Wednesday, April 29, 2015

Tuesday, April 21, 2015

Design of Work and Development of Personnel in Advanced Manufacturing - 1994 - Salvendy - Book Information

Design of Work and Development of Personnel in Advanced Manufacturing
Gavriel Salvendy
John Wiley & Sons, 16-Mar-1994 - Computers - 578 pages

This important work was designed as a companion volume to Organization and Management of Advanced Manufacturing. Together, these two volumes cover the spectrum of human factors issues relevant to the design, operation, and management of advanced manufacturing technology. Today, as manufacturing enterprises become more and more computerized, it is clear that their economic success will depend, to a large degree, on the symbiosis of social, technical, organizational and management, and ecological design efforts. This book reflects three major trends that have developed in this new era of manufacturing: the rapid spread of manufacturing capabilities worldwide...the emergence of advanced manufacturing technologies...and growing evidence that appropriate changes in traditional management and labor practices and organizational structures are needed. Design of Work and Development of Personnel in Advanced Manufacturing explains the urgent need for explicit philosophical acceptance of the vital importance of human work design and development of human resources in advanced manufacturing. Design of Work and Development of Personnel in Advanced Manufacturing presents a framework of problems, issues, and solutions which are relevant to the design of work and effective development of personnel in advanced manufacturing systems. It addresses problems that are experienced worldwide in the industry. The book covers problems of work design and analysis in advanced manufacturing - specifically such ergonomics design issues as cognitive task requirements, human supervisory control, development of human skill, educational requirements, technical choice from a technological perspective, and the dynamics ofhuman performance variability, including fatigue and boredom effects in automated systems. The book discusses the various problems of personnel development as they arise in the context of computer-aided decision support for human-based activity domains as manufacturing process planning, scheduling, maintenance, reliability, inspection, and product quality. Finally, the book discusses future trends in computer-integrated rather than computer-interfaced manufacturing technology, and related human factors issues. Design of Work and Development of Personnel in Advanced Manufacturing will prove to be invaluable to industrial and production engineers, plant managers, human resource personnel, researchers, and students.

Table of Contents

Partial table of contents:

Job Design (G. Spur, et al.).

Human Supervisory Control (T. Sheridan).

Design of Work and Technology (P. Brodner).

Personnel Selection and Training (J. Hedge, et al.).

Decision Support Systems for Computer-Integrated Manufacturing (G. Evans & M. Gupta).

Sources of Performance Variability (T. Smith, et al.).

Human Factors in Test and Inspection (C. Drury & P. Prabhu).

Managing Human Reliability in Advanced Manufacturing Systems (B. Zimolong & R. Trimpop).

Human Aspects of Indutrial Robotics (W. Karwowski, et al.).

Future Trends in Computer-Integrated Manufacturing (W. He & A. Kusiak).


Maintenance System Industrial Engineering - Online Book

Maintenance system  industrial engineering is the study of resource use in various maintenance activities with a view to increasing the efficiency or eliminating the waste wherever possible. While the maintenance is carried out to keep the machines and equipment in good condition to perform, resources are used the activity. This resource use is carefully investigated by the industrial engineering to identify and remove waste. Industrial engineering succeeded in reducing the cost of many processes designed in the first iteration by the managers up to 50% and hence it is a very important activity in systems design or systems engineering.

Famous example of  manufacturing industrial engineering, is Henry Ford's production system redesign, that reduced the price of the automobile by half. Taylor reduced cost of many manufacturing activities. Gilbreth and Harrigton Emerson also achieved similar cost reduction in construction activity and rail road operations.

In subsequent periods, SMED is a very popular example of industrial engineering. Poka-yoke is another example of industrial engineering innovation.

