FALL SEMESTER
AU-424 DESIGN FOR MANUFACTURING
Design and Manufacturing:
Parts and Assemblies, Products and Machines, Product Family and Platforms, Industrial-Engineering-Production Design, Tolerances.
Theory of Sheet Metal Forming:
Material properties, sheet deformation processes, simplified stamping analysis, simplified analysis of circular shells, cylindrical deep drawing, stretching of circular shells, combined bending and tension of sheets.
Design of Sheet Metal Dies:
Design of Piercing Die, Design of Blanking Die, Design of Shearing Die, Design of Bending Die, Design of Forming Die, Design of Drawing Die, Relative Tooling Cost, Total Relative Part Cost.
Plastic Injection Moulding Technology:
Main properties of plastics, design of injection moulds, types of injection moulds, injection moulding process; filling-packing-cooling stages, different types of injection moulds, Relative Tooling Cost, Total Relative Part Cost.
Design of Moulds:
Design of Moulds for plastic parts, Design of Moulds for rubber Parts, Design of Pressure Die Casting, Fiber Reinforced Plastics (FRP), Resins.
Jigs and Fixtures:
Basic Design principles and Classification Materials for jig and fixture development, Consideration for mounting jigs and fixtures
AU-425 THERMAL MANAGEMENT FOR AUTOMOTIVE
Introduction:
Thermal Management in automotive, Automotive Components/Systems requiring thermal management.
Refrigeration, Air-Conditioning and Heating Systems:
Vapor Compression Refrigeration system, Performance estimation of vapour compression refrigeration systems, Refrigerant and its properties, Psychometric analysis, Air distribution inside cabin, Temperature and humidity control to maintain comfort zone, Heating and cooling load calculation with available usage of software, Effective heating inside cabin, Electrical heating.
Engine Cooling and Waste Heat Utilization:
Engine cooling requirement, Types of engine cooling systems, Automotive liquid- cooling circuit architecture and components, Waste heat recovery systems, Utilization of waste heat for automotive heating and cooling systems.
Battery Thermal Management in Hybrid/Electric Vehicle:
Electric vehicle battery technologies, Battery thermal management using air, liquid, refrigeration, phase change, material and vapour chamber, Energy and exergy analysis of battery thermal management system.
ME-435 OPERATION MANAGEMENT
Industrial Management & Systems:
Introduction to industrial management and administration, System concept, Functions of Management, Managerial decision making, Models as decision aids.
Plant Location:
Factors affecting location, Multiplant location, Location analysis, Plant layout, Types of layout, Material handling consideration in layout, Internal and External balancing, product and process layout analysis, Layout comparison.
Production Planning and Control:
Product design, Pre-production planning, Production control for intermittent and continuous process; MRP (Material Requirements Planning), MRP inputs and outputs, Types of MRP; Job shop scheduling; Machine arrangement problems; Control for maximum profit; Scheduling techniques.
Quality Control:
Sampling risk and economics of sampling; OC (operating characteristic) curve and sampling plan; Average outgoing quality; Sampling methods; Attribute and variable sampling, Concept of control chart, Process Variability; , R, MR, p, np, c and u charts.
Methods Analysis:
Process chart; Man-Material flow charts; Work station flow charts; Man-Machine charts. Motion study; Principles of motion economy; Applications, Simo chart.
Work Measurement:
Stop watch time study procedures, Timing methods, Performance rating, Total normal time, Allowance factors, Continuous production study, Work sampling procedures, Predetermined motion time techniques. Wage incentive plan and job evaluation.
Inventory Control and Forecasting:
Inventory Control, Functions of Inventory, Economic order quality model, its limitations, Economic lot size, Safety stock, Stock out cost, Inventory systems, Inventory system under uncertainty, Quantity discount; Forecasting; Moving average and weight moving average; Capacity Planning.
Project Management:
CPM (Critical Path Method) & PERT (Project Evaluation and Review Technique).
AU-314 VEHICLE DYNAMICS
Introduction to Vehicle Dynamics:
Lumped Mass, Sprung & Unsprung Mass, Aerodynamics, Forces on Vehicle, One-mass and Two mass Approximation.
Forward Vehicle Dynamics:
Determination of centre of mass location of a vehicle, tilting conditions for a vehicle in parking on inclined surfaces, applications of Newton’s 2nd law of motion to vehicle acceleration, finding failure conditions for vehicles during acceleration, determination of centre of mass location on banked road conditions.
Tire Dynamics:
Effect of speed on rolling friction coefficient of tire, effect of inflation pressure and load on the rolling friction coefficient, effect of Sideslip Angle on Rolling Resistance, effect of camber angle on Rolling Resistance, longitudinal, lateral and camber force effect on tire.
