Sunday, December 29, 2024

Modern Industrial Engineering - A Book of Online Readings

 Modern Industrial Engineering: Combination of 

PRODUCT INDUSTRIAL ENGINEERING (Value), - Customer Value Engineering, Cost Value Engineering, Design for Cost Efficient Manufacture and Assembly (DFMA).

FACILITIES INDUSTRIAL ENGINEERING  (Lean),  - Manufacturing Facilities, Inspection Facilities, Transportation - Material Handling Facilities, Warehousing - Storage Facilities, Data - Information Processing Facilities, Power Generation Facilities, Auxiliary Supplies Facilities

PROCESS INDUSTRIAL ENGINEERING (Minimizing Effort - Machine - Man). 

Machine Effort Industrial Engineering - Human Effort Industrial Engineering




Modern Industrial Engineering - A Book of Online Readings.

Industrial Engineering of Products, Facilities, Processes, Machine Effort and Human Effort.


Version 1.0 - 27.12.2024

Readings Presented as Modules and Lessons of Modern Industrial Engineering.

You can download pdf version of this article.
Modern Industrial Engineering - A Book of Online Readings.


Covering Themes:
Industrial Engineering Strategy - Products - Facilities - Processes Industrial Engineering.
Science - Engineering - Management
Satisfaction of Customers - Employees - Entrepreneurs and Shareholders
Profitability - Productivity - Quality - Flexibility - Sustainability
Industrial Engineering - Foundations - Principles - Progress - Innovations.
Applied Industrial Engineering - Industrial Engineering with New Technologies - Industrial Engineering in New Technologies

Cost Reduction of Products and Services at unit level through Productivity Improvement of all Resources used in Production Processes is the primary and core function of Industrial Engineering.

Others objectives and goals are included in later years.

Constraints like quality, machine health and human health are there right from the start of  productivity improvement activity.

Introduction to Industrial Engineering


Lesson  1 

Industrial Engineering - History

Industrial engineers (IE) are employed and productivity improvement and cost reduction are practiced in many companies using IE  philosophy, principles, methods, techniques and tools.
Apple Inc. - Industrial Engineering Activities and Jobs

Lesson 2

Industrial Engineering - Definition and Explanation

IE Continuous Improvement - 3 Years - 50% Cost Reduction - Diplexer Line Case Study


Lesson 3

Industrial Engineering Introduction

BMW - Industrial Engineering Activities and Jobs


Lesson 4

Pioneering Efforts of Taylor, Gilbreth and Emerson

Coca-Cola - Cisco Systems - Industrial Engineering Activities and Jobs


Lesson 5

Industrial engineering Principles, Methods Tools and Techniques

DuPont - Industrial Engineering Activities and Jobs

Lesson 6

Functions and Focus Areas of Industrial Engineering

Value Engineering - Paddy Transplanter - Case Study

Lesson 7

Industrial Engineering of Belting - 1893

Ford - Industrial Engineering Activities and Jobs

Lesson 8

Productivity Science

GE going strong on Lean & Kaizen
GlaxoSmithKline - GE - Industrial Engineering Activities and Jobs

Lesson 9

Product Industrial Engineering

Value Analysis and Engineering - Examples by L.D. Miles - Part 1

Lesson 10

Process Industrial Engineering

Process Industrial Engineering - Illustration: Process Industrial Engineering Using Robo Cylinder

Lesson 11

Industrial Engineering Economic Analysis

Honda - Industrial Engineering Activities and Jobs

Lesson 12

IE Measurements

Milling - Estimation of Machining Time

Lesson 13

Value Creation for the Organization by Industrial Engineers - Productivity Engineering

Process Industrial Engineering - Illustration:  Gear Machining Productivity


Module  2 

Contribution of Taylor, Gilbreth, Emerson, Maynard, Barnes, Lehrer, Shigeo Shingo

Lesson 14

Taylor - Productivity Science and Art of Metal Cutting - Important Points

Process Industrial Engineering - Illustration:    Cryogenic Machining Adoption - Productivity Improvement at Lockheed Martin


15

Taylor's Industrial Engineering - First Proposal 1895

Process Industrial Engineering - Illustration - Investment in Sliding-Head Lathe with Chipbreaking Feature

16

Industrial Engineering Described in Shop Management by F.W. Taylor

Process Industrial Engineering - Illustration - Process Improvement via Toolholder Change

17

Productivity Improvement in Machine Shop - F.W. Taylor

Tool Wear and Temperature Analysis for Process Improvement

18

Development of Science in Mechanic Arts - F.W. Taylor

Dynamic Control of Circulatory Pumps for Heating Systems Saves 20% of Energy Cost

19

Time Study for Process Time Reduction - F.W. Taylor

Process Industrial Engineering - Illustration - Additive Manufacturing of Fixtures - Productivity Benefits

20

Taylor on Quality, Human Relations and Management

Process Industrial Engineering - Illustration -Alternative Lubricants and Productivity - Case Study

21

Gilbreth's Human Effort Industrial Engineering Motion Study - Part 1

Illustration of Human Effort Productivity Improvement - Bricklaying Improvement by Gilbreth

22

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 2

Illustration of Human Effort Productivity Improvement - Pig Iron Handling by Taylor

23

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 3

Illustration of Human Effort Productivity Improvement - Bicycle Balls Inspection Example - Taylor

24

Gilbreth's Human Effort Industrial Engineering - Motion Study - Part 4

Case Study - Method Study - Cast Iron Housing Loading and Unloading 2014

25

Gilbreth's Human Effort Industrial Engineering - Productivity Science of Motion Study - Variables Affecting of Motion Time.
ACCELERATION - AUTOMATICITY - COMBINATION WITH OTHER MOTIONS, AND SEQUENCE - COST - DIRECTION AND USE OF GRAVITY - EFFECTIVENESS - FOOT-POUNDS OF WORK ACCOMPLISHED - INERTIA AND MOMENTUM OVERCOME - LENGTH

Case Study - Method Study - Welding Fixture Redesign - Productivity Improvement 2002

26

Gilbreth's Human Effort Industrial Engineering - Productivity Science of Motion Study - Future Scope

Case Study: Method and Motion Study in a Printing Company - 2019

27

Process Charts - Gilbreths - 1921

Case Study - Examining All Operations in a Process

28

It is important that industrial engineers have to recognize that scientific management was evaluated by Lilian Gilbreth, a psychologist from a human behavior  perspective and a positive opinion was given. Industrial engineering, appeared as a part of the system of management and engineering developed to reduce cost of products made using engineering processes and methods.


