USED FOR THE PRODUCTION OF METAL AND NON-METAL PRODUCTS THROUGH PLASTIC DEFORMATION AND CHIP REMOVAL AS WELL AS GUIDELINES TO DESCRIBE, EVALUATE AND INTERPRET THE VARIABILITY IN THE EXPERIMENTAL AND INDUSTRIAL FIELD.

KNOWLEDGE AND UNDERSTANDING.
AT THE END OF THE COURSE, THE STUDENT KNOWS:
- SUBTRACTIVE MANUFACTURING PROCESSES: CUTTING MECHANISM, TURNING, MILLING, DRILLING, RECTILINEAR CUTTING PROCESSES, GRINDING;
- CONSERVATIVE PROCESSING PROCESSES: FORGING AND MOLDING, ROLLING, DRAWING, EXTRUSION;
- STATISTICAL ANALYSIS OF THE PROCESSES AND MANAGEMENT OF QUALITY METHODS

APPLIED KNOWLEDGE AND UNDERSTANDING
AT THE END OF THE COURSE, THE STUDENT IS ABLE TO:
- CHOOSE THE MOST APPROPRIATE MANUFACTURING PROCESS TO CREATE SURFACES MEETING THE SPECIFIC DESIGN REQUIREMENTS
- CALCULATE FORCE AND POWER REQUIRED FOR PROCESSING AND EVALUATE THE FEASIBILITY OF PROCESSING WITH CERTAIN EQUIPMENT AND MACHINES
- SELECT TOOLS AND EQUIPMENT TO PERFORM A SPECIFIC PROCESS
-MONITORING THE PERFORMANCES OF A MANUFACTURING PROCESS AND THE QUALITY OF ITS PRODUCTS.

AUTONOMY OF JUDGMENT
BEING ABLE TO IDENTIFY THE MOST APPROPRIATE PROCESSES TO CREATE SURFACES MEETING THE SPECIFIC DESIGN REQUIREMENTS AND THE MOST APPROPRIATE TOOLS FOR QUALITY CONTROL.

COMMUNICATION SKILLS
BEING ABLE TO DESCRIBE, IN WRITTEN FORM, IN A CLEAR AND CONCISE WAY AND ORALLY PRESENT THE OBJECTIVES USING TECHNICAL-SCIENTIFIC LANGUAGE, THE PROCEDURE AND THE RESULTS OF THE PERFORMED ELABORATIONS.

LEARNING SKILLS
BEING ABLE TO APPLY THE KNOWLEDGE ACQUIRED IN CONTEXTS DIFFERENT FROM THOSE PRESENTED DURING THE COURSE, AND TO DEEPEN THE TOPICS COVERED USING MATERIALS OTHER THAN THOSE PROPOSED.

	Prerequisites
	KNOWLEDGE OF MECHANICAL DRAWING AND GENERAL MATERIALS TECHNOLOGIES IS REQUIRED, IN PARTICULAR: - THE GRAPHIC REPRESENTATION OF MECHANICAL PARTS AND THE UNDERSTANDING OF THE PRESCRIPTIONS GIVEN; - THE DEFINITIONS AND METALLURGICAL AND MECHANICAL PROPERTIES OF THE MAIN ENGINEERING MATERIALS; - THE EFFECTS OF HEAT TREATMENTS

	Contents
	OVERVIEW ON THE LIFE CYCLE OF THE PRODUCT (THEORY HOURS 3) LIFE CYCLE PHASES AND TYPES OF PRODUCTION. MACHINING PROCESSES (THEORY HOURS 12, EXERCITATIVE HOURS 8, LABORATORY HOURS 8) TURNING, MILLING, DRILLING, RECTILINEAR CUTTING PROCESSES, GRINDING. PLASTIC DEFORMATION PROCESSES (THEORY HOURS 10, EXERCITATIVE HOURS 6) ELASTOPLASTIC BEHAVIOR OF MATERIALS, CRITERIA OF PLASTICITY, FORGING, MOLDING, LAMINATION, DRAWING, EXTRUSION. QUALITY CONTROL (THEORY HOURS 4) MASS PRODUCTION, QUALITY CONTROL, PRODUCT AND PROCESS; THE CONTINUOUS IMPROVEMENT OF PROCESSES. REPRESENTATION OF STATISTICAL UNITS (THEORY HOURS 2, EXERCITATIVE HOURS 4) DESCRIPTION OF THE VARIABILITY, BAR DIAGRAMS AND HISTOGRAMS. STATISTICS AND SAMPLING DISTRIBUTIONS (THEORY HOURS 4, EXERCITATIVE HOURS 6) NORMAL DISTRIBUTION, BINOMIAL DISTRIBUTION AND POISSON DISTRIBUTION. STATISTICAL CONTROL OF THE PROCESS (THEORY HOURS 5, EXERCITATIVE HOURS 5) STATISTICAL FOUNDAMENTS OF CONTROL CHARTS, CHOICE OF CONTROL LIMIT, SIZE OF SAMPLING, CONTROL CARDS FOR VARIABLES, CONTROL CARDS FOR ATTRIBUTES.

