Saturday, October 25, 2014

Productivity and Industrial Engineering in Plastics - Material, Resin and Product Manufacturing

North American Industry Classification System

3261 Plastics Product Manufacturing

    Productivity and IE in Plastics Bottle Manufacturing

    Productivity and IE in Plastics Pipe and Pipe Fitting Manufacturing

Productivity Improvement in Plastic Injection Moulding at Gmax Auto Ltd., India

Yudo Hot Runner India has designed, developed and installed automatic production lines for the Bawal (NCR Area) based Gmax Auto Ltd, which supplies high-end solution to Hero Group for all plastics parts for its two wheelers. This new plant solution is designed to increase productivity and reduce the running cost of the plant in terms of electric power consumption, manpower reduction through automated lines and decreased use of space.

Some of the key highlights of this plant are:

Automatic production lines for the plastic parts
Operator free machines, no operator is required on the machine
Redeced Space usage
Energy-efficient electric injection machines
Automatic takeout robots: High speed, high efficiency, collision-free robot
Specially designed chiller using special refrigerant. Latest technology used in pipe line to arrest temperature drop. It saves more than 30% electric power
Delicately designed heating and cooling units to ensure perfect quality
Mass storage silos with load cell to handle raw material efficiently and minimum handling with minimum man power; high efficient thrust loading; and easy access of the stored resin
Matrix based automatic centralised feeding system with SS304 piping to ensure to meet all the requirement of different machines
Efficient drying to ensure quality and dosing unit to ensure correct feeding and mixing
PC base supervisions installed for feeding system and chiller
High speed robots integrates with all machines to ensure optimum cycle time
Specially designed conveyors to control the movement of finished goods
Traffic controlled conveyors to ensure smooth movement of all products

Yudo together with Gmax team  designed the plant. Using the new plant, Gmax is producing approximately 30% more parts with same number of machines compared to other plants in India with very less manpower and also it is saving 30% in electric power cost.

Thursday, October 23, 2014

Design to Cost - Jack V. Michaels and Willaim P. Wood - Book Information

Google Book Link

1989 John Wiley & Sons

Table of Contents
Getting Started.

Defining Activities and Responsibilites.

Designing for Inherently Low Cost.

Choosing Business Strategies.

Estimating and Controlling Costs.

Remembering History.



Tuesday, October 7, 2014

The Principles of Scientific Management - Reassessment after 100 Years in 2011

Scientific management was published in 1911.
Principles of Industrial Engineering by Going also was published in 1911

Relevance of The Principles of Scientific Management 100 Years Later

Special Issue of
Journal of Business and Management – Vol. 17, No. 1, 2011

Papers Included

Frederick Winslow Taylor: Reflections on the Relevance of  The Principles of Scientific Management 100 Years Later
Cristina M. Giannantonio, Amy E. Hurley-Hanson

The Centennial of Frederick W. Taylor’s The Principles of Scientific Management: A Retrospective Commentary
Daniel A. Wren

Taylor is Dead, Hurray Taylor! The “human factor” in Scientific Management: Between Ethics, Scientific Psychology and Common Sense
Riccardo Giorgio Zuffo

The Debate Goes On!  A Graphic Portrayal Of The Sinclair-Taylor Editorial Dialogue
Jeremy C. Short

Citing Taylor: Tracing Taylorism’s Technical and Sociotechnical Duality through Latent Semantic Analysis
Nicholas Evangelopoulos

Taylor’s Unsung Contribution: Making Interchangeable Parts Practical
John Paxton

Scientific Entrepreneurial Management: Bricolage, Bootstrapping, and the Quest for Efficiencies
Manjula S. Salimath, Raymond J. Jones III

Frederick W. Taylor’s Presence in 21st Century Management Accounting Systems and Work Process Theories
Marie G. Kulesza, Pamela Q. Weaver, Sheldon Friedman

The Scientific Management of Information Overload
Linda L. Brennan

Latest Link

Earlier link

Contribution of Taylor to Industrial Engineering - Shop Management and Scientific Management

Shop Management - Themes

1. Definition of Management 

2. Difference in Production Quantity between a first class man and an average man

3. Developing and Employing First Class People in an Organization

4. Confronting Soldiering - Slow Pace of Work

5. Halsey Plan - F.W. Taylor's Comments

6. Task Management

7. Investment for Increasing Productivity or Efficiency

8. Importance of people - organization

9. Modern Engineering and Modern Shop Management

10. Task Management - Starting and Ending Times

11. Task Work - Some More Thoughts

12. Usefulness of Gantt's system

13. Time Study by F.W. Taylor

14. Bicylcle Ball Inspection Case Study

15. Need for Functional Foremanship or Functional Organisation of Foremen

16. Functional Foremanship

17. Production Planning and Control

18. Role of Top Management in Managing Change to High Productive Shop

19. Train Operators in High Productivity One by One and Then in Small Batches

20. Organizing a Small Workshop for High Productivity

21. Introducing Functional Foremanship

22. Personal Relations Between Employers and Employed

23. Don't be in a hurry - It Takes Time to Manage Change

24. Best Practices in Shop Management

Scientific Management - Themes

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

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

The Principles of Scientific Management - Reassessment after 100 Years in 2011

Scientific management was published in 1911.

