Wednesday, August 29, 2012

System Efficiency Engineering - Interesting Web Pages and Reports

Efficiency improvement is also referred to by the term cost reduction. Efficiency improvement is not directly aiming revenue expansion but it is focusing on supply chain efficiency with respect to an accepted marketing or sales goal of the organization. But as efficiency improves and cost is reduced, the organizations may be able to lower prices and get more revenue for product that have elastic demand. But the immediate focus of system efficiency project is improvement in efficiency within the context of a targeted production and sales plan.
Industrial engineering is a discipline that focuses on improving the efficiency of  production and distribution systems.
_______________
Michelin's Industrial Engineering organization
"Eliminate - combine - reduce" is the theme of Michelin's Industrial Engineering organization. Our IEs are trained to leverage their engineering and analytical competencies to systematically create solutions that result in cost savings for the company. Interfacing with people, technology, and business, Michelin IEs are on the front line each day to facilitate continuous efficiency improvement in all areas of the organization.
Industrial Engineer
 Requires a bachelor's degree in mechanical engineering, chemical engineering or industrial engineering or equivalent technical degree.
Conducts productivity improvement and cost reduction projects in the Group Services environment
Works in direct cooperation with employees and managers in the study and implementation of projects through the application of the Michelin IE method and related techniques. Project work includes work processes and flow analysis, organizational benchmarking, manpower planning, and productivity and efficiency improvements.
Begins employment with a training program that combines in-plant project and classroom work in IE functions, methods, and tools.
 accessed on 8.2.2010
______________

TOC for Wiki Improving Process Efficiency with Business Process Accelerator
IBM Wiki -
http://www-10.lotus.com/ldd/lfwiki.nsf/dx/Table_of_Contents_for_Wiki_Improving_Process_Efficiency_with_Business_Process_Accelerator

Improving Software Process Efficiency - 2002 MS thesis
http://www.bth.se/fou/cuppsats.nsf/all/a5cb3e848628d41bc1256bdb0060bb32/$file/mythesisMSE_2002_20.pdf

Performance Monitoring to Improve Service Quality and Efficiency Through Better Management of Bus Operators
http://www4.uwm.edu/cuts/bench/kimpel.pdf

Energy Efficiency in Local Municipality Operations
http://www.epa.gov/statelocalclimate/documents/pdf/ee_municipal_operations.pdf

Process Cycle Efficiency Improvement Through Lean: A Case Study 2011
http://www.thinkinglean.com/ijlt/articles/vol2/issue1/020203m.pdf
Streamlining operations: Discrete manufacturers pursue improved efficiency (EIU Survey during 2007-08)
Production Efficiency Improvement: A Case Study in Roasted and Ground Coffee Industry, 2007
Improving Packing Efficiency for Shipping Container, 2007
Efficiency savings in Forestry Commission Scotland
Public Transport Efficiency Project
ENERGY PROJECT CASE STUDY BOILER EFFICIENCY IMPROVEMENT
Example of Business Operational Efficiency Improvement at Food Supermarkets through Implementation of USCOS (2006)
Improving Energy Efficiency In Pharmaceutical Manufacturing Operations (2006)
MANAGING ENERGY EFFICIENCY IMPROVEMENT at Dow Chemical Company (2006)
JOE ALMAGUER, ENERGY EFFICIENCY LEADER
OPTIMIZING THE SCHEDULING OF THE MILITARY POLICE: A STUDY IN EFFICIENCY IMPROVEMENT IN THE U.S. ARMY,
Proceedings of the Academy of Production and Operations Management, Volume 1, Number 1 New Orleans, 2004
"Efficiency Improvement and Business Excellence"
Address by Dr. Dirk Suwelack, Member of the Board of Management, Bayer CropScience AG (2004 results)
Automotive Efficiency Improvement  Case Study
Efficiency Improvement Possibilities in CCGT Power Plant Technology  (2001)
MAINTAINING THE SOLUTION TO OPERATIONS AND MAINTENANCE EFFICIENCY IMPROVEMENT (1995)
Original knol - http://knol.google.com/k/narayana-rao/system-efficiency-engineering/2utb2lsm2k7a/ 2277


Use the Google Search Results for Process efficiency Presently in page 35. Go forward to P.34

Monday, August 27, 2012

Cost Leadership Strategy and Industrial Engineering

Industrial engineering with its focus on efficiency, productivity and cost reduction has an important role to play  in companies which have decided to compete on cost leadership. In these companies there is special emphasis on examining product as well as processes to identify inefficiencies and wastes and minimize resources.