Psychology Evaluation of Scientific Management by Lilian Gilbreth - 1914

Implementing Standard Work - Issues

29

After discussing the contribution of Taylor and Gilbreth in more detail, the contribution of many other industrial engineering researchers, professionals, consultants and authors are provided in a series of notes to introduce more industrial engineering concepts. These concepts and their applications will be discussed in more detail in various focus area modules of the course.

Harrington Emerson - A Pioneer Industrial Engineer - His Principles and Practices

Case Study: New Scheduling Algorithm Substantially Improves Foundry Productivity - 2017

30

Prof. Hugo Diemer - Taylor's Industrial Engineering

Industrial Engineering Exercise: Productivity Analysis of a Newly Introduced Machine

31

Industrial Engineering - The Concept - Developed by Going in 1911

Productivity Improvement Using Alternative Boring Heads

32

Taylor Society Bulletin

Information for IE: Productivity Improvement Technology in Grinding - 2020

33


Operation Analysis and Improvement: Application of Tribos Toolholder for Productivity

34

H.B. Maynard - HUMAN EFFORT INDUSTRIAL ENGINEERING - Methods Time Measurement (MTM) - Introduction
H.B. Maynard - Methods Time Measurement (MTM) - Introduction (Revised)

Operation Improvement:   Rego-Fix ER Collets for Tools - Productivity Improvement Case

35

Operator Industrial Engineering - Kaizen - Work Simplification - Alan Mogensen
Work Simplification - Alan Mogensen (Revised)

Operation Improvement: Productivity Improvement Through Tool and Toolholder Change - Corogrip

36

Method Study - Ralph M. Barnes - Important Points of Various Chapters

Collet for Corochuck 930 with Mechanical Locking - Productivity Improvement Use Case


37

Product Industrial Engineering for Cost Reduction - L.D. Miles

Value Analysis and Engineering - Examples by L.D. Miles - Part 2

38

L.D. Miles - 13 Techniques of Value Analysis

Unless special effort to know is made, engineers take 10 years to know engineering developments and implement them in their company processes - L.D. MILES.
Prime Turning (TM) - New Turning Process with High Productivity
RE-INVENTING TURNING, SANDVIK COROMANT TECHNICAL PAPER, 2018
https://nraoiekc.blogspot.com/2020/06/sandvik-coromant-cutting-tools.html

39

Yoichi Ueno - Japanese Leader in Efficiency - Productivity Movement

Sandvik PrimeTurning™ Increases Productivity - Case Studies

40

Toyota style Industrial Engineering - Waste Elimination - Ohno

"We have eliminated waste by examining available resources, rearranging machines, improving machining processes, installing autonomous systems, improving tools, analyzing transportation methods and optimizing the materials at hand for manufacturing. High production efficiency has also been maintained by preventing the recurrence of defective products, operational mistakes, and accidents, and by incorporating workers' ideas." Taiichi Ohno (P. 21)

Taiichi Ohno on Industrial Engineering - Toyota Style Industrial Engineering

Productivity Improvement Using Through-Tool High Pressure Coolant

41

Industrial Engineering - Foundation of Toyota Production System

3D Printing Multiple Numbers as a Vertical Stack - Significant Productivity Improvement

42

Taylor's Industrial Engineering in New Framework - Narayana Rao

Seco Jetstream Tooling - Benefit - Case Study

43

Review of Module 1 - Industrial Engineering ONLINE Course

Industrial Engineering Concepts - Industrial Engineering ONLINE Course Module 2 - Review

Module 3 of Industrial Engineering ONLINE Course


Sub-Modules

Productivity Science - Taylor's Research on Machining Productivity Improvement
Metal Cutting Theory - Productivity Focus
Process Planning Principles
Process Charting for Process Analysis
Operation Analysis of Value Adding Transformation (Operation in Process Chart Terminology)
Operation Analysis of Inspection
Operation Analysis of Material Handling and Transport
Operation Analysis of Temporary Delays
Operation Analysis of Storage in Stores
Operation Analysis of Information Generation and Communication

Various organization level issues like plant layout, JIT-lean thinking, and TPM will be covered in the module as part of operation analysis of various tasks in the processes.


Introduction to Process Industrial Engineering
______________


https://www.youtube.com/watch?v=yIpkLPpsA18
______________





Process Industrial Engineering Module 

The module will have 125 lessons (lessons 44 to 175 of IE Course) and case studies/illustrations/information for IE articles


Lesson: 44 

Introduction to Process Industrial Engineering Module


Knowledge Required for Process Industrial Engineering Application and Practice


News - Information for Value-Adding Operation Analysis
Flow Process Chart - Value-Adding Operation - Inspection - Transport - Temporary Delay - Storage - Information

Productivity Science - Taylor's Research on Machining Productivity Improvement


45

IE Research by Taylor Part 1 - Productivity of Machining

You can download pdf file (Free download). 
Productivity Science of Machining - F.W. Taylor - Experiments and Results.


