Product Industrial Engineering

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Lesson 9 & 231 of  Industrial Engineering ONLINE Course   - Introduction to Industrial Engineering Module

Productivity Engineering - Principle of Industrial Engineering

Industrial engineering is concerned with redesign of engineering systems with a view to improve their productivity. Industrial engineers analyze productivity of each  resource used in engineering systems and redesign as necessary to improve productivity.

 Industrial engineering is continuous redesign of products and processes periodically as well as based on events at any time an opportunity arises. Taylor's articles explain the steps required to do industrial engineering. Thinking based on engineering and productivity orientation and then the experiments or prototyping to validate the idea. 

It has to be ensured that the increase in productivity due to the use of low-cost materials, processes and increasing speed of machines and men, should not lead to any decrease in quality of the output and or any desirable performance or aesthetic feature of the product or process. Both Taylor who promoted process industrial engineering and L.D. Miles, who promoted product industrial engineering - value engineering insisted on the condition.

Similarly, operators should not feel any discomfort, not have any health problems or safety issues in the redesigned more productive processes. Gilbreths had done considerable work on this aspect.

Products and Process are two important outputs of engineering activity.

Levels of Industrial Engineering in an Organization

Industrial Engineering Strategy - Enterprise Level Industrial Engineering

Policy Decisions by Top Management: Starting and Expanding IE Department, Approval of Productivity Improvement Project Portfolio as part of Capital Budgeting of the Company, Approving Productivity Policy, Setting Productivity and Cost Reduction Goals. Setting Employee related comfort, health and safety goals. Incentive income policy making.

https://nraoiekc.blogspot.com/2014/11/industrial-engineering-strategy.html

Product Industrial Engineering

Products and Process are two important outputs of engineering activity.

Product Redesign to Reduce Cost is Product Industrial Engineering.

Facilities Industrial Engineering

Facilities are used by processes. Facilities are common to processes. Taylor clearly mentioned in his "Piece Rates - Elementary Rate Fixing System" paper that he has to make modifications to all machines to increase productivity of his machine shop. Toyota even today carries out gradual improvements to the machines in the direction of autonomation. Machines are continuously improved. Period layout studies and readjustments are another example of facilities industrial engineering. 5S that demands upkeep of facilities is another example of facilities IE when it is implemented for the first time and proposed and initiated by the IE department. Thereafter it becomes the activity of operations management.

https://nraoiekc.blogspot.com/2020/05/facilities-industrial-engineering.html

Process Industrial Engineering - Process Machine Effort Industrial Engineering - Process Human Effort Industrial Engineering. Product Industrial Engineering.

Process industrial engineering is the popular method of industrial engineering. But, the process chart method was promoted by Motion Study books. It will be if industrial engineers identify that process industrial engineering is a higher levels activity and machine work study and human work study, that is motion study are part of process studies.

Like processes, multiple products are produced using common facilities.

https://nraoiekc.blogspot.com/2021/11/process-industrial-engineering-process.html

Product Industrial Engineering

Operation Industrial Engineering.

Process chart is a condensed version that show the entire process of producing a full product and the production of each part. The process chart is composed by symbols representing 5 operations. Operation - Inspection - Transport - Temporary Delay (WIP) - Permanent Storage (controlled store). Using process chart, the sequence of operations can be investigated and changed for more benefit. But each operation needs to be improved. It is termed simplification in process chart analysis. To do simplification information on each operation has to be collected in operation information sheets and they have to be analyzed in operation analysis sheets (Stegemerten and Maynard)

https://nraoiekc.blogspot.com/2013/11/approach-to-operation-analysis-as-step.html

Element Level Analysis in Industrial Engineering

Elements are in Operations - We can understand the term "element" from the subject "Design of Machine Elements". Each engineering product has elements. Similarly each operation, that is part of a process has elements. Some are related to machines and tools used in the process. Some are related to human operators. Some are related to working conditions. Some are related to the work being done. Taylor first named the productivity department as "Elementary Rate Fixing Department." It has to improve each and every element in task and determine the output possible for unit time in the work element. The time allowed for that element for a piece or batch is determined through these elementary standard times or allowed times.

Product Industrial Engineering

This article with the title "Product Design Industrial Engineering  was first published on 29  September 2012.