Industrial Engineering curriculums must include an elective subject on developing strategy perspective in IEs especially in relation to the cost leadership strategy.



Bibliography

http://www.costleadershipstrategy.com/



Investigating the tradeoff between cost leadership and differentiation
M.Sc these of Stockholm School of Economics
2007
http://arc.hhs.se/download.aspx?MediumId=315

Term Paper on Cost Leadership - Tata Steel and Reliance Industries are covered in the paper - 2008
http://www.scribd.com/doc/13637922/Cost-leadership-term-paper


Cases Studies on Total Productive Management and Competitive Advantages

Li Chang-Chung, (Department of Industrial Engineering and Engineering Management, National Tsing Hua University, Hsinchu, Taiwan, ROC), Tsai Ping-Chen, (Department of Industrial Engineering and Engineering Management, National Tsing Hua University, Hsinchu, Taiwan, ROC)
Asian Journal on Quality, Vol. 2 Iss: 1, pp.106 - 116

Abstract: The purpose of business strategy is to achieve competitive advantages which includes higher efficiency, better quality, more innovation and faster customer response. In other words, the business strategy is to build unique capability of lower cost and/or differentiation. In production aspect, unique capability means better production power with better performance at 3M(Man, Machine, Material) of input and PQCDSM (Product, Quality, Cost, Delivery, Safety, Moral) from output. The Total Productive Management (TPM), a series of improvement activities focused on reduction of equipment loss, is a tool to establish business competitive advantages.

In this paper, several domestic companies who won the Japan TPM Award have been studied. It is found that there is a strong cause-effect relationship between TPM and competitive advantages because: (1) TPM can change employees mindset effectively; (2) TPM can upgrade employees capabilities; (3) TPM can lead to excellent productivity.

Achieving Cost Leadership - A Sustainable and Pragmatic Approach
Booz Paper
http://www.booz.com/media/uploads/AchievingCostLeadership.pdf

Cost Leadership Strategies
http://ocw.u-tokyo.ac.jp/wp-content/uploads/lecture-notes_eng/Eco_07/e-shintaku-05-2.pdf

Leadership in Operational Excellence - Spencer Stuart
http://content.spencerstuart.com/sswebsite/pdf/lib/opX_0107.pdf

Business Level Strategies and Performance - Ph d thesis 1998
http://repositories.tdl.org/ttu-ir/bitstream/handle/2346/12825/31295012468293.pdf?sequence=1

Cost Leadership - Leadership - Deloitte
http://www.deloitte.com/view/en_CH/ch/insights/privatebankingcentreofexcellence/costleadershipinbusinessoperations/index.htm

Cost Leadership Strategy and Product Specification and Design Choices



In a cost leadership strategy, the focus is not on traditional design problems of form or function, but rather to deliver the lowest retail price at the highest margin with acceptable product quality. Surprisingly, the design thought process has a lot to say about what customers find acceptable within this framework.
http://triginnovation.com/tangents/2011/3/25/design-thinking-for-cost-leadership.html

Design and Design thinking in strategy concepts
http://www.dmi.org/dmi/html/conference/academic08/papers/Stevens%20et%20al/Design%20thinking%20in%20strategy%20concepts%20DMI%2008.pdf



Understanding Customers Important for Cost Leaders

Cost leaders have to dissect the customer value proposition.  A company that examines the value proposition required by its target market may uncover new insights. Such a study may reveal some factors on which the company may be incurring substantial expenditure and yet the customers do not care about the particular feature or facility. Cutting on such frills may help in improving the bottom line. Such cuts on frills can be accompanied by thrust on factors where company’s offering is below the customers’ expectations.