System Industrial Engineering - System Human Effort Engineering - System Efficiency Engineering

Human Effort Engineering - Techniques

1. Principles of Motion Economy
2. Motion Study
3. Workstation Design
4. Application of Ergonomics and Biomechanics
5. Fatigue Studies
6. Productivity/Safety/Comfort Device Design
7. Standardization of  Methods
8. Operator training
9. Incentive Systems
10. Job Evaluation
11. Learning effect capture
12. Work Measurement


1. Process Analysis
2. Operation Analysis
3. Layout Efficiency Analysis
4. Value engineering
5. Statistical quality control
6. Statistical inventory control and ABC Classification Based Inventory Sytems
7. Six sigma
8. Operations research
9. Variety reduction
10. Standardization
11. Incentive schemes
12. Waste reduction or elimination
13. Activity based management
14. Business process improvement
15. Fatigue analysis and reduction
16. Engineering economy analysis
17. Learning effect capture and continuous improvement (Kaizen, Quality circles and suggestion schemes)
18. Standard costing

Industrial Engineering Techniques Specially Applied in Maintenance IE

Replacement analysis
Group replacement analysis
Total productive maintenance
Spare parts inventory decisions
Spare parts storage
Maintenance activities ergonomics
Maintenance work measurement
Lean Maintenance

What Is Lean Maintenance?

Six Sigma Keys to Lean Maintenance

Six Sigma in Maintenance

Plant maintenance management practices in automobile industries: A retrospective and literature review

Total Productive Maintenance Review and Overall Equipment Effectiveness Measurement
Osama Taisir R.Almeanazel
Department Of Industrial Engineering, Hashemite University, Zarqa, 13115 Jordan

Update on 21 April 2015

VTT operation and maintenance solutions deliver trouble-free, predictable fleet operation. Our smart solutions optimize safe fleet operation and maintenance, and constitute new competitive service business models for your knowledge-intensive services. Thanks to our significant experience and deep knowledge in this area, we are able to optimize the total operating performance of your fleet. We can also minimize your maintenance time with fast failure identification and recovery.

Analysis and Scheduling of Maintenance Operations for a Chain of Gas Stations
Mehmet Savsar
Kuwait University, College of Engineering and Petroleum, P.O. Box 5969, 13060 Safat, Kuwait
Journal of Industrial Engineering
Volume 2013 (2013), Article ID 278546
Received 6 November 2012; Revised 2 February 2013; Accepted 3 February 2013

Analysis on Costs for Aircraft Maintenance
U. PeriyarSelvam, T. Tamilselvan, S. Thilakan and M. Shanmugaraja
Department of Aeronautical Engineering, Park College of Technology,
Karumathampatti, Coimbatore – 641 659.
Advances in Aerospace Science and Applications.
ISSN 2277-3223 Volume 3, Number 3 (2013), pp. 177-182
© Research India Publications


An Assessment of Maintenance Practices and problems in Jordanian Industries
K. K. Tahboub. 2011
Department of Industrial Engineering, Faculty of Engineering and Technology, University of Jordan, Amman, Jordan

Ilyas Mohammed Iyoob, Department of Mechanical Engineering, The University of Texas at Austin,
Austin, Texas, USA
C. Richard Cassady, Department of Industrial Engineering, University of Arkansas,
Fayetteville, Arkansas, USA
Edward A. Pohl, Department of Industrial Engineering, University of Arkansas, Fayetteville,
Arkansas, USA

MSc thesis
Department of Mechanical and Industrial Engineering
University of Iceland


Maintenance and Industrial Engineering (GIM)
University Technological Degree in Maintenance and Industrial Engineering (GIM),177,261.html

Book Engineering Maintenance - Modern Approach - B.S. Dhillon, 2002

Just-in-time Maintenance, Repair, & Overhaul (Presentation)
Anonymous. IIE Annual Conference. Proceedings (2008): 1-34.

Updated 21 April 2015
First published on 27 September 2012

Productivity and Industrial Engineering (IE) in Battery Manufacturing


14 April 2015
Research published recently in Nature Climate Change Letters shows battery pack costs may in some cases be as low as US$300 per kilowatt-hour today, and could reach US$200 by 2020. The  cost is decreasing at a faster rate.

The battery in a typical mid-range electric car stores around 25 kilowatt hours of energy. The analysis therefore suggests that the cost of electric car batteries may be as low as $7,500 today and is likely to reduce  to $5,000 by 2020.

Galaxy Power’s QuickForm algorithms for newly assembled batteries save battery manufacturers time, energy, and floor space, producing higher-quality batteries and yields.