I now term this activity as Product Industrial Engineering. I included it in the focus areas of industrial engineering. In the early days of industrial engineering only some peripheral features of the product that facilitated material handling and tolerances were evaluated by industrial engineering for redesign. But Value Engineering, developed by L.D. Miles brought out the scope for radical redesign of the products and components to do cost reduction without affecting the quality, functions or features and customer requirements. It brought out the waste being present in the design done with effectiveness or performance as the focus at the start of a new product introduction by companies. So it called for cyclical approach of effectiveness design followed by efficiency design and also a periodic efficiency design to incorporate recent knowledge regarding efficiency improvement or cost reduction and developments in engineering and technology. Product industrial engineering became an important focus area of industrial engineering and many others techniques facilitating product industrial engineering were developed by industrial engineers and other engineers and managers.

The major techniques that constitute product industrial engineering are:

1. Value Analysis and Engineering
2. Design for Manufacturing
3. Design for Assembly
4. Design for Additive Manufacturing
5. Design to Cost
6. Design to Value
7. Design to Target Cost
8. Engineering Product Design Optimization
9. Six Sigma for Design Improvement - Robust Design (Video)
10. Life Cycle Cost Analysis based redesign
11. Design analysis done during Process Industrial Engineering
12. Lean Product Design Concept

In the product industrial engineering module of IEKC IE Online Course, value engineering will be discussed in detail and other techniques will also be introduced. More detailed articles will be developed in this blog for more specialised information.

Definitions of IE and IE Design for "X"

Many designs for "X" fall under the domain of industrial engineering as per the definition of of IE.

AIIE

“Industrial engineering is concerned with the design, improvement, and installation of integrated systems of men, materials, and equipment. It draws upon specialized knowledge and skill in the mathematical, physical, and social sciences together with the principles and methods of engineering analysis and design, to specify, predict, and evaluate the results to be obtained from such systems.” (AIIE, 1955). [4]

IE Design for "X": Industrial engineering aims to specify, predict, and evaluate the results to be obtained from such systems. Hence the special and unique role of IE is results or performance obtained from systems. Productivity, Time  and cost are the original performance dimensions focused by the IE discipline. Slowly more got added. Still more can be added. 

Narayana Rao (2009)

"Industrial Engineering is Human Effort Engineering and System Efficiency Engineering.

The above definition indicates that all efficiency related dimensions are the focus of the industrial engineer.

Engineering in Industrial Engineering:

The foundation of IE is engineering and its primary area of application is engineering. IEs have to keep themselves abreast of developments in engineering on a continuous basis.

Product Industrial Engineering

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Presented on 13 December 2019

Value Engineering

Value Engineering - Introduction


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Value Engineering In Product Design To Improve World Competitive Position
L.D. Miles, 1963
http://minds.wisconsin.edu/handle/1793/4482


MANAGING VALUE ENGINEERING IN NEW PRODUCT DEVELOPMENT
Don J. Gerhardt, CVS, PhD, PE, Ingersoll Rand
2006
http://value-eng.org/knowledge_bank/attachments/200611.pdf

7 Wastes in Engineering Design

http://ketiv.com/files/articles/pdfs/Simms_The%20Seven%20Wastes_2007.10.pdf


1. Defects
Improper information on a drawing, missing views and incomplete information are all defects that can be avoided through document standardization and proper training of engineering staff.

2. Overproduction
For the engineering department, it would be the unnecessary documentation (modeling or drawing) of a part before it is needed.

3. Inventory
If we draw something before it is actually needed, we are adding to that inventory, thereby incurring waste.

4. Transportation
Movement of drawings and drawing change orders is often called “transportation” because carrying, mailing, or even e-mailing documents stop the design process and add time to the overall design cycle.

5. Waiting
Waiting refers to the time spent by the workers or engineers literally waiting for their work to arrive.

6. Motion
Even the extra step of printing to a PDF and e-mailing it as an attachment is a wasteful operation.

7. Overprocessing
It is  common to see manufacturers using software that has function (and cost) beyond what is needed which is a waste.