Most popular no frills strategy is pursued by Southwest Airlines which based its strategy on clear understanding of the segment of customers it was going to serve by operating the flight services at lowest fares and prompt schedules. The clear understanding of expectations of the segment it was going to serve and competitive value proposition that this segment was being offered by the aviation industry opened up the real opportunity of lowering its costs and yet maximizing the value of low fares and adherence to schedules for its customers by keeping clear of facilities like baggage transfers, meals, seat arrangement etc., which any way the customers were not bothered about. It is an important point to note that Southwest Airlines has done its marketing well and found a target market and its requirement. It is also important to have a large target market that provides strategic advantage over a long period of time.

http://www.alagse.com/strategy/s10.php

Cost Leader Companies in Various Industries - Strategic Programs



Cement Industry
Cost leadership is the only possible strategy
http://tejas-iimb.org/articles/32.php
IIMB Faculty - Student collaboration
Business strategies for Indian Cement Industry
http://www.ipedr.com/vol2/1-P00003.pdf
Heidelberg Cement
In our industry cost leadership is a crucial factor for success.
http://www.heidelbergcement.com/NR/rdonlyres/0639C65D-9BE2-4DC6-9D01-EF6398E1141D/0/GB_2011_E_WebLinks.pdf   2011 annual report.


Retail Sales
Masters Dissertation on Strategies of Walmart and Carrefour in China
http://edissertations.nottingham.ac.uk/1369/1/07MAlixyl25.pdf.pdf


Telecom Networks
Ericsson is technology leader.
Huawei is the cost leader.
http://www.economist.com/node/21541043
Dec 2011

CFD Software - Being Promoted as Cost Effective for Number of Design Problems


CFD software is being promoted as cost effective software for design problems in various industries.

Benefits of CFD

CFD is routinely used today in a wide variety of disciplines and industries, including aerospace, automotive, power generation, chemical manufacturing, polymer processing, petroleum exploration, medical research, meteorology, and astrophysics.

The use of CFD in the process industries has led to reductions in the cost of product and process development and optimization activities (by reducing down time), reduced the need for physical experimentation, shortened time to market, improved design reliability, increased conversions and yields, and facilitated the resolution of environmental, health, and right-to-operate issues.

It follows that the economic benefit of using CFD has been substantial, although detailed economic analyses are rarely reported. A case study of the economic benefit of the application of CFD in one chemical and engineered-material company over a six-year period conservatively estimated that the application of CFD generated approximately a six-fold return on the total investment in CFD (Davidson, 2001a).

http://www.nae.edu/Publications/Bridge/ExpandingFrontiersofEngineering7308/TheRoleofComputationalFluidDynamicsinProcessIndustries.aspx

Davidson, D.L. 2001a. The Enterprise-Wide Application of Computational Fluid Dynamics in the Chemicals Industry. Proceedings of the 6th World Congress of Chemical Engineering. Available on Conference Media CD, Melbourne, Australia.

Comparison between CFD and Wind Tunnel
http://www.cd-adapco.com/pdfs/presentations/adm10/Todd_Leighton.pdf  2010


Usage of CFD


Aircraft Design


Automobile industry

Cement Industry
http://www.turnellcorp.com/Publications/WorldCement2012-CFD-Duct%20Optimization.pdf - 2012 article

HVAC
http://usa.autodesk.com/manufacturing/building-products-equipment-fabrication/#tab1


Courses and Consultants for CFD

http://www.energo.rs/CFD%20-%20COMPUTATIONAL%20FLUID%20DYNAMIC.htm



CFD Books

Sunday, August 26, 2012

Industrial Engineering Concepts Question Paper - September 2011


PGDIE 41 – First Quarter End Examination
OP-03 Industrial Engineering Concepts

Date 16.9.2011                                                                                        Max. Marks: 60

Answer any FIVE  questions
All questions carry equal marks

1. Industrial  engineering is an engineering-based management staff-service discipline that deals with the design of human effort and system efficiency in all occupations.