Contents

OVERVIEW ON THE LIFE CYCLE OF THE PRODUCT (THEORY HOURS 3)
LIFE CYCLE PHASES AND TYPES OF PRODUCTION.

MACHINING PROCESSES (THEORY HOURS 12, EXERCITATIVE HOURS 8, LABORATORY HOURS 8)
TURNING, MILLING, DRILLING, RECTILINEAR CUTTING PROCESSES, GRINDING.

PLASTIC DEFORMATION PROCESSES (THEORY HOURS 10, EXERCITATIVE HOURS 6)
ELASTOPLASTIC BEHAVIOR OF MATERIALS, CRITERIA OF PLASTICITY, FORGING, MOLDING, LAMINATION, DRAWING, EXTRUSION.

QUALITY CONTROL (THEORY HOURS 4)
MASS PRODUCTION, QUALITY CONTROL, PRODUCT AND PROCESS; THE CONTINUOUS IMPROVEMENT OF PROCESSES.

REPRESENTATION OF STATISTICAL UNITS (THEORY HOURS 2, EXERCITATIVE HOURS 4)
DESCRIPTION OF THE VARIABILITY, BAR DIAGRAMS AND HISTOGRAMS.

STATISTICS AND SAMPLING DISTRIBUTIONS (THEORY HOURS 4, EXERCITATIVE HOURS 6)
NORMAL DISTRIBUTION, BINOMIAL DISTRIBUTION AND POISSON DISTRIBUTION.

STATISTICAL CONTROL OF THE PROCESS (THEORY HOURS 5, EXERCITATIVE HOURS 5)
STATISTICAL FOUNDAMENTS OF CONTROL CHARTS, CHOICE OF CONTROL LIMIT, SIZE OF SAMPLING, CONTROL CARDS FOR VARIABLES, CONTROL CARDS FOR ATTRIBUTES.

	Teaching Methods
	THE COURSE IS COMPOSED BY THEORETICAL LESSONS AND CLASSROOM EXERCISES INTEGRATED WITH LABORATORY VISITS AND PRACTICAL DEMONSTRATIONS OF MECHANICAL PROCESSING. THE THEORETICAL LESSONS ILLUSTRATES THE MANUFACTURING PROCESSES, WITH REFERENCE TO THE OBTAINABLE COMPONENTS, THE MACHINES, THE EQUIPMENT, THE TOOLS USED AND THE METHODS OF QUALITY CONTROL. THE EXERCISES ARE AIMED AT THE PLANNING OF THE ANALYZED PROCESSES AND AT THE QUALITY CONTROL, IN RELATION TO THE PROCESS SETUP AND TO THE WORKING PARAMETERS USED. THE EXECUTION OF THE EXERCISES IS PERFORMED BY THE TEACHER INVOLVING EVENTUALLY ANY OR MORE STUDENTS IN THE RESOLUTION. THE DEMONSTRATIONS IN THE LABORATORY ARE AIMED AT PROVIDING A PRACTICAL REVIEW OF THE THEORETICAL NOTIONS EXPLORED IN THE THEORETICAL LESSONS.

Teaching Methods

THE COURSE IS COMPOSED BY THEORETICAL LESSONS AND CLASSROOM EXERCISES INTEGRATED WITH LABORATORY VISITS AND PRACTICAL DEMONSTRATIONS OF MECHANICAL PROCESSING.
THE THEORETICAL LESSONS ILLUSTRATES THE MANUFACTURING PROCESSES, WITH REFERENCE TO THE OBTAINABLE COMPONENTS, THE MACHINES, THE EQUIPMENT, THE TOOLS USED AND THE METHODS OF QUALITY CONTROL.
THE EXERCISES ARE AIMED AT THE PLANNING OF THE ANALYZED PROCESSES AND AT THE QUALITY CONTROL, IN RELATION TO THE PROCESS SETUP AND TO THE WORKING PARAMETERS USED. THE EXECUTION OF THE EXERCISES IS PERFORMED BY THE TEACHER INVOLVING EVENTUALLY ANY OR MORE STUDENTS IN THE RESOLUTION.
THE DEMONSTRATIONS IN THE LABORATORY ARE AIMED AT PROVIDING A PRACTICAL REVIEW OF THE THEORETICAL NOTIONS EXPLORED IN THE THEORETICAL LESSONS.

