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Production and Quality Management Systems

FELICE RUBINO Production and Quality Management Systems

0612600022
DEPARTMENT OF INDUSTRIAL ENGINEERING
EQF6
INDUSTRIAL ENGINEERING AND MANAGEMENT
2024/2025

OBBLIGATORIO
YEAR OF COURSE 2
YEAR OF DIDACTIC SYSTEM 2018
SPRING SEMESTER
CFUHOURSACTIVITY
990LESSONS
FELICE RUBINO T Curriculum
-
Objectives
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 BY PLASTIC DEFORMATION AND CHIP REMOVAL MACHINING, AS WELL AS THE GUIDELINES FOR DESCRIBING, EVALUATING AND INTERPRETING VARIABILITY IN EXPERIMENTAL AND INDUSTRIAL SETTINGS.

KNOWLEDGE AND UNDERSTANDING:
AT THE END OF THE COURSE THE STUDENT KNOWS:
- SUBTRACTIVE MACHINING PROCESSES: CUTTING MECHANISM, TURNING, MILLING, HOLE MACHINING, STRAIGHT-LINE CUTTING, GRINDING;
- MACHINING PROCESSES FOR PLASTIC DEFORMATION: FORGING AND STAMPING, ROLLING, DRAWING, EXTRUSION; SHEET METAL PROCESSING
- STATISTICAL ANALYSIS OF QUALITY MANAGEMENT PROCESSES AND METHODS
APPLIED KNOWLEDGE AND UNDERSTANDING:
AT THE END OF THE COURSE THE STUDENT IS ABLE TO:
CHOOSE THE MOST APPROPRIATE MACHINING PROCESS TO CREATE SURFACES THAT MEET THE SPECIFICATIONS IMPOSED BY THE DRAWING
CALCULATE FORCE AND POWER REQUIRED FOR MACHINING AND VERIFY THE FEASIBILITY OF MACHINING
SELECT TOOLS AND FIXTURES TO PERFORM A SPECIFIC JOB
- MONITOR THE PERFORMANCE OF A PROCESS AND THE QUALITY OF THE PRODUCTS.
MAKING JUDGEMENTS
BE ABLE TO IDENTIFY THE MOST APPROPRIATE PROCESSES TO CREATE SURFACES THAT MEET THE SPECIFICATIONS IMPOSED BY THE DRAWING AND THE MOST APPROPRIATE TOOLS FOR QUALITY CONTROL.

COMMUNICATION SKILLS
TO BE ABLE TO DESCRIBE, IN WRITTEN FORM, IN A CLEAR AND CONCISE WAY AND TO EXPLAIN ORALLY WITH PROPRIETY OF LANGUAGE THE OBJECTIVES, THE PROCEDURE AND THE RESULTS OF THE ELABORATIONS CARRIED OUT.

LEARNING SKILLS:
BE ABLE TO APPLY THE ACQUIRED KNOWLEDGE TO CONTEXTS DIFFERENT FROM THOSE PRESENTED DURING THE COURSE, AND 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.

CUTTING MECHANISMS (THEORY HOURS 10, EXERCITATIVE HOURS 3)
THERMOMECHANICAL ASPECTS OF CHIP FORMATION, ERNST-MERCHANT MODEL, LUBRICANTS-COOLING FLUIDS, TOOL GEOMETRY AND COMPOSITION, CUTTING TOOL WEAR.

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, SHEET METAL PROCESSING.

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, VARIABLES CONTROL CHART, ATTRIBUTES CONTROL CHART.
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 THREE NUMERICAL EXERCISES AIMED AT ASSESSING THE PLANNING SKILLS OF THE PROCESSES ANALYZED DURING THE COURSE AND ONE OPEN THEORETICAL QUESTION. 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 PROVIDED BY THE TEACHER
- M. GIUSTI, F. SANTOCHI - TECNOLOGIA MECCANICA E STUDI DI FABBRICAZIONE ED. AMBROSIANA
F. GABRIELLI, R. IPPOLITO, F. MICARI: ANALISI E TECNOLOGIA DELLE LAVORAZIONI MECCANICHE, MC GRAW- HILL 2012
- D.C. MONTGOMERY: CONTROLLO STATISTICO DELLA QUALITÀ, MCGRAW-HILL, MILANO, 2012
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