Explain the statement by briefly explaining
a) the contribution of Taylor and Gilbreth.
b) Going’s explanation
c) Lehrer conceptualization of the discipline
d) AIIE’s definition
e) Definitions of recent days – Sawada, Narayana Rao, and Yamashina

2  a). Explain the principles used in making a motion analysis of an operator.

b) What are local fatigue and whole body fatigue? What human effort design criteria will prevent them? How do you measure those criteria?

3 a). Production methods are designed by functional production engineers and industrial engineers analyze them for waste reduction opportunities in methods efficiency engineering. In Single Minute Exchange of Dies, or set up time reduction, the focus is on reducing the time for set up. How the Eliminate, Combine, Rearrange and Simplify steps were used in developing SMED method?

b) Value Engineering examines product designs and component production methods to reduce cost and provide the intended function. What are the six important analysis techniques of value engineering? What is your engineering discipline and discuss relevance of value engineering to a product of your discipline.

4 a) Explain an application area for mathematical method in the design of a component or a subsystem in your discipline of engineering.

b) In the Maynard Book chapter on Operations Research, the following case studies were given.

i) Production planning at Harris Corporation ii) Gasoline Blending at Texaco iii) FMS Scheduling at Caterpillar iv) Fleet assignment at Delta Airlines v)Keycorp Service Excellence Management System.

Explain any one case study.



5 a). What is management and what is the process of total productivity management?

b). Engineering economic analysis is to be done by all engineers in various engineering departments and industrial engineering department has to do engineering economic appraisal. Differentiate between engineering economic analysis and engineering economic appraisal.


6 a) . Dramatic productivity improvements were demonstrated by Taylor and Gilbreth. Give examples.

b). Employee involvement in methods improvement project is to be encouraged at every stage by industrial engineers. Explain.

c). What therbligs or  basic work elements are used in MTM to determine standard times?

7 a). In every system design, there is a role for industrial engineering department. Describe that role briefly.

b). What are the wastes in software development similar to the wastes identified in manufacturing systems under Toyota Production System (TPS).

c). Describe some steps for increasing the efficiency of energy use in factories and offices.
   

---------

Friday, August 24, 2012

Ergonomics - A Collection of Recent Articles



http://www.intechopen.com/books/ergonomics-a-systems-approach



Work-Related Musculoskeletal Disorders Assessment and Prevention
by Isabel L. Nunes and Pamela McCauley Bush


Work-Related Musculoskeletal Discomfort in the Shoulder due to Computer Use
By Orhan Korhan

More articles in the collection by InTech

Industrial Engineering and Sustainability



Manufacturing and the Science of Sustainability
Keynote Address byTimothy G. Gutowski
Massachusetts Institute of Technology, Cambrige, MA 02139
2011
http://web.mit.edu/ebm/www/Publications/Gutowski_CIRP_Keynote_2011.pdf  - Important Paper


There are many opportunities for Industrial Engineering to work on sustainability issues.
http://ime.calpoly.edu/profiles/industrial-engineering-and-sustainability/

University of Central Florida - IE Department incorporate sustainability into curriculum
http://iems.ucf.edu/Sustainability_Education/index.html

Interesting statement by a student
"As an industrial engineer, I think we have a lot to provide society, because we are getting the skills on how to do things more effectively and more efficiently, so we are not reinventing the wheel, we are just making the wheel a little better. If we can do this with the concept of how can we do this and protect the environment at the same time... Because any environmental movement that is not profitable, is not going to be picked up in the commercial world. If the company cannot do it and be profitable, the company is not going to exist."


Industrial Engineering for Sustainability
http://www.livegreen.iastate.edu/involved/projects/project.php?a=view&id=207


Improve the performance of closed-loop supply chains with remanufacturing to reduce waste and conserve material and energy.
Design and analyze governmental incentives and fees related to reduce, reuse, and recycle.
Improve manufacturing systems for wind energy systems to increase reliability and decrease cost of energy production.