Improving Design

www.ceet.niu.edu/cecourse/Regina_problem_domain.ppt

Tolerance Analysis

Tolerance analysis - Wikipedia
Tolerance analysis - Sigmetrix


Design Issues in Mechanical Tolerance Analysis
K. W. Chase
Mechanical Engineering Department
Brigham Young University
Provo, UT 84602

W. H. Greenwood
Sandia National Laboratories
Albuquerque, NM 87185
http://adcats.et.byu.edu/Publication/87-5/WAM2.html

Design to Cost Analysis

ACHIEVING  TARGET  COST  /DESIGN-TO-COST  OBJECTIVES
Kenneth Crow, DRM Associates
http://www.npd-solutions.com/dtc.html

Design to Standards Analysis

Design to standards - Wikipedia article
http://en.wikipedia.org/wiki/Design_to_standards

Design for Manufacturability

Design for Manufacturability: How to Use Concurrent Engineering to Rapidly Develop Low-Cost, High-Quality Products for Lean Production - David M. Anderson - 2014 Book Information

Engineering Economics Analysis

Engg. Economics - Chemical Engineering
http://faculty.kfupm.edu.sa/CHE/alamer/ChE_425/CHE_425_First_introductory_Lecture.pdf

Statistical Tools for Design

Statistical Tools for the Rapid Development & Evaluation of
High-Reliability Products
http://www.stat.iastate.edu/preprint/articles/1995-07.pdf

Optimization and OR in Product Design

Quantitative methods to produce optimal designs.

Design of Experiments
Response Surface Methods
Multi-Response Optimization
Robust Design
Reliability/Weibull Analysis
Hypothesis Testing
Failure Mode and Effects Analysis (FMEA)
Data Analysis
Statistical Modeling

A Systematic Optimization Design Method for Complex Mechatronic Products Design and Development
Jie Jiang, Guofu Ding, Jian Zhang, Yisheng Zou, and Shengfeng Qin
Mathematical Problems in Engineering
Volume 2018, Article ID 3159637, 14 pages
https://www.hindawi.com/journals/mpe/2018/3159637/

A framework for optimal design of complex products
Authors: Deyi Xue, David Imaniyan
Procedia CIRP
Volume 70, 2018, Pages 416-421
https://www.sciencedirect.com/science/article/pii/S221282711830369X

OPTIMIZATION OF PRODUCT DESIGN THROUGH QUALITY FUNCTION DEPLOYMENT AND ANALYTICAL HIERARCHY PROCESS:  CASE STUDY OF A CERAMIC WASHBASIN
2011
http://jfa.arch.metu.edu.tr/archive/0258-5316/2011/cilt28/sayi_1/1-22.pdf

Design Optimization Practice in Product Development
Panos Y. Papalambros, 2002
https://pdfs.semanticscholar.org/8141/1a46103a3ed9674c3241e5afab68418f9290.pdf

Optimization - Finishing touch in product design
http://www.ricardo.com/Documents/Downloads/pdf/wave_finishing_touch.pdf

An Optimization Framework for Product Design
Leyuan Shi
Qun Chen
(Department of Industrial Engineering, University of Wisconsin-Madison, Madison, Wisconsin )

Sigurdur Ólafsson
(Department of Industrial and Manufacturing Systems Engineering, Iowa State University, Ames, Iowa )
http://mansci.journal.informs.org/content/47/12/1681.abstract
https://ideas.repec.org/a/inm/ormnsc/v47y2001i12p1681-1692.html

I am a happy. Prof. Beth Cudney, Ph.D, Professor of Data Analytics, Maryville University liked my comment. 

"Industrial engineering inputs to the product development process are important. Product industrial engineering makes significant contribution to product development."

on the post: 

https://www.linkedin.com/posts/bethcudney_delighted-to-share-that-my-latest-paper-entitled-activity-7087126844298203136-pieD  

Degree in Industrial Engineering and Product Design

Ubiquity of Industrial Engineering Principle of  Industrial Engineering

Industrial Engineering is applicable to all branches of engineering. IE is applicable to all engineering products of various engineering branches.

An early article by Taylor describes and illustrates the productivity engineering of belting system based on the cost data accumulated over a period of 9 years (Industrial Engineering of Belting - 1893). I saw an article on industrial engineering with the title "continuous reengineering." I agree with the term and promote the term.

Accompanying Case Study: Value Analysis and Engineering - Examples by L.D. Miles - Part 1

Lesson 8. Productivity Science -  Principle of Industrial Engineering.

Lesson 10. Process Industrial Engineering

Lesson 8. Productivity Science -  Principle of Industrial Engineering.

Lesson 10. Process Industrial Engineering

Updated 25.11.2023,  17.11.2023, 27.7.2023, 1.6.2022,  15.11.2021,  8 June 2021, 25 May 2020,  15 December 2019,   16 July 2019, 22 June 2019,  31 May 2019,  15 May 2019, 26 July 2018
First published on 29 September 2012