	Verification of learning
	THE EVALUATION OF THE ACHIEVEMENT OF THE OBJECTIVES WILL TAKE PLACE BY A WRITTEN TEST AND AN ORAL INTERVIEW WHERE THE DEGREE OF KNOWLEDGE ACQUIRED AND THE ABILITY OF EXPOSURE OF THE DISCUSSED TOPICS WILL BE ASSESSED. THE TOTAL ASSESSMENT IS EXPRESSED IN THIRTYTHS. IN ORDER TO ACCESS THE ORAL EXAM, THE WRITTEN TEST MUST BE PASSED AT LEAST WITH A MINIMUM SCORE OF 18/30. THE WRITTEN TEST CONSISTS OF TWO NUMERICAL EXERCISES AIMED AT ASSESSING THE PLANNING SKILLS OF THE PROCESSES ANALYZED DURING THE COURSE AND TWO OPEN THEORETICAL QUESTIONS. THE WRITTEN TEST IS TO BE CARRIED OUT IN A TIME LIMIT OF TWO HOURS. THE PROPOSED QUESTIONS CONCERN THE CALCULATION OF: A) CUTTING PARAMETERS AND SIZING IN TERMS OF STRENGTH AND POWER IN CHIP REMOVAL PROCESSES; B) THE SIZING OF PROCESSES FOR PLASTIC DEFORMATION; C) STATISTICAL CONTROL OF THE MANUFACTURING PROCESSES. THE ORAL EXAM IS AIMED AT DEEPENING THE LEVEL OF THEORETICAL KNOWLEDGE, THE AUTONOMY OF ANALYSIS AND JUDGMENT, AS WELL AS THE STUDENT'S PRESENTATION SKILLS. IN PARTICULAR, QUESTIONS ARE PROPOSED ON THE FUNDAMENTAL PRINCIPLES OF CONVENTIONAL MECHANICAL MACHINING, ON THE EQUIPMENT USED, ON THE TOOLS AND ON THE RESULTS OBTAINABLE IN TERMS OF GEOMETRIC-DIMENSIONAL PRECISION AND SURFACE FINISH. THE EVALUATION OF THE TESTS TAKES INTO ACCOUNT THE ABILITY TO IDENTIFY THE MOST APPROPRIATE METHODS FOR MACHINING MECHANICAL COMPONENTS, THE ABILITY TO CLEARLY AND CONCISELY EXPOSE THE OBJECTIVES, THE PROCEDURE AND THE RESULTS OF THE ELABORATIONS CARRIED OUT, AS WELL AS THE ABILITY TO DEEPEN THE TOPICS TREATED USING MATERIALS OTHER THAN THOSE PROPOSED. THE MINIMUM ASSESSMENT GRADE (18/30) IS ATTRIBUTED WHEREAS THE STUDENT DEMONSTRATES A SCARCE UNDERSTANDING OF THE DIFFERENT MANUFACTURING PROCESSES, HAS A POOR DISPLAY CAPACITY AND LIMITED AUTONOMY AND JUDGMENT. THE MAXIMUM GRADE (30/30) IS ATTRIBUTED WHEREAS THE STUDENT DEMONSTRATES A COMPLETE AND IN-DEPTH KNOWLEDGE OF THE METHODS AND IS ABLE TO SOLVE THE PROPOSED PROBLEMS BY IDENTIFYING THE MOST APPROPRIATE METHODS TO ANALYZE THE PRODUCTION PROCESSES AND SHOWS A REMARKABLE CAPACITY IN PLANNING PROCESSES AND IN THEIR PRESENTATION. THE FINAL MARK, EXPRESSED IN THIRTIETHS WITH POSSIBLE HONOR, IS OBTAINED AS THE AVERAGE OF THE TWO TESTS. THE HONOR IS AWARDED WHEN THE CANDIDATE DEMONSTRATES SIGNIFICANT MASTERY OF THE THEORETICAL AND OPERATIONAL CONTENTS AND SHOWS HIS ABILITY TO PRESENT THE TOPICS WITH SIGNIFICANT LANGUAGE PROPERTIES AND AUTONOMOUS PROCESSING CAPACITY EVEN IN CONTEXTS OTHER THAN THOSE PROPOSED BY THE TEACHER.

