Industrial Engineering is System Efficiency Engineering. It is Machine Effort and Human Effort IE. 4 Million Page View Blog. 200,000+ visitors. (36,000+ pv, 25,500+ visitors in 2025.)------------------
Blog Provides Industrial Engineering Knowledge: Articles, Books, Case Studies, Course Pages and Materials, Lecture Notes, Project Reviews, Research Papers Study Materials, and Video Lectures. 2025 - New Project - Effective Industrial Engineering and Productivity Management.
Online Education/Training Session on "Effective Industrial Engineering and Productivity Management."
I developed an online education/training session on "Effective Industrial Engineering and Productivity Management." I can present the session in one hour, one and half hour or two-hour long sessions. The sessions will be valuable when company industrial engineers and other engineers and managers attend as a group. Industrial engineers require active cooperation and participation of other engineers and managers in their studies and projects. Hence a common presentation and discussion on effectiveness will be very useful.
Supporting Information.
Effective Industrial Engineering - Some Thoughts by Narayana Rao K.V.S.S.
Effective industrial engineering has to satisfy management about the contribution it made to the organization year after year.
The prime contribution of IE has to be cost reduction through productivity improvement.
Jigs and Fixtures improve productivity of process, equipment and operators.
Basic Principles of Jig and Fixture Design
1. Reduction of handling time: Method of location and clamping should be such as to reduce handling time to minimum.
2. Rigidity: The jigs and fixtures have to be rigid. Cast iron which absorbs shocks more readily is recommended as body material.
3. Clearance between Jig walls and component: There should be good amount of clearance between component and body of jig to provide for variations in the dimensions of the component. Clearance is also required for chips to come out.
4. Swarf Clearance: There has to be clearance for swarf. Cored holes are provided for this purpose in bigger jigs.
5. Locating and supporting surfaces wherever possible be removable and be of hardened material.
6. Easy loading and unloading: The process of loading and unloading the component should be as easy as possible. In case of heavy components, it should be possible to slide the component into the fixture.
7. Clamping: Clamping should always be arranged directly above the points supporting the work.
8. Fool proofing: Incorporate arrangements that ensure that jig closes only when the component is inserted correctly.
9. Design for safety: Do not leave any sharp edges in the jig body.
10. Component should be ejected when the jig cover is opened.
11. Spring Locations: The number of locations on any rough component should never exceed three in any one plane.
12. Jig Base: A jig which is not bolted to machine table must be provided with four legs.
13. Accuracy and Variations: Jig design must permit only acceptable variation in the dimensions of the finished component.
14. Jig bushes: Jig bushes fixed in jig plates are used to guide drills, reamers and boring bars. They can be replaced when worn.
Locating and Principles of Location
A work piece in space which is free to move in any direction can move in 12 directions. To restrict the movement of the work piece completely it has to be restricted in all its 12 directions. Restricting the movement of the work piece in all its degrees of freedom or in some degrees of freedom is done by location in a jig or fixture.
Principles of Location
1..3:2:1 Method of location: A work piece can be positively located by means of six pins so positioned that collectively they restrict the work piece in nine of its degrees of freedom. 3 pins are in one plane, 2 in a plane perpendicular to it and one in a plan perpendicular as well as adjacent to both of the planes.
2. Points more than necessary should not be used in any plane.
3. Principle of extreme position of locating points.
4. The principle of mutually perpendicular planes.
INDUSTRIAL ENGINEERING is redesign (engineering) of Products, Facilities and Processes for Productivity increase. Productivity Management Imperative for USA - McKinsey. Returning US productivity to its long-term trend of 2.2 percent annual growth would add $10 trillion in cumulative GDP over the next ten years (2023 - 2030).
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. E-Book FREE Download.
Human Effort Industrial Engineering is guided by Principles of Motion Economy. In each process, for each operation, human effort has to be recorded, in two handed process charts and still more micro charts as required for further productivity or industrial engineering analysis.
Lean Management for Enhancing Productivity - Prof. Narayana Rao
Presentation by Professor K.V.S.S. Narayana Rao, National Institute of Industrial Engineering, Mumbai, India on the occasion of Productivity Week Celebration of 2014 with the theme "Lean Management for Enhancing Productivity" for the Senior Managers of Tata Steel Limited, Jamshedpur.
Suggestions on the above process - I posted in Linkedin, and FaceBook
On Linkedin
Michel Baudin
Takt Times Group
It's wonderful of you to post this example. It's clearly a target-rich environment and great to use in classes.
It's wonderful of you to post this example. It's clearly a target-rich environment and great to use in classes.
