Production and Industrial Engineering (PI)

Candidates preparing for Graduate Aptitude Test in Engineering (GATE) examination can choose their subject from a total of 29 subject papers. Provided below is the detailed syllabus for Production and Industrial Engineering (Code: PI). The paper comprises 7 sections with various sub-topics under each section.  

Section 1: Engineering Mathematics 

• Linear Algebra: Matrix algebra, Eigenvalues and Eigenvectors, Systems of linear equations
• Calculus: Functions of single variable, Limit, continuity and differentiability, Mean value theorems, Evaluation of definite and improper integrals, Partial derivatives, Total derivative, Maxima and minima, Gradient, Divergence and Curl, Vector identities, Directional derivatives; Line, Surface and Volume integrals; Stokes, Gauss and Green’s theorems.
• Differential Equations: First order equations (linear and nonlinear), Cauchy’s and Euler’s equations, Initial and boundary value problems, Higher order linear differential equations with constant coefficients, Laplace transforms 
• Complex Variables:  Taylor series, Analytic functions, Cauchy’s integral theorem
• Probability and Statistics: Conditional probability, Definitions of probability and sampling theorems, Mean, median, mode and standard deviation, Random variables, Linear regression, Poisson, normal, binomial and exponential distributions 

• Numerical Methods: Integration by trapezoidal and Simpson’s rules, Numerical solutions of linear and nonlinear algebraic equations, Single and multi-step methods for differential equations 

Section 2: General Engineering 

• Engineering Materials: Stress-strain behavior of metals and alloys, Heat treatment of metals and alloys and its influence on mechanical properties, Structure, physical and mechanical properties, and applications of common engineering materials (metals and alloys, semiconductors, ceramics, polymers, and composites – metal, polymer and ceramic based); Iron-carbon equilibrium phase diagram

• Applied Mechanics: Engineering mechanics – equivalent force systems, free body concepts, equations of equilibrium; Trusses; Strength of materials – stress, strain and their relationship; Failure theories; Mohr’s circle (stress); Deflection of beams, bending and shear stresses; Euler’s theory of columns; Thick and thin cylinders; Torsion.

• Theory of Machines and Design: Analysis of planar mechanisms, cams and followers, Friction and lubrication, Governors and flywheels, Interference/shrink fit joints, Design of bolted, riveted and welded joints, Design of shafts, keys, couplings, spur gears, belt drives, brakes and clutches, Pressure vessels 

• Thermal and Fluids Engineering:  Dimensional analysis, Fluid mechanics – fluid statics, Bernoulli’s equation, flow through pipes, laminar and turbulent flows, equations of continuity and momentum, capillary action, Thermodynamics – zeroth, first and second laws of thermodynamics, thermodynamic systems and processes, calculation of work and heat for systems and control volumes, Heat transfer – basic applications of conduction, convection and radiation; Air standard cycles 

Section 3: Manufacturing Processes I 

• Casting: Types of casting processes and applications; Sand casting: patterns – types, materials and allowances; molds and cores–materials, making, and testing; design of gating system and riser; casting techniques of cast iron, steels, and nonferrous metals and alloys; analysis of solidification and microstructure development; Other casting techniques: Pressure die casting, Centrifugal casting, Investment casting, Shell mold casting; Casting defects and their inspection by non-destructive testing
• Metal Forming: Stress-strain relations in elastic and plastic deformation; von Mises and Tresca yield criteria, Concept of flow stress; Hot, warm and cold working; Bulk forming processes – forging, rolling, extrusion and wire drawing; Sheet metal working processes – blanking, punching, bending, stretch forming, spinning and deep drawing; Ideal work and slab analysis; Defects in metal working and their causes

• Joining of Materials: Classification of joining processes; Principles of fusion welding processes using different heat sources (flame, arc, resistance, laser, electron beam), Heat transfer and associated losses; Arc welding processes – SMAW, GMAW, GTAW, plasma arc, submerged arc welding processes; Principles of solid state welding processes – friction welding, friction stir welding, ultrasonic welding; Welding defects – causes and inspection; Principles of adhesive joining, brazing and soldering processes
• Powder Processing: Production of metal/ceramic powders, Cold and hot isostatic pressing, Compaction and sintering of metals and ceramic powders