Steering Dynamics:
Kinematic steering, vehicle with more than two axles, vehicle with trailer, space requirement for a vehicle, four wheel steering.
Driveline Dynamics:
Engine dynamics, driveline and efficiency, gearbox and clutch dynamics, gearbox design, geometric ratio, progressive ratio gearbox design.
Suspension Dynamics:
Roll-centre and roll axis, camber variation of double A-arm suspension system, car tire relative angles and their effect on suspension dynamics.
Applied Dynamics:
Four bar linkage, slider-crank dynamics, instant centre of rotation, universal joint dynamics.
SPRING SEMESTER
AU-438 ELECTRIC & HYBRID ELECTRIC VEHICLES
Architecture / Configuration of Electric and Hybrid Electric Vehicle
Economic and Environmental Impact of EVs & HEVs, Configurations of EVs, Architecture of Hybrid Electric Vehicle Drive Trains, Analysis and design principles of Series HEV and Parallel HEV Drive Train, Power Flow in HEVs, Analysis of Series and Parallel HEV Drive Train.
Electric Propulsion Systems (Traction Motors)
Types of traction motors for EVs / HEVs, Induction Motor Construction and Classification, Induction Motor Drives, Control and Applications in EVs/HEVs, Permanent Magnet Motor Configuration and Optimization, Permanent Magnet Motor Drives, Control and Applications in EVs/HEVs, Role of Switch Reluctance Motors and present issues.
Converters for EVs / HEVs
AC-DC rectifier, DC-AC Inverter for EV and HEV Applications, Buck (Step-down) converter, Boost (Step-up) Converter, Buck-Boost Converter.
Energy Storage System
Architecture of the electrical energy management system: Battery System, High speed Flywheels, Ultra-capacitors, Energy Storage System, Types of Batteries and performance parameters, Charging and Discharging rate calculations, Battery technology for automotive applications.
AU-430 QUALITY MANAGEMENT & RELIABILITY
Introduction to Quality:
Definition and dimensions of quality, Quality control and Assurance, Cost of quality and its related indices, Vision, Mission and Quality Policy, Customer satisfaction and feedback system.
Statistical Process Control:
Controls charts for mean standard deviation and proportion defective, process capability indices, Acceptance sampling, single and multiple sampling, introduction to six-sigma, DMAIC.
Japanese Production System:
Principles and operating strategies, Takt-time, Quality circle, Kanban 5S, Pokayoka,
Cost concept, 3M (Mura, Muri, Muda).
TQM:
Pareto, Flow chart, Cause and Effect diagram, Failure Mode & Effect Analysis (FMEA), Improvement Strategies, Lean concepts and waste reduction methods, PDCA Cycle, KAIZEN, Quality Function Deployment (QFD), Introduction to Quality Management System (ISO).
Reliability:
Definition, failure rate functions, Hazard functions, Reliability function, Weibull distribution, Bath-tub curve, series parallel reliability network, MTBF, MTTR, Availability, Product liability and warranty.
AU-428 AUTOMOTIVE HEALTH SAFETY & ENVIRONMENT
Introduction of Health and Safety:
Industrial Safety: introduction objectives of Safety, Importance of Safety in an industry, Industrial accidents, Effects of accidents, Types of accidents incidence of fire. Fire prevention and control.
Techniques of Safety Management:
Principles of accident prevention, hazard analysis. Legal, humanitarian and economic reason for action. Safety inspection procedures. Safety training, First aid and emergency procedures.
Environment and Health:
Introduction: importance of clean environment, Scale of Environmental Pollution. Environmental Act. Health and Safety Act.
Safety and Environmental Standards:
ISO Standards (ISO 14000), Total Safety Management (TSM), OSHA Standard, Emission Standards and Regulations (EURO compliance), Environmental Protection Agency (EPA) standards, Overview of Pakistan Motor Vehicle Act, Highway Safety Standards.
Vehicle Safety:
Concepts and Principles of Vehicle Safety, Adaptive Cruise Control (ACC), Traction Control System (TCS), Electronic Stability Program (ESP), Braking Systems and Antilock Braking systems (ABS).
Occupant Safety:
Restraint Systems(Seat Belts, Airbags), Head Restraints, Child Restraint System, Multipoint Restraint Systems, Passive Restraints, Occupant Sensing Methodologies.
AU-499 AUTOMOTIVE ENGINEERING PROJECT
A final year design project (FYDP) is the most important activity which requires the students to apply their theoretical and practical knowledge towards the end of an engineering program.