News - Information for Inspection Operation Analysis


46

Part 2 - IE Research by Taylor - Productivity of Machining

News - Information for Material Handling and Transport Operation Analysis

47

Part 3 - IE Research by Taylor - Productivity of Machining.

News - Information for Analysis of Delays in Processes

48

Part 4 - IE Research by Taylor - Productivity of Machining
https://nraoiekc.blogspot.com/2020/07/part-4-ie-research-by-taylor.html

News - Information for Storage/Warehousing Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-storagewarehousing.html

49

Part 5 - IE Research by Taylor - Productivity of Machining
https://nraoiekc.blogspot.com/2020/07/part-5-ie-research-by-taylor.html

News - Information for Information Generation & Transmission - Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-information.html


Sub-Module - Metal Cutting Theory - Productivity Focus Lessons


50

Metal Cutting Processes - Industrial Engineering and Productivity Aspects
https://nraoiekc.blogspot.com/2020/07/metal-cutting-processes-industrial.html

News - Information for Maintenance Operation Analysis
https://nraoiekc.blogspot.com/2020/07/news-information-for-maintenance.html

51

Machine Tools - Industrial Engineering and Productivity Aspects

52

Machining Cutting Tools - Industrial Engineering and Productivity Aspects

53

Machine Tool Toolholders - Industrial Engineering and Productivity Aspects

54

Metal Cutting Temperatures - Industrial Engineering and Productivity Aspects

55

Machining Process Simulation - Industrial Engineering and Productivity Analysis

56

Cutting Tool Wear and Tool Life Analysis - Industrial Engineering and Productivity Aspects

57

Surface Finish - Industrial Engineering and Productivity Aspects

58

Work Material - Machinability - Industrial Engineering and Productivity Aspects

59

Machine Rigidity - Industrial Engineering and Productivity Aspects

60

Machining Time Reduction - Machining Cost Reduction - Industrial Engineering of Machining Operations

61

Machine Tool Cutting Fluids - Industrial Engineering and Productivity Aspects


62

High Speed Machining - Industrial Engineering and Productivity Aspects

63

Design for Machining - Industrial Engineering and Productivity Aspects


One has to know how the process is designed to analyze it later and improve it. IEs have to know complete engineering/planning of a process.


Process Planning Principles


64.

Production Process Planning - Foundation for Production

65.

Assembly Design - Process Planning & Industrial Engineering Perspective

66.

Technical Drawings - Important Guidelines - Process Planning and Industrial Engineering

The Lean Revolution in Lantech - 1992-2003 - Womack and Jones

67.

Selection of Metal Removal Processes - Initial Steps - Process Planning and Process Industrial Engineering

Lean System in Lantech - 2004 Onwards

68.

Fixturing and Clamping the Work Piece - Process Planning and Process Industrial Engineering

69.

Determining Depth of Cuts for Multiple Cuts - Process Planning and Process Industrial Engineering

70.

Selecting Cutting Speed - Process Planning and Process Industrial Engineering

71.

Selecting a Machine for the Operation - Process Planning and Process Industrial Engineering

72.

Selecting Tools for a Machining Operation - Process Planning and Process Industrial Engineering





Process Analysis for Productivity Improvement Opportunities


81



82


83



84



85



86



87



88



89



90


91


92



93



94. 



95


96


97



Productivity Engineering


101


102

103

104

105

106

107


108

109


111.

112.
Productivity Automation Engineering
Redesigning products or processes by incorporating automation to improve productivity.
http://nraoiekc.blogspot.com/2017/09/productivity-automation-engineering.html

113.
Productivity Software Engineering
Redesigning products or processes by including software solutions, or developing software solutions to improve productivity in any activity or process
http://nraoiekc.blogspot.in/2017/09/productivity-software-engineering.html

114.
Productivity VR Engineering: Redesigning products and processes using VR to improve productivity.
http://nraoiekc.blogspot.in/2017/09/productivity-vr-engineering.html

115.
Productivity IoT Engineering
Using IoT technology and systems to improve productivity of engineering and engineering related products and processes.
http://nraoiekc.blogspot.com/2017/09/productivity-iot-engineering.html

Inspection Operations Improvement


126


127


128



129




132




Transport - Material Handling Operations

136-145

136



137


Supporting Materials

138

139


140

141










Storage - Warehousing Operations

146 - 155

146







Analysis and Elimination of Delays

156 - 165

156




______________________________________________________________________

166 - 175

Supply Chain Industrial Engineering - Supply Chain Processes Industrial Engineering

166

167 

168

169

170
171


Process Human Effort Industrial Engineering Module Lessons

201

Process Human Effort Industrial Engineering - Lesson 1. Process Human Effort Industrial Engineering - Introduction to The Module 
Lesson 201 of Industrial Engineering FREE ONLINE Course. 

202
Human Effort Waste Elimination Through Scientific Management - F.W. Taylor
Lesson 202 of Industrial Engineering FREE ONLINE Course. 

203


204


205


206


207


208



209

Paper on Therbligs by Gilbreth

https://nraoiekc.blogspot.com/2012/07/paper-on-therbligs-by-gilbreth.html

210

Principles of Motion Economy

https://nraomtr.blogspot.com/2016/06/principles-of-motion-economy.html

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

https://nraoiekc.blogspot.com/2012/02/principles-of-motion-economy-some-more.html


211

Operation and Flow Process Charts - Origin, Evolution and Application

212



213

SIMO Chart Using Therbligs - Two Handed Chart for Micro-Motion Study


214

Motion Analysis - Two Handed Operation/Process Chart - Operator Motions Chart


215

SIMO Chart Analysis

216

More Charts and Diagrams - Human Effort Industrial Engineering


217

Human Comfort Industrial Engineering - Human Effort Industrial Engineering

217a.