An Integer Programming Model to Maximize Battery Manufacturing Productivity
Hesham K. Alfares (King Fahd University of Petroleum and Minerals, Saudi Arabia)
Copyright © 2014. 12 pages.
Alfares, Hesham K. "An Integer Programming Model to Maximize Battery Manufacturing Productivity." Management Science, Logistics, and Operations Research. IGI Global, 2014. 26-37. Web. 19 Feb. 2014. doi:10.4018/978-1-4666-4506-6.ch002

Your partner for
battery manufacturing


Best Practice Deployment using Power Steering (CI Trac) at Johnson's Controls

Emission Estimation for Lead Acid Battery Manufacturing Processes, 1999

Learning, Reducing Cost and Increasing Productivity at Exide Technologies, Vernon Recycling Facility
Lean Manufacturing Implementation - Training Initiatives
Kaizen Events:

Reduction in length of the line from 51 ft to 17 ft.
WIP down to 4 units from 44 units.
Productivity improved by 11%.
Manhours per ton of lead produced improved by 42%
Vernon's OEE improved to 86.4%  -  1.4% more than world standard
Profitability increased by 42%.

U.S. Battery Manufacturing Company

Deep Cycle Battery 101 Manufacturing - YouTube Video



Top Manufacturers of Lead Acid Batteries

In USA, Johnson Controls took the highest market share for a single vendor in lead-acid market in 2010, with over a quarter of the market share. Other vendors, such as Exide Technologies, GS YUASA, Enersys, and East Penn, took less than a 10% market share each. Other than GS YUASA, all of the top five vendors belong to the United States. GS Yuasa is market leader in Japan and also in Global sales.

World wide battery manufacturers and Brands

About Lead Acid Batteries

Updated  21 April 2015,
8 Nov 2014

Operations Improvement Role of Industrial and Systems Engineer - Conception of Gavriel Salvendy

This article is an adaptation of the view expressed by Salvendy in the 2001 Handbook

Salvendy states that improving technology to increase efficiency and quality at the work cell level was the initial focus of ISEs. He recommends that now ISEs need to focus at enterprise level and supply chain level.

Salvendy also highlights the role of work measurement as a device to quantify improvement. Then he advocates that many more things are to be measured now and ISE has to come forward and measurement. It is very interesting presentation and every IE needs to read it.

Operations Improvement Role

The traditional role of ISE is that of problem solving and operations improvement. Improvements in efficiency, quality, and technology (e.g., methods, hardware, software, procedures, processes) belong to this category. ISE's use of classical methods improvement techniques, operations research,
human factors, modern manufacturing methods or management systems methodology results in changes in how things are done and these changes have to be such that total system performance is improved. Traditionally, ISEs have operated at the work center level. Over the past 30 years (reference to 2001) the scope of the system of interest has broadened.

Unfortunately, industrial engineering tended to lag behind other disciplines in the evolutionary process. Our profession has missed opportunities to continue to add value over the past 30 years.  We believe that the decades to come will provide opportunities for ISE to reintegrate and reposition itself as a leader and doer in the field of performance improvement. This requires rethinking the role and relationship among positioning and strategy, conditions for success, and operations improvement.

The author say that their contention is that the bulk of the Handbook focuses on the traditional ISE role in achieving operations effectiveness. However, in the first chapter, they covered  a couple of areas of operations improvement that they felt might not have been  represented or covered adequately. These ares are: systems and process improvement (more specifically, business process reengineering) and measurement systems.

Business Process Improvement

The term unit of analysis applies to the scope of the system of interest. When IE first began, the unit
of analysis—the scope of the system of interest—was confined to the worker, the work cell, and
individual work methods. Over time, the scope of the system of interest to the ISE has increased to enterprise and now further to supply chain optimization .  Attending to larger units of analysis is a ‘‘transcend and include’’ strategy.

This migration to a larger system of interest also happened to process improvement. The focus on improving embedded processes has shifted to an enterprise-level focus on improving business processes. Once again we see the transcend-and-include principle being required. A business process begins and ends with the customer. Organizations can no longer afford to optimize a subsystem (embedded process) at the expense of the performance of the larger system (business process). So the techniques and methods that were employed to improve smaller processes are being adapted and enhanced with some expertise borrowed from organizational leadership and management of change, creating a whole new line of business for a large group of professionals.

