Design for Manufacturing
Spring 2010

ICON, Moodle

Syllabus quick links: Course Description, Learning Objectives, Texts, Basis of Grade

Course Information

Days & Times: Monday, Wednesday, and Friday, 1:30 PM - 2:20PM
Labs: Thursday, 10:30AM, 11:30AM, 12:30PM, 1:30PM or 2:30PM
Location: 140 SH (Shaeffer Hall)
Credits: 3 hours
Prerequisites: 057:015 - Materials Science
Instructor: Dr. Richard Jerz
Contact Information:
  Phone: (563) 333-6183
  Office: 1139SC
Office Hours: MW: 12:00PM-1:30PM, 2:30PM-3:30PM. Others by appointment

Teaching Assistants

Mr. Matias Perret (photo), Office G405,
Office Hours: Tuesdays, 11:00AM-2:00PM. Others by appointment.
Phone:335 5549

Mr. Brian Johns (photo),, Office G405,
Office Hours: Wednesdays, 11:30AM-12:30PM and 2:30PM-4:30PM. Others by appointment.
Phone: 335 5549

Mr. Howard Chen (photo),, Office G405,
Office Hours: Wednesdays, 12:30PM-1:30PM and Fridays, 11:30AM-1:30PM. Others by appointment.
Phone: 335-5549

Anoop P Verma (photo),, Office G405,
Office Hours: Mondays, 11:30AM-1:30PM and 2:30PM-3:30PM. Others by appointment.
Phone: 335-5549

Course Description

Fundamentals of engineering product design, engineering graphics, and manufacturing processes; computer-aided design using Pro/ENGINEER for CAD and CAM; typical industrial processes, including casting, welding, machining, forming; laboratory exercises and projects.

Learning Objectives

  • Students will understand the basics of manufacturing processes including casting, forming, machining, assembly, surface treatment and plastic processing.
  • Students will develop the ability to use computer-aided design (CAD) software to design and create part models and assemblies with the opportunity to demonstrate this ability through hands-on training.
  • Students will develop and understanding of computer-aided manufacturing (CAM) and CAD/CAM technologies, and have the opportunity to implement CAD/CAM through hands-on practice
  • Students will develop an understanding of engineering graphics principles, and the ability to create engineering drawings using CAD software and to interpret engineering drawings.
  • Students will develop an in-depth understanding of the forces associated with machining processes and how to derive machine tool power requirements.
  • Students will develop the ability to determine the sequence of operations necessary to produce a part and understand how to estimate the operation cost.
  • Students will develop an understanding of the relationship between customer desires, project materials, product design, and manufacturing process selection.


Manufacturing Engineering and Technology, S. Kalpakjian and S.R. Schmid, 6th Edition, Prentice Hall, Upper Saddle River, NJ, Copyright 2009. ISBN-10: 0136081681.

Pro/Engineer Wildfire4.0 Tutorial, Roger Toogood and Jack Zecher, SDC Publications, 2006. ISBN-10: 978-1-58503-415-4 (This is the red textbook).

Additional Course Resources

Turning Technologies - ResponseCard RF can be purchased at the bookstore for a onetime fee of $37.35 and can be used in multiple class.

You will need an account on the college's Computer Support Systems (CSS) infrastructure. If you do not already have an account, see for instructions.

Additional readings may be provided by the instructor. This will almost always be available on this course website.

Basis of Grade

Class attendance and participation 10%
Homework/Labs/ProE 30%
Exams 45%
Project 15%

>= 99: A+, 94-98: A, 90-93: A-, 87 - 89: B+, 83 - 86: B, 80-82: B-, 77 - 79: C+, 73 - 76: C, 70 - 72: C-, 67-69: D+, 63-66: D, 60-62: D-, below 60: F.

As the semester progresses, you will be informed about your assignment grades.

You are reminded about the College policy about academic misconduct, and plagiarism at

This course is given by the College of Engineering. This means that class policies on matters such as requirements, grading, and sanctions for academic dishonesty are governed by the College of Engineering. Students wishing to add or drop this course after the official deadline must receive the approval of the Dean of the College of Engineering. Details of the University policy of cross enrollments may be found at:

Participation and Attendance: Attendance is very important. Please feel free to ask questions when you don't understand something that is presented in the lecture or in the lab section. Further, more material will be covered in lecture than is simply "in the book." You are responsible for all reading and all material presented in lecture. In class, "clickers" will be used to allow you to participate. You get points for participation. If you are not in class, or if you do not click, you do not get participation points.

Homework and ProE Assignments: Reading assignments are provided for each week on the Resouces link. It is always best to read the material before lecture so that you can get the most out of the lectures. Most reading assignments are accompanied by a homework assignment. Many (but not all) assignments are completed online, and you have three attempts to do well. Homework is always due on Wednesdays.

ProE assignments will also be due approximately each week. For Pro/E, you are expected to work through the textbook chapters on your own. The textbook presents Pro/E in a step-by-step fashion, which most students enjoy. Visit with the TA's if you are ever having problems. ProE assignments are due on Fridays and are dropped into Moodle.

Complete the assignments individually (i.e., put the answers into your own words) although discussion with other students is allowed and encouraged. Students are expected to complete the assignments by the due date which will always be shown on Moodle. Some assignments may have different weights assigned to them to reflect their difficulty. The grade will be based on approach to the problem, effort, and answer quality. If you copy someone else's homework or let someone copy yours, you can expect to get a zero for the entire day's assignment and possibly face more serious disciplinary action. Be a professional; do your own work.

Late homework is not accepted.

Labs: There is a lab every Thursday. These labs are designed to provide reinforcement of design and manufacturing concepts, hands-on experience with some specific manufacturing technologies, and as a way to support the project described below.

Lab Safety: You will be working with hand tools and industrial machines as part of this course. There are a number of situations where your personal safety may be compromised if you do not follow the rules. Because your safety and the safety of the other students is more important than any grade, if you are behaving in an unsafe manner, you may be asked to leave the lab, or in extreme cases, be banned from the lab. Points lost as a result of safety violations. You may lose points as a result of safety violations.

Exams: There will be three examinations, including a ProE exam, a midterm, and a final. Exams are not comprehensive. Please let the instructor know if you cannot make the exam date and time. These exams are difficult and the student is expected to read and study the assignments, attend lectures, and ask questions.

Project: The class also involves a project, which will have a series of deadlines periodically throughout the semester.  The class will be divided into small groups, which will each complete the project. This semester long project challenges you to apply your knowledge to a product design and manufacturing scenario. This is a team project, and you will be assigned to a manufacturing team.