Ergonomics in Human Effort Industrial Engineering - Introduction

218

Work-Related Limb Disorders - Musculoskeletal Disorders - Topic in Human Effort Industrial Engineering



219

Ergonomics of Work System Design - Human Effort Industrial Engineering


220

Ergonomic Information on Work Environment for Human Effort Industrial Engineering


221

Behavioral, Cognitive and Managerial Ergonomics for Human Effort Industrial Engineering


222

Ergonomics - Methods and Techniques - Implementation for Human Effort Industrial Engineering


223

Man Machine Interface Design  - Industrial Engineering


224



Work Station Design - Introduction


225

Human Effort Industrial Engineering - Provision and Design of Hand Tools and Safety Accessories 
Industrial Engineering - Hand Tools, Cutting Tools and Machine Accessories for Productivity


Product Industrial Engineering Module Lessons 

(Module of IEKC Industrial Engineering Online Course Notes)


Product Industrial Engineering Methods - Value Engineering and DFMA

Value Engineering











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

Value Engineering Case Studies, Case Study Collections and Information





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






DFMA







Industrial Engineering Measurements - Module


271. Industrial Engineering Measurements - Online Course Module - Introduction and Index

272. Cost Measurement - Essential Activity of Industrial Engineering

273. Basics of Accounting for Industrial Engineers.

274. Cost Accounting - Introduction

Job Costing - Review Notes

Process Costing - Review Notes

Cost Center Reports and Analysis

Cost Behavior Analysis and Relevant Costs Concept

Machine Cost and Work Measurement - Time and Cost Estimates for Metal Forming Processes

Cost Measurement in Manufacturing Execution System (MES)

285. Cost Engineering


Time Study - Work Measurement

Engineering tasks are to be divided into elementary operations or elements, and the time to complete them has to be understood through various elements contributing to it. Through that understanding the time to do an element has to be reduced. These elements have to be classified into standard elements that are present in multiple tasks. 

Time study has to be done at the start of the process improvement study. At intermediate points in the study. At the end of the study. Then after some training and practice in the new method, it has to be done to fix the output expected from the new process as standard.

Taylor's Time Study: Taylor wanted time study to generate standard data for specified elements of work of machines and men. This standard data can be at national or universal level, industry level or company level. Taylor and Gilbreth recommended study of the best person to understand the best way of doing a work element. They spent time to further improve the way of doing based on productivity science developed them on the work element. For them the output  of time study has to be the best way of doing a work element and the minimum time in which it can be done. Taylor insisted from the beginning that the speed specified for operations has to be the speed that can be done comfortably, safely and healthily for the entire career span of the operators. What is that speed? Industrial engineering discipline later on developed a standard for that speed as 3 miles per hour. But is it scientifically validated? It may be necessary to provide solid logic and empirical foundation for this standard. Do people feel  happy and comfortable to walk 24 miles per day in 8 hours? This standard has corresponding specification in various work elements. In which work element, people are happy and comfortable to do as per the standard? It is an important question to be answered IE discipline.



291. Time Study - Explanation by F.W. Taylor in Shop Management Paper/Book


Description of Time Study in Motion and Time Study Books

Time Study and Work Measurement - ILO Work Study Book Explanation

Work Sampling

Work Measurement for Recording Times in Process Charts is ignored in current work measurement theory. 


Therbligs (Elements of Human Effort or Work) by Gilbreth

Productivity Measurement


Productivity Measurement

Measuring Productivity - OECD
http://www.esri.go.jp/jp/workshop/050325/050325paper06.pdf

{Productivity Measurement within a new architecture for the U.S. National Accounts: Lessons for Asia  http://www.apo-tokyo.org/files/mp_apo-keo_jorgenson_lec.pdf not available now.]

APO 2019 Productivity Data Book
https://www.apo-tokyo.org/publications/wp-content/uploads/sites/5/APO-Productivity-Databook-2019_light.pdf


How to Measure Company Productivity using Value-added: A Focus on Pohang Steel (POSCO)
http://www.anderson.ucla.edu/faculty/marvin.lieberman/docs/Lieberman_POSCO.pdf

The productivity slump—fact or fiction: The measurement debate
August 2016
https://www.brookings.edu/research/the-productivity-slump-fact-or-fiction-the-measurement-debate/

Estimates of Industry Multifactor Productivity, 2017-18
https://www.abs.gov.au/AUSSTATS/abs@.nsf/Lookup/5260.0.55.002Main+Features12017-18?OpenDocument


Measuring developer productivity in 2019 for data-driven decision makers
https://www.gitclear.com/measuring_developer_productivity_a_comprehensive_guide_for_the_data_driven
By Bill Harding
Last updated July 19, 2019.

Waste Measurement

Waste measurement is highlighted by Taiichi Ohno and other Toyota industrial engineers. Material and information flow diagram is totally Toyota invention and it measures and highlights inventory. A setup time is the variable that controls inventory (lot size), it records setup times.

Taking the cue from TPS, industrial engineering discipline has to start measurement of waste as industrial engineering measurement area.

Ohno's Seven Wastes

Losses identified in TPM

16 Losses given by Yamashina in Manufacturing Cost Reduction Deployment

Value Stream Mapping to Identify Inventory Accumulations

The Seven Value Stream Mapping Tools for Identifying Seven Wastes - Peter Hines and Nick Rich 

Waste Measurement and Reporting Using MES - Manufacturing Execution System


Industrial Engineering Economic Analysis


Industrial Engineering Economics - Important Component of Industrial Engineering




Rate-of-Return Calculations


Equivalent Annual-Worth Comparisons

Expected Values and Risk of Project Revenues and Costs


Case Studies



Inkjet Versus Laser Printing - Engineering Economics

Productivity Improvement Using Rapier Looms in Place of Shuttle Looms - IE Economic Analysis.