FYDP is a compulsory requirement and involves a range of activities including:
• Literature review
• Problem analysis
• Design, modelling and simulation using various methods and means including hardware and software tools to demonstrate a functional concept including rapid prototyping, where applicable
Design project will encompass complex engineering problems and design of systems, components or processes integrating core areas with appropriate consideration for public health and safety
FYDP will include cultural, societal, and environmental considerations encompassing SDGs.
FYDP should lead to an integration of the knowledge and practical skills as required in the Program Learning Outcomes (PLOs)
MG-481 ENTREPRENEURSHIP
Understanding the Entrepreneurship Mind-set
• The revolution impact of Entrepreneurship
• The individual Entrepreneurship Mind-set
• Corporate Entrepreneurship Mind-set
• The Social and Ethical perspectives of Entrepreneurship
Launching Entrepreneurship Ventures
• Creativity and innovations
• Methods to initiate ventures
• Legal challenges in Entrepreneurship
• The search for Entrepreneurship
Formulation of Entrepreneurship
• The assessment of function with opportunities
• The marketing aspects of new ventures
• Financial statements in new ventures
• Business plan preparation for new ventures
Strategies perspectives in Entrepreneurship
• Strategies growth in Entrepreneurship
• Valuation challenges in Entrepreneurship
• Final harvest of a new venture
ELECTIVE COURSES:
TECHNICAL ELECTIVE – I
AU-422 AUTOMOTIVE TRANSMISSION & DRIVES
Over view:
Overview of vehicle transmission/drive train components and layouts.
Clutch:
Design calculations; engagement time; performance during engagement and thermal properties; synchromesh design and gear engagement calculations.
Manual Transmissions:
Theory and power flow of standard transmissions/transaxles; gearbox; synchronizers; synchromesh design and gear engagement calculations; lubrication of gears.
Automatic and Semi-Automatic Transmissions:
Hydrokinetic transmissions: fluid coupling and torque converter; epicyclical gears; compounding; performance characteristics; matching; overview of continuously variable transmission (CVT) designs. Comparison of performance attributes for the different types of transmissions.
Power Train Matching:
Combined engine, transmission and vehicle characteristics, gear ratio selection criteria and calculations, effect of undergearing / overgearing on vehicle performance and fuel economy, impact of engine type and characteristics. Universal and C-V joints; drive shafts; axles and differentials. Fundamentals of power transmission for belts and chains; linkages; cams; functions and principles of operation and applications of governors and gyroscopes.
Different Systems:
Hydraulic, electro-hydraulic and pneumatic systems: automotive steering, brakes, windows operation and other special applications.
AU-429 VEHICLE DEVELOPMENT
Vehicle Development Projects:
Design Level, Design Content, Innovation Level, Options and Country Versions, Platforms and Model Lines, Product Evolution Process (PEP), Vehicle Project Management, Product Strategy.
Phases of the Product Evolution Process:
Initial Phase, Technical Feasibility, Economic Feasibility, Concept Phase, Vehicle Concept Design, Target Agreement, Series Development Phase, Component Design, Complete Vehicle Integration, Prototype Build, Launch Preparation, Series Support and Further Development, Design to Ramp Up Production.
Management of Vehicle Development:
Target Management, Complete Vehicle Requirements, Design Problem Management, Release and Change Management, Quality Management, Definition of Quality, Pre-delivery (Internal) Quality Assessment, Post-delivery (External) Quality Assessment, Quality Management Systems, Quality Costs.
Vehicle Characteristics:
Registrability, Total Vehicle Costs and Cost of Ownership, Design Appeal, Cabin Comfort, Infotainment, Agility, Passive Safety, Theft Deterrence, Reliability, Sustainability.
AU-435 AUTOMOTIVE VENDOR DEVELOPMENT
Overview of Vendor Development:
Classification of Vendors or Suppliers, Tier 1, Tier2 etc., Supplier and Vendor Market, local and global scenario, Vendor-OEM synergy.
Supplier Development Programs:
Introduction, Capability Development Process Overview, Technical & Management Aspects, Human Resource Development, Homologation with industry standards.
Supplier Qualification Process:
Evaluation Matrix, Attributes & Assessment Criteria, and Certification Process.
Performance Monitoring:
Factors for performance analysis, Performance scoring system, Performance feedback to supplier, compliance to standards.
Buyer-Supplier Relationship Management:
Communication, Training Programs, Acquiring and sharing best practices and standardization.
AU-436 AUTOMOTIVE STRUCTURE DESIGN
Body structural requirements:
Vehicle loads and their estimation, terminology, torsion and bending stiffness, Stiffness optimization, fatigue analysis, body concept for design in automotive structures; design criteria; basic assumptions regarding structural element interactions and stress distributions; standard loading cases.