Relevance of The Principles of Scientific Management 100 Years Later
Special Issue of
Journal of Business and Management – Vol. 17, No. 1, 2011
Link for full journal

Tuesday, September 30, 2014

September - Industrial Engineering Knowledge Revision Plan

Motion-Economy Device Design - Important Devices
Combination Tools

Summary - Principles of Jig and Fixture Design
Jig and Fixture Design - Detailed Treatment

Introduction to Engineering Economics
Time Value of Money Calculations

Cash Flow Estimation for Expenditure Proposals
Required Rate of Return - Cost of Capital

Depreciation and Other Related Issues
NPV - IRR and Other Summary Project Assessment Measures


Income Expansion Projects
Cost Reduction Projects

Replacement Decisons
Expected Values and Risk of Project Revenues and Costs

Engineering Economy or Engineering Economics: Economic Decision Making by Engineers
Introduction to Engineering Economics

Time Value of Money
Present-Worth Comparisons

Required Rate of Return for Investment or Expenditure Proposal..
Rate-of-Return Calculations


Equivalent Annual-Worth Comparisons
Replacement Analysis

Replacement Problem - Engineering Economy Analysis
Machine Selection Problem for an Engineer - Engineering Economic Analysis

Depreciation and Income Tax Considerations
Sensitivity Analysis

Structural Analysis of Alternatives

1. The Function of Methods Efficiency Engineering
2. Approach to Operation Analysis as a Step in Methods Efficiency Engineering

3. Scope and Limitations of Methods Efficiency Engineering
    Operation Analysis Sheet


    Using the Operation Analysis Sheet
    Analysis of Purpose of Operation

    Analysis of All Operations of a Process as a Step of Each Operation Analysis
    Analysis of Tolerances and Inspection Standards

    Analysis of Material in Operation Analysis
    Tool Related Operation Analysis

    Material Handling Analysis in Operations
    Operation Analysis of Setups

    Operation Analysis - Man and Machine Activity Charts
    Operation Analysis - Plant Layout Analysis

    Operation Analysis - Analysis of Working Conditions and Method
    Operation Analysis - Common Possibilities for Operation Improvement

    Operation Analysis - Check List
Industrial Engineering - Foundation of Toyota Production System

Toyota Production System Industrial Engineering - Shigeo Shingo
Introducing and Implementing the Toyota Production System - Shiego Shingo


Principles of Motion Economy
Principles of Motion Economy - More Details - R.M. Barnes

Motion Study - Human Effort Engineering
Variables of Motion Related to the Operator - Description by Frank Gilbreth

Motion Study - Operation Analysis - Questions


Tuesday, September 16, 2014

Frederick Winslow Taylor - A Pioneer Industrial Engineer


Important Events in Life

Date of Birth: 20th March, 1856
Mr. Taylor was born at Germantown, Philadelphia, on March 20, 1856

Taylor took a home study course to get his college degree in mechanical engineering in 1883 from Stevens Institute of Technology at Hoboken, New Jersey

1905 and 1906
President of ASME
Taylor was President of the American Society of Mechanical Engineers in 1905 and 1906.

1911 -  Tuck School hosted a major conference that helped launch the scientific management movement started by Frederick Winslow Taylor.

Taylor was awarded the honorary degree of Doctor of Science by the University of Pennsylvania. Taylor was made a Professor by the Tuck School of Business at Dartmouth College. He spent some time in teaching and research at this business school.

21st March 1915: F. W. Taylor, Expert in Efficiency, Dies
PHILADELPHIA, March 21--Frederick Winslow Taylor, originator of the modern scientific management movement, died here today from pneumonia. He was 59 years old, and was a former President of the American Society of Mechanical Engineers.

Frederick Taylor University (FTU) established in 1994, is named after the “Father of Scientific Management” Frederick Winslow Taylor (March 20, 1856 – March 21, 1915), who obtained his degree from Stevens Institute of Technology via distance education (correspondence) in 1883.
Bibliography on F.W. Taylor
Taylor's Biography  and His Methods and Contribution to Industrial Engineering and Management Thought
The Story Schmidt (An excerpt from Scientific Management)

Taylor's Shovel

Science for Coal Shoveling

In this article a point is made on using body weight instead of muscle and thus reducing effort of the worker.

A recent paper by Frievalds on shoveling

Original knol - 2314

MS in IE& OR in USA - Likely Cost

Georgia Institute of Technology (Ranked as Number one by US News)
(  )
In the above linked the tuition fee was given as  was given as $27,130 per year.
But  gives tuition fee information on semester basis.

University of Michigan Ann Arbor
The Masters degree requires 30 credit hours and is intended for the student with a technical undergraduate degree.
US News says tution fee is $41,998 per year.
The university website says $21,868 per term 9+ credits or $2,752 for first hour and 2,390 per additional hours. At this rate  30 credit hours come to appx $75,000.

Direct application to Phd is possible for undergraduates.

Columbia University


MS in IE OR  $80,727

MS in FE $102,435