Can Efficiency Improvements Reduce Resource Consumption?
A Historical Analysis of Ten Activities
http://stuff.mit.edu/afs/athena.mit.edu/course/2/2.813/OldFiles/www/readings/DahmusGutowskiEfficiency.pdf



Important Paper 1999 with number of issues and more than 300 references

Issues in environmentally conscious manufacturing and
product recovery: a survey
Computers & Industrial Engineering 36 (1999) 811±853
http://eco-design.gr/docs/ecodesign/SCIENCE_3.pdf

Presentation by Dr. Anna Bella Siriban-Manalang
Industrial Engineering Department, DLSU, Philippines
International Panel Member for Sustainable Resource
Management, UNEP-DTIE
(link to be given)


Environmentally Benign Manufacturing
Large number of articles - Collection by MIT
http://web.mit.edu/ebm/www/publications.htm



Wednesday, August 22, 2012

Resource Efficiency View of Industrial Engineering


Human Resource Efficiency

   Human Effort Engineering

Equipment Efficiency

Material Efficiency

   Inventory Reduction


Energy Efficiency

Energy Use Efficiency - IE for Energy Resource
http://nraoiekc.blogspot.com/2012/04/energy-use-efficiency-ie-for-energy.html

Revolutionizing Data Center Energy Efficiency  2008 McKinsey Company Report
http://www.ecobaun.com/images/Revolutionizing_Data_Center_Efficiency.pdf

Information System Efficiency




IE Techniques and Their Contribution to Resource Efficiency

Standardization

Variety Reduction

World Class Manufacturing - Explanation by Studio Base Group


The World Class Manufacturing, "WCM"

The World Class Manufacturing, "WCM" has its origins in the 80s, edited by Richard J. Schonberger, who collected dozens of cases, experiences and testimonies of companies that had embarked on the path of continuous improvement "Kaizen" for excellence in production, trying to give a systematic conceptual to the various practices and methodologies examined. these techniques have been known for some time , but through approach WCM, of Schonberger, we obtained a perfectly integrated together, with the highest organizational flexibility, capable of achieving a competitive company with high quality products at competitive prices, in line with the needs of the customer. The main model where the WCM system is inspired by the Toyota Production System (TPS), a method of organizing alternative to mass production based on the assembly line of Henry Ford. 's World Class Manufacturing is based on a few fundamental principles:


the involvement of people is the key to change;

the voice of the customer must come in all departments and offices;

all leaders must demand respect for the standards set;

methods should be applied with consistency and rigor;

all forms of waste is a Muda not tolerable;

all faults must be made visible;

The World Class Manufacturing traditionally takes into account already known disciplines such as Total Quality Control, Total Productive Maintenance, Total Industrial Engineering, Just In Time, Lean Manufacturing. According to Fiat Group, "World Class Manufacturing (WCM)" is,


a system of structured and integrated production that covers all the processes of the plant, the security environment, from maintenance to logistics and quality. The goal is to continuously improve production performance, seeking a progressive elimination of waste, in order to ensure product quality and maximum flexibility in responding to customer requests, through the involvement and motivation of the people working in the establishment . (Source: Fiat)

Fiat Group, has customized the WCM approach to their needs, calling, Prof. Hajime Yamashina Kyoto University, to redesign and implement the model through two lines of action:

ten pillars or other technical activities
ten pillars managerial

The pillars of technology or activities are structured improvement processes that must be present (Pillars), together with various tools (Tools). Together, they constitute the FIAT Production System. The pillars are technical:


Safety
Cost Deployment
Focused Improvement
Quality Control
Autonomous Activities
Professional Maintenance
Logistics / Customer Services
Early Equipment Management
People Development
Environment


The pillars managerial or management, are vice versa actions that must  be played by the central coordinator of Team WCM (WCM leader or plant manager). They  are aimed at promoting the commitment and responsibilities of the various managers assigned to specific pillars of activity  to carry out plans and projects through the dissemination of know-how.

The Managerial pillars are:

Commitment: "commitment, motivation and total involvement"
Management plans and objectives
Knowledge management
The culture-oriented retail

The growing sensitivity to issues of safety and energy has been transposed by Fiat Group, also in the methods of WCM, developing within the pillar Environment under a specific pillar called Energy, to stimulate the capacity of staff to identify and implement initiatives which will reduce waste and improve energy use. Achieving the different levels of performance at the Company is certified by external audits, carried out by a team chaired by representatives of the WCM Association. This audit system based on an indicator called IIM (Index Implementation Methodology), for a continuous internal benchmarking between the different entities by assigning symbolic medals, bronze, silver, gold and world class.