Robots - Engineering Economic Analysis

Robotic Applications in Indian Companies - Engineering Economic Analysis

Productivity Management Module


337. Functions of Productivity Management

338. The Evolution of Productivity Management

339. Productivity Management - F.W. Taylor

340. Productivity Management in Operations Management Since 1886

341. Productivity Management - Improving Productivity - Stevenson in Operations Management Book

342. Functional Foremanship - F.W. Taylor

        Productivity - Basic Concepts

Harrington Emerson - 12 Principles of Efficiency - Productivity Management

343. Harrington Emerson - The Twelve Principles of Efficiency - Part 1 - Principles of Productivity Management

344. Harrington Emerson - The First Efficiency Principle: Clearly Defined Ideals (Objectives and Goals)

345. Industrial Engineering #Data. Harrington Emerson - The Sixth  Efficiency Principle: Reliable, Immediate, Adequate, and permanent Records. 

346. Harrington Emerson's The Seventh Efficiency (Productivity Management) Principle: Despatching.

347. Harrington Emerson's Eighth Efficiency (Productivity Management) Principle: Standards and Schedules 

https://nraoiekc.blogspot.com/2013/10/chapter-10x-eighth-principle-standards.html

348. Harrington Emerson's Ninth Efficiency (Productivity Management) Principle: Standardized Conditions. 

https://nraoiekc.blogspot.com/2013/10/chapter-11-ninth-principle-standardized.html


349. Harrington Emerson's Tenth Efficiency (Productivity Management) Principle: Standardized Operations. 

https://nraoiekc.blogspot.com/2013/10/chapter-12-tenth-principle-standardized.html


350. Harrington Emerson's Eleventh Efficiency (Productivity Management) Principle: Written  Standard-Practice Instructions. 

https://nraoiekc.blogspot.com/2013/10/chapter-xiii-eleventh-principle-written.html

351. Harrington Emerson's Twelfth  Efficiency (Productivity Management) Principle: Efficiency Reward. 

https://nraoiekc.blogspot.com/2013/10/chapter-14-twelfth-principle-efficiency.html

352. Harrington Emerson:  12 Efficiency Principles  Applied to Measurement and Cure of Wastes. 

https://nraoiekc.blogspot.com/2013/10/chapter-15-efficiency-principles.html


354.  Industrial Engineering - Its Role in Productivity Improvement

355.  Productivity Planning

356.  Manufacturing Cost Reduction Policy Deployment - Introduction.

357. Organizing for Industrial Engineering Department and Function

358. Resourcing for IE Department and Productivity Improvement Projects

359. Productivity - Communication

360. Productivity Training by Industrial Engineers

361. Productivity Control - Productivity Management - Koontz & O'Donnell

https://nraoiekc.blogspot.com/2022/03/productivity-control.html

362. Principles and Practices of Productivity Management

https://nraoiekc.blogspot.com/2021/06/principles-of-productivity-management.html



366. Industrial Engineering Strategy

367. Success Stories - Industrial Engineering, Productivity Improvement and Productivity Management


IEOR Module


371. Operations Research - An Efficiency Improvement Tool for Industrial Engineers

372. PRINCIPLES AND APPLICATIONS OF OPERATIONS RESEARCH
(from the perspective of an industrial engineer)
(From Maynard's Industrial Engineering Handbook, 5th Edition, pp. 11.27-11.44)
Jayant Rajgopal (From Rajgopal's website)
http://www.pitt.edu/~jrclass/or/or-intro.html

373. Engineering Optimization - Introduction


374. Single Variable Optimization - Engineering Problems

375. Multi-Variable Optimization - Engineering Problems

376. Constrained Optimization - Engineering Applications

377







Crankshaft - Engineering Optimization - Bibliography


Optimization - Minimization of Resources Used in Big Data Storage and Analysis


Engineering Optimization - Courses and Resources

What is mathematical programming?
http://coral.ie.lehigh.edu/~ted/files/ie316/lectures/Lecture1.pdf

Examples of Mathematical Programming.
http://coral.ie.lehigh.edu/~ted/files/ie316/lectures/Lecture2.pdf



Simplex Method
http://mat.gsia.cmu.edu/classes/QUANT/NOTES/chap7.pdf

Transportation Problem
http://orms.pef.czu.cz/text/transProblem.html

Queing Models
http://orms.pef.czu.cz/text/QueTeory/QueuingModels.html

Simulation

http://orms.pef.czu.cz/text/NolinearProgramming/simulation.html


An Overview of Optimization Techniques for CNC Milling Machine
https://www.alliedjournals.com/download_data/IJEMS_V1IS50005.pdf

New Technology and Optimization of Mobile Phone Battery
https://theseus.fi/bitstream/handle/10024/110646/Liu%20Jian_Zhang%20Yixian.pdf?sequence=1

Combustion Optimization in PF Boilers
http://www.eecpowerindia.com/codelibrary/ckeditor/ckfinder/userfiles/files/Session%201%20Combustion%20and%20Optimisation%20in%20coal%20fired%20boilers_KBP_17_09_2013.pdf

Application of Optimization Techniques in the Power System Control
https://uni-obuda.hu/journal/Kadar_43.pdf

More cases to illustrate the application in each operation of the process chart will be collected.


Overview of injection molding process optimization technology

Optimal inspection strategy for a multi-stage production process using simulation optimization.