Body structural elements:
Analysis of trusses by method of joints, analysis of frames, Types of automotive structures, Body-On Chassis, Ladder Frame, Grillage Frame, Backbone, Monocoque, Space frame, unitary body structures.
Production of automotive structures:
Design aspect and design procedures for vehicle structures, Manufacturing and assembly techniques used in production of the vehicle structures, Surface engineering, diffusion techniques, deposition methods, high and low energy beam; surface treatments.
Body structural Design:
Design for body bending, Design for body torsion, Design for crashworthiness, Design for vehicle and styling integration, Design for vibration, Design and analysis of body sub-assemblies and model variants, sizing of sections and joints.
Vehicle Mass and Crashworthiness:
Engineering Materials and their incorporation into vehicle design, Material property charts Material selection, Crashworthiness and its influence on vehicle design. Fracture strength and crack propagation: Their effect on safe life and flaw tolerant design.
TECHNICAL ELECTIVE – II
AU-417 AUTOMOTIVE PAINTS AND COATINGS
Introduction:
Paints and coatings, Classification of Paints and coatings, Scope of Automotive Paint Industry, Current Paint Manufacturers.
Automotive Painting Processes:
General Painting Process, Pretreatment, Sand and Shot blasting Sequence of Treatment, Degreasing, Activation, Zinc Phosphating, Baking Oven, Passivation, Pre-Treatment of multi-metal car bodies, Pre-Treatment of Plastic Parts, Car Body Pre Treatment Lines, Primer Surface, Sealing and Underbody Protection, Top Coats and Clear Coats.A
Electro Deposition (ED) Coatings:
Types of ED coatings. Difference between Anodic and Cathodic ED Paint Process. Layout of an ED Paint Shop. Design of Car ED Lines. General Functions and Equipment of an Electro-coat Line.
Paint Shop Design and Quality Aspects:
Typical Layout of an Automotive Paint Shop, The designing of an Automotive Paint Shop, Design capacity of Paint Shop, Quality Aspects, measurement of Paint thickness, measurements of basic paint properties (Viscosity, scratch resistance, stone chip resistance), Leak and shower test.
Paint Defects during Applications and their Prevention:
Paint Defects, Why defect appears and How to repair the defects, Prevention of paint defects.
AU-442 FEM & FVM: APPLICATIONS IN AUTOMOTIVE ENGINEERING
Computational Modelling – Basic Concept:
Introduction, Physical problems in Engineering; Computational Modelling Using FEM; Simulation visualization.
Review of Mechanics of Solids and Structures:
Equations for beams; Truss members; Two-dimensional solids; Three-dimensional solids.
Fundamentals of Finite Element Method:
Introduction; Strong and weak forms; Hamilton’s principle; FEM procedure; Static analysis; FEM for trusses, beams, two-dimensional solids, and three-dimensional solids.
Numerical Integration Techniques:
Techniques for solving linear (matrix) equations; direct method, iterative methods; Techniques for solving non-linear problems.
Finite Element Modelling Technique:
Introduction; CPU time estimation; Geometry modeling; Meshing, mesh compatibility; Use of symmetry; Modeling offsets, supports, joints; Contact formulations.
Special Topics in FEM:
Crash Analysis; Noise-vibration-harshness (NVH) analysis.
Introduction to Computational Fluid Dynamics (CFD):
Governing equations; Discretisation with help of Finite Volume Method; simple one dimensional flow problem
AU-434 AUTOMOTIVE SERVICE & DEALERSHIP
Overview of Automotive Service:
Role of Service, Dealer and Dealer Staff (Service Manager, workshop controller, service advisor, maintenance technician, diagnostic technicians, body & paint shop staff), standard automotive workshop areas (mechanical shop, body & paint shop, service station, auto parts warehouse, reception, parking area, AC repair pit, training area, mess, engine overall shop, library etc.), 3S Dealership.
Service Operation Management:
Standard Service Transaction, Customer Appointments, Work Control, Customer Reception, Reception Diagnosis, Repair Orders, Quality Control, Active Delivery, Follow-up Calls, Customer Database, workshop Control, Vehicle Security and Immobilizer Systems, use of Workshop Manuals, Wiring Diagrams, Understanding the Periodic Maintenance Procedures as per Manufacturer’s standards, Service Fast Track Processes and work Flow Management.
Development of Communication and Interpersonal Skills:
Service Advisor's Role, Interpersonal Skills in Service Transactions, Positive First Impression, active listening and clear explanation, Complaint Handling, Business Strategies in after sales Industry, Manufacturer’s Trainings for after sales Staff, Time Management, Technical Report, Service Bulletin, Warranty Reports.