StudioBase thanks to the origin of some of its advisors from the world and Fiat, deep knowledge of the Toyota model and World Class Manufacturing is able to assist the Medium and Small Italian companies who wish to pursue efficiency through the introduction of global and / or part of these approaches.

http://www.studiobase.eu/world_class_manufacturing.html

Industrial Engineering Technicians- Occupational Outlook for 2010-20

Saturday, August 18, 2012

Is Industrial Engineering a Strategic Function?



The answer is yes. Industrial Engineering is a strategic function. Its focus is efficiency, waste elimination, planning of optimal cost for the enterprise and hence profit maximization subject to the revenue constraints or maximum sales achieved by the organization. Is profit a strategic measure for the organization? Yes, it is. Then is not the function that has a focus on optimizing the profit using technical as well as managerial alternatives available a strategic function? The answer is yes. It is.

What is industrial engineering?
It is human effort engineering and system efficiency engineering.


Annual profit planning and long-tern profit planning are board level issues and board has to take decisions regarding IE targets and programs. Total productivity management is a good management method to plan enterprise level improvement activities and  then involve local units to achieve enterprise improve and thereby targeted profit. Total cost management is enterprise level cost management with active participation of all.


Board and Its Responsibilities

http://www.ncbi.nlm.nih.gov/pmc/articles/PMC1276331/

Board look for Efficiency with IT
http://www.directorship.com/boards-look-for-efficiency-with-it/

NHS Commissioning Board Plans new improvement body to promote efficiency
JIM Easton, Director of  Improvement and Efficiency
July 2012
http://www.hsj.co.uk/news/policy/commissioning-board-plans-new-improvement-body-to-drive-efficiency/5047152.article


Functional Engineering and Management Certifications for Industrial Engineers

Wednesday, August 15, 2012

Safety Engineering and Management for Industrial Engineers



Industrial engineers integrate men, materials and machines through work station designs that improve productivity and comfort of workers. In doing such a design, they have to take care of safety engineering and management aspects also. Also when they are doing value engineering of engineering equipment say in equipment producing companies, they have to make sure that all the safety benefits provided in the design being examined are kept intact and any feature change does not reduce the safety of the item. It is better to say that Industrial engineers have the objective of taking care of safety of operators.

Hence industrial engineers have to learn the safety theories and methods developed so far various safety scholars and professionals and enrich them with their insights.

In Maynard's handbook 5th edition there is a chapter on Safety Engineering and Management.

It identified three areas;

Behavioral safety
Safety Engineering
Systems safety

As a part of safety management, it discussed recording accidents, reporting them and analyzing them.


_____________________________________

Safety Engineering and Management - Bibliography

New model of Safety - STAMP - 2002 - Nancy G. Levenson - MIT Professor
Book System Safety Engineering Back to the Future , 2002,
Donwload from Author's site
http://sunnyday.mit.edu/book2.pdf

Home Page of Prof Levenson
http://sunnyday.mit.edu/
There are many pages on safety from sunnyday page that appear in Google search results on safety.

Friday, August 10, 2012

Introduction to Industrial Engineering - Course at NITIE


Industrial Engineering Concepts Course at NITIE

Contents

Objective, Contents, Supporting Knols, Engineering Revision, Chapters Recommended from Maynard's Handbook and Knols, Industrial Engineering Course Pages on Web, Articles, Books, Bulletin Boards, Course Pages.

___________________________________________________________________
Programmes at NITIE

 PGDIE  - PGDIM  - PDITM  - PGDISEM 
_____________________________________________________________________

Revision articles for Introduction to Industrial Engineering - http://nraomtr.blogspot.com/search/label/Industrial%20Engineering

More and Detailed articles on Industrial Engineering -  http://nraoiekc.blogspot.com/

Recent Interesting Information on IE - IE  Bulletin - Information Board

_____________________________________________________________________

Objective

To provide students an understanding of  the scope of industrial engineering in issues related to human resource, efficient utilization of various resources, system efficiency, productivity, safety, comfort, health and systems design and improvement.