First, systems thinking is required to do BPR. ISEs are trained to think systems. Second, many of the substeps in the process  require specific knowledge and skills that ISEs are grounded in. We understand that ISEs are involved in many BPR efforts in organizations today. We also know that many BPR efforts are information technology-driven and many exclude ISE involvement. We believe this is an error that leads to underperformance.

Building Effective Measurement Systems

Work measurement and methods engineering are terms that have traditionally described actions taken
to quantify the performance of a worker or a work unit and to improve the performance of the
individual and the unit. The relevant body of knowledge has been developed and preserved through
the entire history of ISE. Throughout that history, one principle has served as its unifying force: an
appreciation for and the applied knowledge of systems. In fact, Frederick Taylor (1856–1915), who
is generally recognized as the father of industrial engineering, wrote in 1911, ‘‘The system must be
first.’’ Methods engineering was pioneered by Frank Gilbreth and his wife Lillian, whose lives were
memorialized in the Hollywood film Cheaper by the Dozen. Soon after methods engineering began
to be practiced, the need for measurement technology became clear. This was inevitable. Once analysts proposed improvements to the way a job was done, natural curiosity led to the question ‘‘How much better is it?’’ The ISEs translation of and response to that question led to the development of tools and techniques for measuring work.

More recently, the importance of methods engineering and work measurement was underscored
by the late W. Edwards Deming in his legendary seminars.  He argued that insufficient thought and
planning went into the design of work systems. The lack of sufficient high-quality output, he taught, stemmed not from poor worker attitude, but from poor management and poor design of the methods, tools, and systems we provide to the otherwise willing worker.

Dr. Deming also promoted the ISEs contribution through work measurement with his insistence that decisions regarding process improvements be data driven. In practice, this means that effective  systems improvement activities require evidence as to whether the changes make any difference. The requirement is that we use our measurement expertise to quantify the results of our efforts to design and implement better systems. 

The ability to measure individual and group performance allowed organizations to anticipate work
cycle times, which led to more control over costs and ultimately more profitability and better positioning in the marketplace. Understanding how long it actually takes to do a task led to inquiry about how long it should take to do work through the application of scientific methods. Standard times became prescriptive rather than descriptive. The next step in the evolution was the integration of production standards into incentive pay systems that encouraged workers to exceed prescribed levels of output. Application of extrinsic rewards became an additional instrument in the ISE toolbox,
vestiges of which linger on.

So much for the evolution of the work measurement and methods aspects of traditional ISE

The following are some evolutionary enhancements that have become part of the ISE measurement
value proposition:

• Statistical thinking plays a more critical role in understanding work performance. Variation is
inherent in all processes and systems. Discovering the underlying nature of variation and managing
the key variables to reduce defect has become now an important activity under name of six sigma.

• The role of production quotas is being reexamined. Should we throw out all standards, quotas,
and targets, as Dr. Deming suggested? We think not. We contend that the effective approach is
to establish a system within which teams of employees hold themselves and each other accountable
for system performance and are encouraged to reduce variation and improve performance
on their own. Standards that control and limit employee creativity should be eliminated.
The key is understanding performance variation and what causes it and creating a partnership
with employees so that they are integral members of the team working to improve it.

• Work measurement and methods improvement became detached, to some extent, from the larger
system of improvement efforts. Today, efforts to improve what workers do and how they do it
is being tied to overall business strategy and actions. This means that measures of performance
at the work unit level will have to be tied to and integrated with measures of performance for
larger units of analysis. Linkages between individual worker and team performance and system level
measures of performance are becoming better understood and managed. Here again, the authors'
message is ‘‘transcend and include.’’ Efforts to understand how long something does or should
take at the employee or work center level will expand to include understanding of how the unit level
systems need to perform in order to fill the treasure chest of the organization.

• Time and quality are no longer the only indicators of organizational performance. The balance score card approach recommends a set of performance indicators, including efficiency, effectiveness, productivity, financial performance, quality of work life, customer satisfaction, and innovation (Kaplan and Norton 1996).