Optimization of material handling in production by G Ioannou · 2004


Optimization designed to optimize surgery scheduling for a hospital system.
https://www.youtube.com/watch?v=LHlAAuQTfgQ


IE Statistics - Six Sigma Module Lessons


Lesson 401

Statistics and Industrial Engineering

http://nraoiekc.blogspot.com/2012/07/statistics-and-industrial-engineering.html

402

Statistical Quality Control – Industrial Engineering

https://nraomtr.blogspot.com/2011/12/statistical-quality-control-industrial.html


403
Basics of Statistics

https://eng.libretexts.org/Bookshelves/Industrial_and_Systems_Engineering/Book%3A_Chemical_Process_Dynamics_and_Controls_(Woolf)/13%3A_Statistics_and_Probability_Background/13.01%3A_Basic_statistics-_mean%2C_median%2C_average%2C_standard_deviation%2C_z-scores%2C_and_p-value




404

Statistical Process Control
http://www.itl.nist.gov/div898/handbook/pmc/section1/pmc12.htm
http://www.itl.nist.gov/div898/handbook/pmc/section3/pmc3.htm

Evaluation Improvement of Production Productivity Performance using Statistical Process Control, Overall Equipment Efficiency, and Autonomous Maintenance,
Amir Azizi
Procedia Manufacturing
Volume 2, 2015, Pages 186-190
open access
http://www.sciencedirect.com/science/article/pii/S2351978915000335

405

Statistical Quality Control
http://www.itl.nist.gov/div898/handbook/pmc/section2/pmc2.htm


406

Calculation of Sample Sizes in Work Measurement and Work Sampling

http://www.measuringu.com/sample_continuous.htm
http://www.prenhall.com/divisions/bp/app/russellcd/PROTECT/CHAPTERS/CHAP08/HEAD06.HTM  (WorK measurement full chapter - Includes sample size calculation for time study and work sampling)

407

Test of Hypothesis

Test of hypothesis is to be used by industrial engineers to confirm or validate that their redesign or a process has resulted in the increase of productivity. This becomes useful when there is variation in the output from various workstations or persons.  We can also visualize activities in different places. In such case we test the hypothesis that productivity has improved in the workstations where redesign is is implemented.

http://www.randomservices.org/random/hypothesis/index.html

HYPOTHESIS TESTING FOR THE PROCESS CAPABILITY RATIO - 2002 MS Thesis
https://etd.ohiolink.edu/!etd.send_file%3Faccession%3Dohiou1040054409%26disposition%3Dinline

One More presentation
http://fac.ksu.edu.sa/sites/default/files/DOE_Lecture%204%20test%20of%20hypothesis.pdf

408

Design of Experiments

http://asq.org/learn-about-quality/data-collection-analysis-tools/overview/design-of-experiments-tutorial.html

http://www.itl.nist.gov/div898/handbook/pmd/section3/pmd31.htm


409

Six Sigma

http://www.intechopen.com/books/quality-management-and-six-sigma/six-sigma

http://nraomtr.blogspot.com/2014/05/six-sigma-introduction.html


410

Initiating Six Sigma - IE Six Sigma - Robust Productive Process Design


https://nraoiekc.blogspot.com/2022/03/initiating-six-sigma-ie-six-sigma.html

411

Measurements for Six Sigma - IE Six Sigma - Robust Productive Process Design

https://nraoiekc.blogspot.com/2022/03/measurements-for-six-sigma-ie-six-sigma.html


412

Data Analysis for Six Sigma - IE Six Sigma - Robust Productive Process Design

https://nraoiekc.blogspot.com/2022/03/data-analysis-for-six-sigma-ie-six.html

413

Improve The Process - IE Six Sigma - Robust Productive Process Design

https://nraoiekc.blogspot.com/2022/03/improve-process-ie-six-sigma-robust.html

414

Control the Process - IE Six Sigma - Robust Productive Process Design

https://nraoiekc.blogspot.com/2022/03/control-process-ie-six-sigma-robust.html

415

Implementing and Getting Results from Six Sigma - IE Six Sigma - Robust Productive Process Design

https://nraoiekc.blogspot.com/2022/03/implementing-and-getting-results-from.html


416

Design for Six Sigma (DFSS) - IE Six Sigma - Robust Productive Process Design

https://nraoiekc.blogspot.com/2022/03/design-for-six-sigma-dfss-ie-six-sigma.html

417

Application of Six Sigma. Successful Projects from the Application of Six Sigma Methodology - Jaime Sanchez and Adan Valles-Chavez.

https://www.intechopen.com/chapters/17409



Additional Content


Application of Six Sigma
http://www.wseas.us/e-library/conferences/2013/Vouliagmeni/INMAT/INMAT-01.pdf

Application of Six Sigma
http://www.journalamme.org/papers_amme05/1414.pdf



Applied Industrial Engineering - IE in Various Branches of Industrial Engineering

Industrial engineering is primarily an engineering discipline with productivity orientation. It major application is in incremental improvement of processes that give benefit within one year and hence it became closely allied with management in increasing profits, reducing costs and providing the company with the potential to reduce prices and increase profit. Hence Taiichi Ohno said industrial engineering is profit engineering. If a company is not using IE, it is losing an opportunity.

The application of industrial engineering is in processes of all engineering branches. Engineering activities like product design, production, maintenance of machines in factories, and service of consumer items are important engineering activities. In addition material handling and storage also involve engineering. Unfortunately, industrial engineering profession has not given enough attention to makes its presence in various engineering branches visible and systemic. Only limited attempts were done to create textbooks that discuss IE in specific engineering branches.

Industrial Engineering in Chemical Engineering


Industrial Engineering in Civil Engineering

Industrial Engineering in Computer Engineering and Information Technology

Industrial Engineering in Electrical Engineering

Industrial Engineering in Electronics Engineering

Industrial Engineering in Health Care

Information Systems Industrial Engineering - Information Systems Engineering

Industrial Engineering in Textile Engineering

Applied Industrial Engineering in New Technologies

IE in New Technologies - IE with New Technologies


Implementation of  Industrial Engineering Principles and Techniques in New Technologies (Engineering Processes) and Business Processes


Lesson 433


Lesson 434

435
Industrial Engineering in Data Center Design and Processes


436


437


438


439
Electric Batteries and Productivity Applications. - Productivity and Industrial Engineering (IE) in Battery Manufacturing


441
Productivity Automation Engineering - Automation and Productivity

A Good Example of Applied IE - Improving Processes using New Technologies

Industry 4.0 Technology and Manual Assembly
By Amanda Aljinovic
March 15, 2023

Digital work instructions, cobots, radio frequency identification (RFID), augmented reality (AR) and other Industry 4.0 technologies can help. These technologies are designed to provide cognitive and physical support to people on the assembly line.  How can engineers decide when such technologies are a worthwhile investment?