Dealership Equipment Workshop and Compliance:
Common tools, special service tools (SST), types of lifts, workshop equipment’s, standard & quality control, certifications, Layout, health & safety requirements, flooring, Equipment Installation and Calibration.
MANAGEMENT ELECTIVES
MG-483 Supply Chain Management
• Introduction to Supply Chain management, Historical perspective of Supply Chain, Objective and Importance of Supply chain Decisions, Process views of Supply Chain.
• Financial measures of Supply Chain, Drivers of Supply Chain performance
• Supply Chain designing, Network designing in supply chain, Global supply chain networks
• Coordination in Supply chain , Bullwhip effect
• Transportation in Supply chain
SOCIAL SCIENCE ELECTIVES
HS-228 SOCIOLOGY & DEVELOPMENT
Definition, nature, scope, and importance of Sociology; Study of social life; exploring the global village; Sociology as a science; relationship with other social sciences; The sociological imagination; development of Sociology, pioneers of Sociology; Historical Development of Sociology; Society and Community, Social interaction processes;
Social Groups & Social Institution: Definition, functions and types of social groups; Structure and functions of social institutions; Inter-relationships among various social institutions; Culture and Related Concepts: Definition, types and elements of culture; Role of culture in organization; Mid-term Socialization and personality; Social Stratification: Factors of Social
Stratification; Approaches to study social stratification; Power, prestige, and authority; Social mobility; Migration; Social and cultural change: Definition of social change; Dynamics of social change; Impact of globalization on society and culture; Resistance to change; Sociology & Development: Significant sociological questions; Measures of inequality and development; Modernization theory and explanation of under-development; Education, industrial & development.
HS-230 ORGANIZATIONAL BEHAVIOUR
Introduction to Organizational Behavior:
Foundations of OB: Management functions, roles, and skills; Effective versus successful managerial activities; Replacing intuition with systematic study; Exploring OB challenges and opportunities facing globalization; OB Model
Foundations of Individual Behavior:
Biographical traits and ability; Personality; Perceptions and individual decision making; Values, attitudes and job satisfaction; Motivation - basic concepts and applications; Work stress
Foundations of Group Behavior:
Group in OB: Defining and classifying groups; Stages of group development, work group behavior; Dynamics of groups; Understanding work teams; Leadership: basic approaches and contemporary issues; Conflict & negotiation
Foundations of Organizational Structure:
Organizational structure and design; Organizational culture; Organization change and development.
HS-321 LOGIC & CRITICAL THINKING
Introduction to the Study of Logic:
Definitions, Terminology, Concepts of Logic & Critical Thinking. Scope and Impact. Why study logic and critical Thinking- Intellectual Moral Virtues. Basic Principles of Logic: Structure of an Argument, Valid/Invalid versus Sound/Unsound argumentation, Deduction versus Induction, Three classical Aristotelian Laws of Logic, Principle of sufficient reason; Deductive reasoning- Syllogism, Linear ordering, Tree diagrams; and Inductive Reasoning - Valid and invalid arguments. Fallacies.
Thinking:
Thinking process while working towards goals, making decisions and analyzing issues. Thinking tools and their applications. Simple tools (e.g. facts and opinions, verification of sources and credibility of authorities etc.); Theoretical Frames (e.g. Scientific Methods/Approach etc.) and Formal Tool (e.g. PMI, STAR method, Shewhart Cycle, Socratic Method, RW & D, Quality Thinking- Paul & Elder Framework etc.)
Thinking Critically:
Critical Thinking standards: clarity, precision, accuracy, relevance, consistency, logical correctness, completeness, and fairness. Barriers to Critical Thinking: Egocentrism, sociocentrism, unwarranted assumptions and stereotypes, relativist thinking, and wishful thinking. Critical Thinking Approach: Thinking actively, using questions for probing situations, evaluating our evidences and their types, Impartial versus adversarial critical thinking.
Critical Thinking in Everyday Life:
Problem Solving: Defining a problem, attitudes towards problems-general and desired, Problem solving process, case studies on problem analysis Perceiving: Defining perception and its prominence in succeeding through life, Critical thinking and perception, Evaluating the differences in perception (through tests, optical illusions etc.), Perception processes, Factors governing perception, Difficulties / errors in perception process (perceptual errors). Believing and Knowing: Believing versus knowing, values and their types, identifying one’s values in life; defining and classifying beliefs, Accuracy scale for evaluating thoughts, Thinking patterns and organizing concepts, Ways to Organize Thoughts, Types of causal relationships – causal chains, contributory and interactive causes.