• Visibility of measurement systems and portrayal of performance data are being recognized as
critical elements in the deployment of enhanced measurement systems. Traditionally, a worker
knew the standard and that was it. In the future, employees at every level of the organization
will have continual access to their scorecard indicators. Furthermore, they will be aware of how
these measures are linked to the performance of more inclusive systems. For example, employees
at the checkout counter will understand that their behaviors and attitudes influence whether
the store is a compelling place to shop and will have data to tell them how this helps to fill the
treasure chest and how that affects them. As a result, daily, hourly, moment-to-moment
decisions will be made on the basis of visible data and facts.

The ISE's have to participate in the design, implementation, and maintenance of these comprehensive and very visible measurement systems.

Organizational Systems Performance Measurement

An organizational system is two or more people whose activities are coordinated to accomplish a
common purpose. Examples of organizational systems are a work unit, a section, branch, plant,
division, company, enterprise.

The management system consists of three elements: who manages, what is managed, and how managing is accomplished. In a traditional organization, ‘‘who’’ may be the manager; but in the contemporary organization, ‘‘Who’’ refers to a management team. For the long-range planning horizon, the management team establishes the goals and objectives—the vision—of what the organization is to become. In the short time horizon, levels of system performance must be specified. The ‘‘What’’ is the system that is being managed; the organization, system, or process of interest, the object of the management efforts. ‘‘How’’ refers to managerial processes and procedures and more specifically to the transformation of data about the performance of the organization (‘‘What’’) into information regarding the need for actions or interventions.

The management system model can also be characterized as a feedback or closed-loop control
system. In this version, the management team is the controller (who), the process is the system being
controlled (what), and the instrumentation (how) monitors the system states and feeds these back to
the controller so that deviations between the actual and the desired states can be nulled. The interfaces between each of the elements also represent the management process. Between the ‘‘what’’ and the ‘‘how’’ elements is the measurement-to-data interface. Between the ‘‘how’’ and ‘‘who’’ elements is the information portrayal/information perception interface. And between the ‘‘who’’ and the ‘‘what’’ elements is the decision-to-action interface. Viewed from the perspective of this model, the management of a function would entail:

1. Determining what performance is expected from the system
2. Monitoring the system to determine how well it is performing in light of what is expected
3. Deciding what corrective action is necessary
4. Putting the correction into place
Note that any embedded organizational system is operating in the context of a larger system and
the linkages are critical to total system optimization (Sink and Smith 1994).

This model provides the frame and the outline to be followed in building an effective measurement

What constitutes success for an embedded system must be clearly understood and operationally defined. The model for success must also be operationalized and understood.

Without a clear, specific, focused understanding of what the key result areas and their related key performance indicators are, it is difficult for workers or managers to assess how they are doing and on what basis to make those assessments. The measurement system allows for effective Study (S) in the Shewhart/Deming PDSA improvement cycle. A modern measurement system will have to be comprehensive, well integrated, and strategic as well as operational. It needs to portray causal linkages from the system of interest to the next-larger system. This assists in ensuring that we do not fall into the trap of optimizing the subsystem at the expense of the larger system.

In our experience, ISEs understand measurement perhaps better than other disciplines.  The key to ISE being better integrated to enterprise improvement is that ISEs apply their strengths in a way that avoids suboptimization and clearly ties to the higher organizational good.

Industrial Engineering and Productivity Improvement - Coal Sector - by - Prof K.V.S.S. Narayana Rao

Mining in the 21st Century - Quo Vadis
19th World Mining Congress 2003

First Keynote Address on Sustainable Development and Coal Mining. Important.

William M. Boal* July 2014
Coal was a vital industry, employing 860,000 workers in the U.S. at its peak in 1923, and the United Mine Workers of America was a huge union, counting 422,000 dues-paying members in the U.S. at its peak in 1921.

The paper examines the effect of unionism on productivity in coal mines of west virginia. It did not give any numerical estimates of productivity per employee in any year of the study.  2015 annual meeting paper. It can be downloaded from

Great Britain - 1987

Saleable coal per man shift (OMS - output per shift) in coal mines during September 1983 was 2.44 tonnes. Two years later, it increased to 2.71 tonnes. During 1986/7, it averaged 3.29 tonnes. In March 1987, it increased to record level of 3.76 tonnes. It is a striking rise in productivity in three and half years as compared to long term trend.