Verification of learning

THE EVALUATION OF THE ACHIEVEMENT OF THE OBJECTIVES WILL TAKE PLACE BY A WRITTEN TEST AND AN ORAL INTERVIEW WHERE THE DEGREE OF KNOWLEDGE ACQUIRED AND THE ABILITY OF EXPOSURE OF THE DISCUSSED TOPICS WILL BE ASSESSED. THE TOTAL ASSESSMENT IS EXPRESSED IN THIRTYTHS.

IN ORDER TO ACCESS THE ORAL EXAM, THE WRITTEN TEST MUST BE PASSED AT LEAST WITH A MINIMUM SCORE OF 18/30. THE WRITTEN TEST CONSISTS OF TWO NUMERICAL EXERCISES AIMED AT ASSESSING THE PLANNING SKILLS OF THE PROCESSES ANALYZED DURING THE COURSE AND TWO OPEN THEORETICAL QUESTIONS. THE WRITTEN TEST IS TO BE CARRIED OUT IN A TIME LIMIT OF TWO HOURS.
THE PROPOSED QUESTIONS CONCERN THE CALCULATION OF:
A) CUTTING PARAMETERS AND SIZING IN TERMS OF STRENGTH AND POWER IN CHIP REMOVAL PROCESSES; B) THE SIZING OF PROCESSES FOR PLASTIC DEFORMATION; C) STATISTICAL CONTROL OF THE MANUFACTURING PROCESSES.
THE ORAL EXAM IS AIMED AT DEEPENING THE LEVEL OF THEORETICAL KNOWLEDGE, THE AUTONOMY OF ANALYSIS AND JUDGMENT, AS WELL AS THE STUDENT'S PRESENTATION SKILLS. IN PARTICULAR, QUESTIONS ARE PROPOSED ON THE FUNDAMENTAL PRINCIPLES OF CONVENTIONAL MECHANICAL MACHINING, ON THE EQUIPMENT USED, ON THE TOOLS AND ON THE RESULTS OBTAINABLE IN TERMS OF GEOMETRIC-DIMENSIONAL PRECISION AND SURFACE FINISH.
THE EVALUATION OF THE TESTS TAKES INTO ACCOUNT THE ABILITY TO IDENTIFY THE MOST APPROPRIATE METHODS FOR MACHINING MECHANICAL COMPONENTS, THE ABILITY TO CLEARLY AND CONCISELY EXPOSE THE OBJECTIVES, THE PROCEDURE AND THE RESULTS OF THE ELABORATIONS CARRIED OUT, AS WELL AS THE ABILITY TO DEEPEN THE TOPICS TREATED USING MATERIALS OTHER THAN THOSE PROPOSED.
THE MINIMUM ASSESSMENT GRADE (18/30) IS ATTRIBUTED WHEREAS THE STUDENT DEMONSTRATES A SCARCE UNDERSTANDING OF THE DIFFERENT MANUFACTURING PROCESSES, HAS A POOR DISPLAY CAPACITY AND LIMITED AUTONOMY AND JUDGMENT.
THE MAXIMUM GRADE (30/30) IS ATTRIBUTED WHEREAS THE STUDENT DEMONSTRATES A COMPLETE AND IN-DEPTH KNOWLEDGE OF THE METHODS AND IS ABLE TO SOLVE THE PROPOSED PROBLEMS BY IDENTIFYING THE MOST APPROPRIATE METHODS TO ANALYZE THE PRODUCTION PROCESSES AND SHOWS A REMARKABLE CAPACITY IN PLANNING PROCESSES AND IN THEIR PRESENTATION.
THE FINAL MARK, EXPRESSED IN THIRTIETHS WITH POSSIBLE HONOR, IS OBTAINED AS THE AVERAGE OF THE TWO TESTS.
THE HONOR IS AWARDED WHEN THE CANDIDATE DEMONSTRATES SIGNIFICANT MASTERY OF THE THEORETICAL AND OPERATIONAL CONTENTS AND SHOWS HIS ABILITY TO PRESENT THE TOPICS WITH SIGNIFICANT LANGUAGE PROPERTIES AND AUTONOMOUS PROCESSING CAPACITY EVEN IN CONTEXTS OTHER THAN THOSE PROPOSED BY THE TEACHER.

	Texts
	- NOTES AND SLIDES OF LECTURES AND EXERCITATIONS AVAILABLE AT THE WEBSITE: HTTP://ELEARNING.DIMEC.UNISA.IT/ - M. GIUSTI, F. SANTOCHI - TECNOLOGIA MECCANICA E STUDI DI FABBRICAZIONE ED. AMBROSIANA - D.C. MONTGOMERY: CONTROLLO STATISTICO DELLA QUALITÀ, MCGRAW-HILL, MILANO, 2012

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Pierpaolo CARLONE | Production and Quality Management Systems