• Polymers and Composites:  Polymer processing – injection, compression and blow molding, extrusion, calendaring and thermoforming; Molding of composites

Section 4: Manufacturing Processes II 

• Machining:  Orthogonal and oblique machining, Single point cutting tool and tool signature, Chip formation, cutting forces, Merchant’s analysis, Specific cutting energy and power; Machining parameters and material removal rate; tool materials, Tool wear and tool life; Thermal aspects of machining, cutting fluids, machinability; Economics of machining; Machining processes – turning, taper turning, thread cutting, drilling, boring, milling, gear cutting, thread production; Finishing processes – grinding, honing, lapping and superfinishing
• Machine Tools: Lathe, milling, drilling and shaping machines – construction and kinematics; Jigs and fixtures – principles, applications, and design
• Advanced Manufacturing:  Principles and applications of USM, AJM, WJM, AWJM, EDM and Wire EDM, LBM, EBM, PAM, CHM, ECM, Additive manufacturing techniques, Effect of process parameters on material removal rate, surface roughness and power consumption 

• Computer Integrated Manufacturing:  Basic concepts of CAD and CAM, Geometric modeling, CNC; Industrial Robots – configurations, drives and controls; Automation in Manufacturing; Cellular manufacturing and FMS – Group Technology, CAPP 

Section 5: Quality and Reliability 

• Metrology and Inspection:  Accuracy and precision; Types of errors; Limits, fits and tolerances; Gauge design, Interchangeability, Selective assembly; Linear, angular, and form measurements (straightness, flatness, roundness, runout and cylindricity) by mechanical and optical methods; Inspection of screw threads and gears; Surface roughness measurement by contact and non-contact methods

• Quality Management:  Quality – concept and costs; Statistical quality control – process capability analysis, control charts for variables and attributes and acceptance sampling; Six sigma; Total quality management; Quality assurance and certification – ISO 9000, ISO14000
• Reliability and Maintenance: Reliability, availability and maintainability, Determination of MTBF and MTTR, Reliability models, Distribution of failure and repair times, Total productive maintenance, Determination of system reliability, Preventive and predictive maintenance and replacement

 Section 6: Industrial Engineering 

• Product Design and Development:  Principles of product design, tolerance design; Quality and cost considerations; Product life cycle; Standardization, simplification, diversification; Value engineering and analysis; Concurrent engineering; Design for “X”
• Work System Design: Taylor’s scientific management, Gilbreths’s contributions; Job evaluation and merit rating; Method study, Micro-motion study, Principles of motion economy; Productivity – concepts and measurements; Work measurement – time study, Work sampling, Standard data, PMTS; Ergonomics

• Facility Design:  Materials handling systems, Facility location factors and evaluation of alternate locations, Computer aided layout design techniques, Types of plant layout and their evaluation, Assembly line balancing

Section 7: Operations research and Operations management 

• Operation Research: Linear programming – problem formulation, simplex method, duality and sensitivity analysis; Transportation and assignment models; Integer programming; Constrained and unconstrained nonlinear optimization; Markovian queuing models; Simulation – manufacturing applications
• Engineering Economy and Costing: Elementary cost accounting and methods of depreciation; Techniques for evaluation of capital investments; Financial statements; Break-even analysis; Activity based costing 
• Production control: Forecasting techniques – causal and time series models, moving average, exponential smoothing, trend and seasonality; Aggregate production planning; Master production scheduling; MRP, MRP-II and ERP; Routing, scheduling and priority dispatching; Push and pull production systems, concepts of Lean and JIT manufacturing systems; Logistics, distribution, and supply chain management; Inventory – functions, costs, classifications, deterministic inventory models, quantity discount; Perpetual and periodic inventory control systems
• Project management:  Scheduling techniques – Gantt chart, CPM, PERT and GERT