Efficiency and Capacity of Boilers
Chapter of Steam: Its Generation and  Use

Productivity Change in the Coal Industry and the New Industrial Relations
Ray Richardson and Stephen Wood
British Journal of Industrial Relations
Volume 27, Issue 1, pages 33–55, March 1989

Updated  21 April 2015
First published on 28 March 2015

Monday, April 20, 2015

July - Industrial Engineering Knowledge Revision Plan

New Articles to be added from IE techniques

Scientific Management of Taylor

First Week

1. Importance of National Efficiency

2. Foundation of Scientific Management

3. Soldiering and Its Causes

4. Underlying Philosophy for the Old Systems of Management

5. Scientific Management - Introduction


7. Illustrations of Success of Scientific Management - - Pig Iron Handling

8. Background for Development of Scientific Management - -Midvale Steel Company Machine Shop

9. Elaborate Planning Organization - Need and Utility

10. Illustrations of Success of Scientific Management - Bricklaying Improvement by Gilbreth

Second Week of July

11. Illustrations of Success of Scientific Management - Bicycle Balls Inspection Example

12. Scientific Management in Machine Shop

13. Development of Science in Mechanic Arts

14. Study of Motives of Men

15. Scientific management in its essence

16. Role of Top Management in Implementing Scientific Management

17. Scientific Management Summarized

12 Principles of Efficiency by Harrington Emerson

15. Efficiency Principles Applied to Measurement and Cure of Wastes

Old scheme - Now to be removed.

2014 July 1 -4

System Engineering Process and Its Management
Systems Improvement Process

Systems Installation - Installing Proposed Methods
Productivity, Safety, Comfort, and Operator Health Management

Organizing for Industrial Engineering: Historical Evolution of Thinking
Current Research in IE

Managing Change in Improvement Projects - Comfort Zone to Comfort Zone
Supply Chain Cost Reduction

July 7 - 11

Total Improvement Management
Total Industrial Engineering - H. Yamashina

Organizational Behavior is an important subject for industrial engineers as human effort engineering is an exclusive focus of industrial engineers in engineering disciplines. Ergonomics and organizational behavior are equally important for industrial engineers to understand the abilities and limitations of people in work situations. Also organizational behavior also has focus on productivity. Hence in productivity management, organizational behavior theories are to be used by industrial engineers.

Introduction to Organizational Behavior
Environmental context: Information Technology and Globalization

 Environmental context: Diversity and Ethics
 Organizational Context: Design and Culture

Organizational Context:: Reward Systems
Perception and Attribution

Personality and Attitudes
Motivational Needs and Processes

July 14-18

Positive Psychology Approach to OB

 Decision Making
 Stress and Conflict

Power and Politics
Groups and Teams

 Managing Performance through Job Design and Goal Setting
 Behavioral Performance Management

Effective Leadership Process
Great Leaders: Styles, Activities, and Skills

July 21 - 25

Industrial engineering is a management activity. It focuses on cost reduction and thereby increase of sales due to lower prices and increased profits to the organization and through it increased incomes to employees of an organization apart benefit to other stakeholders of the organization. Also the managerial activities of planning, organizing, staffing, directing and controlling are relevant in industrial engineering practice. Industrial engineering are asked to do efficiency studies managerial processes also. So they have to know the output and inputs of managerial processes and how managerial processes are carried out. Industrial engineering programs have principles of management as a course in the curriculum.

Management: Definition and Process
Evolution of Management Thought and Theory - Review Notes

Process of Management
Planning: A Management Process

The Nature and Purpose of Planning - Review Notes
Objectives and Goals - Review Notes

Strategies, Policies, and Planning Premises - Review Notes
Business Firm and Society - The External Environment, Social Responsibility and Ethics - Review Notes

Decision Making - Review Notes
Summary - Principles of Planning

July 28

The Nature of Organizing - Review Notes
Departmentation in Organizations - Review Notes

June - Industrial Engineering Knowledge Revision

One Year Industrial Engineering Knowledge Revision Plan

January - February - March - April - May - June

July - August - September - October - November - December

In months after June the articles prescribed have to be modified as a new scheme is started in 2015.