Contents

  1. Definition
  2. Component Areas of IE: Human Effort engineering, System Efficiency Engineering and Systems Engineering
  3. Pioneering Efforts of Taylor, Gilbreth and Emerson
  4. Human Effort Engineering: Motion Study, Task Analysis
  5. Measurement for Human Effort Engineering: Work Measurement - Time Study
  6. Ergonomics: The Applied Science for Human Effort Engineering
  7. Work Measurement:  PMTS, MTM
  8. System Efficiency Engineering: Methods Efficiency - Method Study, Methods Design
  9. System Efficiency Engineering: Product design efficiency - Value Engineering
  10. System Efficiency Engineering: Inspection methods efficiency  SQC and IE of Quality Management
  11. Modelling Systems for Efficiency Engineering: Operations Research and Quantitative Techniques
12. System Efficiency Engineering: Plant Layout - Efficiency of Material handling and operator movement
13. Developments in IE in Japan
14. Systems Engineering: Systems Design and Industrial Engineering
15. Systems Improvement
16. Systems Installation
17. Management of IE Projects and Objectives: Productivity, Safety, Comfort, and Operator Health  Management
18. Management of IE Department: Organization of IE departments
19. Current Research in IE
Reference Book
Kjell B. Zandin, Maynard’s Industrial Engineering Handbook, 5th Edition, McGraw-Hill, 2004.

In Brief


Industrial Engineering is Human Effort Engineering and System Efficiency Engineering.

According to IIE, IE is concerned with designing systems. The concerns are made explicit in the above statement.

The three component areas of IE can be stated as:


  1. Human Effort engineering,
  2. System Efficiency Engineering and
  3. Systems Design, Installation and Improvement Management 

The third component is an augmented activity for industrial engineering and is a natural progression for industrial engineers. In many companies, various responsibilities in this augmented component are given to industrial engineering departments/sections.

Supporting Knols


Engineering Revision

Industrial Engineering = Knowledge in a branch of engineering + Knowledge in Industrial engineering objective, tools, techniques, methods and functional branded solutions of industrial engineering (This is especially true in courses wherein engineering graduates from various disciplines are admitted into post-graduate diploma or degree course.)

Industrial engineers must have adequate knowledge of engineering in their field of specialisation and improve the knowledge further with study and experience. Industrial engineers have to absorb more and more technical knowledge so that they can understand product designs and process plans and think of alternative designs and processes to compare with proposed ways or current ways of doing work. Industrial engineers have to do research in engineering and create more efficient engineering solutions that consume less resources. For example high speed steel developed by Taylor increased the cutting speed and reduced machining times. This is an example of an engineering solution with focus on less resources. Industrial engineers must have the ability to describe the processes being used by efficient operators to other operators.

Industrial engineers need to have open mind but not blank mind. There is need to have good amount of engineering knowledge to analyze engineering products and processes. Similarly if industrial engineers join service organizations like banks, they have to acquire knowledge of banking and banking operations adequately.

Exercise
In your branch of engineering
Identify some products, their components, design elements and inspection procedures for them.
Describe the procedure of maintaining them.
Develop the production process of each of the components and assembly of the final item, description of the production equipment and maintenance and inspection procedures of the production equipment.

Introduction to Industrial Engineering



The Component Areas of Industrial Engineering

   

Pioneers









Human Effort Engineering


 







System Efficiency Engineering







Machining - Bibliography  link to be changed



Systems Design, Installation and Improvement Management

 

Managing Industrial Engineering Department and Function





Knol Books on Industrial Engineering Techniques






___________________________________________________________________


Chapters Recommended from Maynard's Handbook and Knols for Various Sessions



  1. Definition





Class Lecture slides

----------------------------


______________________ ______________________
----------------------------

 2. Component Areas of IE: Human Effort engineering, System Efficiency Engineering and Systems Engineering







      



Class Lecture Slides

--------------------------------


___________________ ___________________
-------------------------------


   3. Pioneering Efforts of Taylor, Gilbreth and Emerson

       Frederick Winslow Taylor - A Pioneer Industrial Engineer













--------------------------------





---------------------------------







-----------------------------------
________________________
________________________
   4. Human Effort Engineering: Motion Study, Task Analysis