In a case study, industry 4.0 technologies application in a gear-box assembly line was studied.

Seven Industry 4.0 technologies were considered: RFID, digital work instructions, pick-to-light technology, AR, cobots, automated guided vehicles, and ergonomic manipulators.



Four quantitative criteria were used to rank the technologies: total investment cost, worker effort, workspace utilization and cycle time reduction. 

RFID is one of the most important technologies for identifying and tracking assemblies in a production system. It provides precise information about the locations or states of goods in real-time and serves as a capstone for the establishment of the IoT within production.

Digital instructions are proven to reduce the assembly time and errors with complex assemblies.

Pick-to-light systems use LEDs on racks or shelves to show assemblers where to pick parts for an assembly and how many to retrieve. The lights guide assemblers through each step in the process. These systems are often connected with warehouse management systems.

AR also offers the possibility of significant improvement in cycle time, error rate, mental strain, worker focus.

Cobots are particularly desirable when people are confronted with heavy loads and repetitive, tedious activities. People can share the same workspace with the cobots, allowing managers to allocate tasks in a more flexible, efficient way.

AGVs can eliminate the need for people to transport parts and assemblies to and from the assembly line.

The ergonomic manipulator is an electronic device developed to improve ergonomics at the fifth assembly workstation. The device reduces the amount of physical effort needed to handle heavy components that must be mounted to the gearbox.

This article is a summary of a research paper co-authored by Aljinovic, Nikola Gjeldum, Ph.D., Boženko Bilic, Ph.D., and Marko Mladineo, Ph.D. 


Industrial Engineering 4.0


442

Industrial Engineering 4.0 - IE in the Era of Industry 4.0

443
Industry 4.0 - A Note for Industrial Engineers for Industrial Engineering 4.0 (IE 4.0) 

444
Augmented Reality - Exploration


445
Autonomous Robots - A Note for Industrial Engineers for Industrial Engineering 4.0 (IE 4.0)

446
Data Analytics Period in Productivity Improvement - Productivity Engineering and Management

447
Cloud Computing - Engineering Economic and Financial Analysis

448
IoT Technology - Exploration - Industrial Engineering Point of View

449
Simulation and Forecasting - A Note for Industrial Engineers for Industrial Engineering 4.0 (IE 4.0)

Specific Industries and Technologies

456
Productivity and IE in Tire Manufacturing - Applied Industrial Engineering

457
Industrial Engineering in Health Care

458
Productivity Engineering of Tractors and Agriculture - Smart/Intelligent/Autonomous/IoT Tractors

459
Industrial Engineering of Welding Processes





460
Productivity and IE in Printed Circuit Board Manufacturing

461
Die Casting Productivity - Bibliography

462
Productivity Success Story - Coca Cola

463
Productivity and IE in Motor and Generator Manufacturing

464
Productivity and IE in Motor Vehicle Metal Stamping

465
Productivity and IE in Screw, Nut, and Bolt Manufacturing

466
Productivity and IE in Spring Manufacturing

467
Productivity and IE in Iron and Steel Forging

468
Productivity and IE in Automobile Manufacturing

469
Productivity in Machine Shops - Industrial Engineering and Lean Thinking

470
Productivity and IE in Paint, Coating, and Adhesive Manufacturing

471 
Productivity and IE in Motorcycle and Scooter Manufacturing

472
Productivity and IE in Pharmaceutical and Medicine Manufacturing

473
Grinding - Productivity Science and Productivity Engineering - Opportunities for 2020 and Beyond

474
Productivity and IE in Dies , Jig, and Fixture Manufacturing
 
475
Productivity and IE in Apparel Manufacturing

476
Productivity and IE in Electronic Assembly Manufacturing

477
Productivity and IE in Iron and Steel Pipe and Tube Manufacturing

478

Bosch Automotive - Bursa - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Deployed  AI use cases such as close loop process control for hydro-erosion, and upskilling 100% of the workforce.  

They reduced unit manufacturing cost by 9% and improved OEE by 9%.

479
CEAT - Halol, India Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant.

CEAT deployed Fourth Industrial Revolution use cases like advanced analytics to optimize cycle times and digitalization of operator’s touchpoints. 

The site reduced cycle times by 20%, process scrap by 46%, and energy consumption by 15% . 
Overall, this resulted in approximately a 2.5 times increase in export and OEM sales in two years.

480
Dr Reddy's - Hyderabad Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

The site deployed 40+ 4IR use cases by operating in garage mode and leveraging IIoT & democratized platform for advanced analytics. 

It improved manufacturing cost by 43% while proactively enhancing quality and reducing energy by 41%.

481
Ericsson - Lewisville Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

The use of digital twins led to substantial enhancements: a 25% increase in throughput and a 50% reduction in unplanned downtimes.

482
Foxconn - Shenzen Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


Shenzhen factory uses computer-controlled autonomous manufacturing in the dark, basically without assembly line workers in the production of electrical equipment components used in smartphones. It is  equipped with an automated optimization system for Machine Learning and AI devices, an intelligent self-maintenance system, and an intelligent real-time monitoring system. 

The factory’s production efficiency has been increased by 30%  and the inventory cycle reduced by 15%.


