Courses » Design for Quality, Manufacturing and Assembly

Design for Quality, Manufacturing and Assembly


In the context of product design, it is very important to appreciate the limitations of a design from manufacturing and assembly perspective and to produce high quality products at low cost. This course will introduce methods that can provide guidance to design teams in simplifying product structure to reduce manufacturing and assembly costs, quantify improvements and how robust design concepts can be used for ensuring quality. This course aims at introducing the need to account for variability, mathematically represent it, formulate it and control it. Concepts such as quality, robustness, six sigma and orthogonal array will be discussed. 

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Final Exam (in-person, invigilated, currently conducted in India) is mandatory for Certification and has INR Rs. 1100 as exam fee.

INTENDED AUDIENCE: Final year UG students, Masters and PhD Students, Engineering practitioners in industry


UG/PG: UG and PG

PREREQUISITES: Basic knowledge on manufacturing such as manufacturing techniques and probability

INDUSTRY SUPPORT:Fiat Chrysler Automotive, Daimler India, Cyient, Saint Gobain 


Prof. Saravana kumar is interested in development of representational and computational tools for virtual and physical prototyping applied to arrive at solutions to design problems. Some of the specific research areas include CAD and 3D data acquisition technologies: geometrical modelling schemes, X-ray tomography, photogrammetry and image-based modelling systems, and rapid prototyping

Prof. Palaniappan Ramu’s research interest revolves around optimization and treating uncertainties in product and process design to obtain reliable, robust and quality designs. Most of his work is focused on reduction of computer or physical experiments, building better metamodels, intelligently explore design space and enable better predictions and optimal designs under uncertainties. 


Week 1  : Introduction, course expected outcomes, discussion on quality
Week 2  : Measuring quality: Quality loss function. Discussion on robustness, six sigma concepts 
Week 3  : Quantifying robustness: Signal to Noise Ratio, problem formulation using SNR. Design of experiment discussions
Week 4  : Orthogonal array, linear graphs, triangular tables, finding optimum combinations. Case studies
Week 5  : Design for Manufacturing: over the wall design, most influential phase in design, best practices in injection molding and Design for additive manufacturing
Week 6  : Do’s and dont’s in manual assembly, assembly time estimation, design for robotic assembly considerations
Week 7  : Design for Assembly: Boothroyd Dewhurst method, theoretical minimum number of parts, Xerox producibility index (XPI) method
Week 8  : Usage of DFMA software and Design for sustainability


1.Madhav Phadke, “Quality Engineering Using Robust Design”, Prentice Hall, NJ, USA
2.Phillip J. Ross, Taguchi Techniques for Quality Engineering, McGraw-Hill , 1989
3.Geoffrey Boothroyd, Peter Dewhurst, “Product Design for Manufacturing and Assembly”, Winston Knight, Mercel Dekker, 2001
4.Daniel E. Whitney “Mechanical Assemblies” Oxford University Press, 2004

  • The exam is optional for a fee.
  • Date of Exams : October 07 (Sunday)
  • Time of Exams : Morning session 9am to 12 noon; Afternoon session: 2pm to 5pm
  • Exam for this course will be available in both morning & afternoon sessions.
  • Registration url: Announcements will be made when the registration form is open for registrations.
  • The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published.


  • Final score will be calculated as : 25% assignment score + 75% final exam score
  • 25% assignment score is calculated as 25% of average of Best 6 out of 8 assignments.
  • E-Certificate will be given to those who register and write the exam and score greater than or equal to 40% final score. Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Madras.It will be e-verifiable at nptel.ac.in/noc.