  1. Principles of Human Effort Engineering 
  2. Principles of Motion Economy
     Motion Study - Operation Analysis - Questions      http://www.archive.org/details/EasierWa1946 (Video clip)
        


         Reference: Ralph M. Barnes, Motion and Time Study Measurment of Work, John Wiley & Sons, New York, 1980, Chapters 15,16, 17, pp.174-236)


Reference:
Motion Study by Frank Gilbreth  http://archive.org/stream/motionstudymetho00gilbrich#page/n5/mode/2up
Fatigue Study Frank Gilbreth and Lilian Gilbreth
http://archive.org/stream/fatiguestudyeli00gilbgoog#page/n8/mode/2up
       Human Effort Engineering - Course Proposal



-------------------------------------------------------------------------------

---------------------------------------------------------------------------------
_______________________________________________ ________________________________________________

5. Work Measurement -  Time Study       
         
        Ch. 17.2:   Stopwatch Time Study.

------------------------


-----------------------
_______________________ _______________________
  6.  Ergonomics: The Applied Science for Human Effort Engineering
            Ergonomics - Introduction
        Ch.  6.4:    Manufacturing Ergonomics.

        Reference
        Ergonomic Aspects of Biomechanics - http://www.cdc.gov/niosh/pdfs/74-177-r.pdf
          Ergonomics Cost Benefits Case Study in a Paper Manufacturing Company
        http://www.danmacleod.com/Articles/Cost_Benefits_Paper_Manufacturing.htm 
-----------------


----------------
_________________ _________________

  7. Work Measurement, PMTS, MTM
        Ch.  5.1     Measurement of Work
        Predetermined Motion Time Systems (PMTS)
----------------


---------------
_______________________ _______________________
  8.  System Efficiency Engineering: Method Study, Work Study, Methods Design
           
Methods Efficiency Engineering
        Ch.  4.1: Methods Engineering and Workplace Design. 
  9. Value Engineering
           
Product Design Efficiency Engineering
        Ch. 13.3: Value Management

10.SQC and IE of Quality Management
        Inspection Methods Efficiency Engineering       
        Ch. 13.6 The Role of Statistical Process Control in Improving Quality.
11.Operations Research and Quantitative Techniques
        Ch.  11.2: Principles and Applications of Operations Research. Available at:
         Reference

        The Optimization of PCB manufacturing by improving the drilling process productivity by Mirca Ancau, Computers and Industrial Engineering, September 2008, pp. 279-294.
12. Plant Layout
        Ch.  8.2: Facilities Layout and Design.

13. Engineering Economics
14. Developments in IE in Japan
15. Systems Engineering: Systems Design and Industrial Engineering
16. Systems Improvement
      Ch.2.3: Total Productivity Management.

      Review of Total Productivity Management ch 2.3 of Maynard Book
      Systems Improvement       
      Productivity Improvement Idea Bank
17. Systems Installation
18. Productivity, Safety, Comfort, and Operator Health  Management
      Prescribed chapter from Maynard's book
       Ch.  6.10: Occupational Safety Management and Engineering. 
       Reference
       A chapter collection - Under development
       Productivity, Safety, Comfort, and Operator Health Management - Article Collection
       http://nraoiekc.blogspot.in/2012/04/productivity-safety-comfort-and.html 
19. Organization of IE departments
20. Current Research in IE
       For 2012
       Student assignments and Presentation in the class
       For 2011

IE Studies - Illustrations
         Electronics Manufacturing Company Hand Assembly Productivity Improvement
         By Mr. Bill D. Bailey & Mr. Paul Cheng-Hsin Liu


For supporting the assignments of the course



















Links to Assignments

PGDIE 2010 Batch Assignments



PGDIE 2011 Batch Assignments







Question Bank




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For More Articles on Industrial Engineering


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Industrial Engineering Course Pages on Web

Methods Engineering
Engineering Economics - King Faud University
Operations Research I
Operations Research II
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Presentations





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Original Knol - Number 2105