483
GlaxoSmithKline (GSK) Hertfordshire Plant - Industrial Engineering 4.0

The GSK plant has applied advanced technologies throughout its manufacturing operation, using advanced analytics and neural networks.  This has improved line speeds at the site by 21%, cut downtime, increased yields, and delivered an OEE (overall Equipment effectiveness) improvement of 10%.

GSK has applied deep-learning image recognition to detect quality defects, and is using artificial intelligence to optimise machine throughput. 

By implementing digital twin technologies, it has boosted capacity by 13%, while cycle time monitoring and the use of digital visualisation tools have cut cycle times by 9%.

484
Haier - Hefei Plant - Industrial Engineering 4.0 - Industry 4.0 WEF-McKinsey Lighthouse


Haier’s Hefei air conditioner factory applied advanced algorithms, digital twins, knowledge graphs and other cutting-edge technologies in the research and development (R&D), production and testing of household central AC systems, resulting in a 33% increase in energy efficiency, a 58% drop in the defect rate, a 49% increase in labour productivity and a 22% drop in unit manufacturing costs.

485
Ingrasys - Taoyuan, Taiwan Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

By deploying AI use cases across order forecasting, warehouse and production scheduling, product design, quality and assembly-testing domains, Foxconn Industrial Internet’s Taiwan factory has achieved a 73% increase in production efficiency, a 97% reduction in product defects, a 21% reduction in lead time and a 39% decrease in unit manufacturing costs.


486
Johnson & Johnson - Industrial Engineering - Productivity Improvement Activities - Industry 4.0 Lighthouse Plant

Johnson Xi’an replaced its manual facility with a Fourth Industrial Revolution-enabled new factory in 2019. This facility includes digital twins for technology transfer and material handling, intelligent automation of continued process verification (CPV) and batch execution processes. 

This has shortened the product transfer time by 64% during site relocation and has enabled a 60% decrease in non-conformance, while improving productivity by 40%, operating costs by 24% and GHG emissions by 26%.


487
K-Water - Hwaseong - REPUBLIC OF KOREA - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

K-water launched a next-generation AI water treatment plant to reduce production costs, improve responsiveness and reduce human error. It is being scaled across 40+ other sites.

It has helped K-water to reduce its chemical usage by 19%, improve labour efficiency by 42% and reduce power consumption by 10%.

488
LONGi Solar - Jiaxing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Jiaxing site implemented more than 30 Fourth Industrial Revolution use cases, using AI and advanced analytics to boost manufacturing operations. 

The site achieved a 28% reduction in unit manufacturing costs, a 43% cut in yield loss and an 84% decrease in production lead time within one year, while also lowering energy consumption by 20%.

489
Mondelēz - Beijing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Mondelez - Sricity

Mondelēz Beijing implemented 38 Fourth Industrial Revolution use cases, such as an AI-powered dough-making lights-off workshop and gas consumption optimization by machine learning. As a result, Mondelēz Beijing has achieved a 28% net revenue growth and 53% increase in labour productivity while reducing GHG emissions by 24% and food waste by 29%.


490
Novo Nordisk - Hillerød Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Novo Nordisk has invested in digitalization, automation and advanced analytics, building a robust Industrial Internet of Things operating system to be scaled across their manufacturing footprint, increasing equipment efficiency and productivity by 30%.

491
Procter & Gamble - Takasaki Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

The site implemented Fourth Industrial Revolution use cases such as data flow integration, digital twin, machine learning across end-to-end value chain (from R&D to customers). 

As a a result, the innovation lead time accelerated by 72%, shutdown days for trial were reduced by 21%, and order horizon from customers improved 14-fold.

The plant leverages 4IR capabilities such as data science, AI and machine learning across end-to-end value chain from R&D to retail customers. Altogether, it has been improving productivity and enabling faster reaction to market needs while growing production capability.


492
Quaker Houghton - Industrial Engineering 4.0 - Intelligent Die Casting

493
Schneider Electric - Hyderabad

Over four years, the plant reduced its energy consumption by 59 per cent, improved waste optimisation by 64 per cent, decreased CO2 emissions by 61 per cent, and reduced water consumption by 57 per cent.

To improve energy efficiency and thereby reduce CO2 emissions, the Hyderabad team focused on the highest energy consumers in the plant: air compressors and chillers. An IoT-enabled device, Equaliser 4.0, was installed to regulate the compressors, thereby improving their efficiency. For the chillers, a data-driven energy management system with closed-loop control was fitted to constantly monitor and adjust energy consumption in real-time, optimising energy efficiency.

494
The Coca-Cola Company - Ballina

The site implemented digital, and analytics use cases. As a result, it improved cost by 16% while expanding its SKU portfolio by 30%

495
Unilever - Sonepat

Unilever Sonepat implemented 30+ Fourth Industrial Revolution use cases in its E2E supply chain. Top use cases included boiler and spray dryer process twins, as well as customer data-informed no-touch production planning and inventory optimization. 

This improved service by 18%, forecast accuracy by 53%, conversion cost by 40% and Scope 1 carbon footprint by 88%.

496
Western Digital - Bang Pa-In

497
Zymergen - Emeryville

Biotechnology firm Zymergen brought robotics and artificial intelligence (AI) to bioengineering labs, traditionally highly manual sites. 

Innovation rates soared, allowing Zymergen to use bioengineering for products previously were not feasible.



-----------------------------------
498
Course End Summary - Part 1 - IEKC IE Online Course - Engineering in Industrial Engineering

499
Course End Summary - Part 2 - IEKC IE Online Course - Support from Non-Engineering Subjects


Modern Industrial Engineering - A Book of Online Readings.
Now on Academia-Edu Platform.
#industrialengineering #productivity #costreduction




Ud. 29.12.2024
Pub. 27.12.2024












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