More context would be helpful. From the video, we can infer quite a bit but it may not be correct. In particular, we don't know the company's pain points. Is it struggling with productivity, quality, delivery? Does it have many injuries? How is the employee turnover? Are they able to retain employees?
In terms of process technology, work methods, layout, flow, safety, etc., this shop looks 50 to 100 years behind the times. It also does not look like a company that can invest in state-of-the-art CNC lathes or would know how to use them.
On the other hand, they most likely could afford safety glasses, go/no-go gauges, posted work instructions, chucking that doesn't require manually tightening bolts, and powered positioning to replace cranks... And they could have a one-piece flow cell at least through the lathes and drill press.
Also, the video looks to be in fast motion. It's good to visualize the entire process but not for time studies.
The key question after that is where to start improving.
Comments On the video
yarrdayarrdayarrda
Seemingly primitive fixtures to drill the oil passages, and yet he hit the middle of the main journal, nice!
Jeff Yates
Saw the castings were Perkins, the way we do them in the States at Caterpillar and how they do it there shows how far we’ve come. I am surprised Caterpillar has their subsidiary still do like Henry Ford did it in the 20’s
Machining Description of machining CTQ characteristic pertaining
Operation no. operation to the machining operation
10 Facing and centering Center to center distance
Diameter and chamfer angle of
locating hole
20 Milling of crankshaft web Flatness of web
30 CNC Rough turning of journals Diameter of journal
40 Whirling of pins Phase-out of pins
Throw of pins
Pin diameter after whirling
Journal diameter after whirling
50 Finish turning of journals Journal diameter after finish
turning
60 Gun drilling of oil hole Diameter of oil hole
70 Finish turning of flange end Diameter of flange
Circularity of flange
80 Drilling and tapping of bolt Pitch circle diameter of bolt holes
holes over the PCD Thread pitch of bolt holes
90 Stub end boring and Stub-end-hole diameter
chamfering using a Chamfer angle
combination boring-cum
chamfering inserts tool bar
100 Grinding of journals Finish diameter of journals
Circularity of journals
110 Grinding of pins Finish diameter of pins
Circularity of pins
120 Detection of magnetic cracks Check for internal cracks
130 Sursulfing Hardeness of journals and pins
after sursulfing operation
140 Pins and journals lapping Surface roughness of journals
and pins after lapping
150 Final inspection quality check
Thesis chapter on grinding
http://shodhganga.inflibnet.ac.in/jspui/bitstream/10603/194947/11/11_chapter%205.pdf
Rough- and finish-grinding of a crankshaft in one set-up
Abstract
Method of grinding a concentrically clamped crankshaft, a crankshaft grinding machine for carrying out the method, and a crankshaft of high-alloy steel or cast material. The method provides for pin journals and main journals of the crankshaft to be ground in one set-up such that first, at least the main journals are rough-ground and then the pin journals are finish-ground and after that the main journals are finish-ground. The crankshaft grinding machine forms a machining center by means of which corresponding rough-grinding and finish-grinding is possible in a single set-up.
B24B5/42 Single-purpose machines or devices for grinding crankshafts or crankpins
Application US09/980,764 events: 1999-04-30 Application filed by Erwin Junker Maschinenfabrik GmbH: 2000-04-20 Assigned to ERWIN JUNKER MASCHINENFABRIK GMBH: 2004-02-20 Application granted: 2005-04-12
Publication of US6878043B1: 2020-02-29
Application status is Active: 2020-04-20
The JUNKER Group drives forward with digitalization
Process-optimized production with the digital twin
09/06/2019
Combining real and virtual machines results in an intelligent system able to predict characteristics and operating behavior from the production planning stage and throughout the product lifecycle. The digital twin for JUNKER grinding machines is a virtual representation of the real system, enabling comprehensive digital exchange between the virtual and real world. https://www.junker-group.com/news/detail/news/process-optimized-production-with-the-digital-twin/
Hyundai Compact Line Center for Crankshaft Machining WH40RS
Video in the page demonstrates the working of the machine.
(See the video WFL M60 MillTurn Complete Crankshaft Machining - MARTECH Machinery, NJ - USA, 26 Jul 2012 https://www.youtube.com/watch?v=81UjjSH2iFw also)
Special -Purpose Machine for Crankshaft both end MBE
Special-Purpose Machine for Crankshaft Oil Holes MOH
Fixture for Crankshaft Oil Holes Machining CRANKMASTER Series https://www.horkos.co.jp/english/products/mc/spm.php
2008 Developed the CNC crankshaft rough milling machine
2009 Developed the Crankshaft pin turner
An effective facility layout ensures that there is a smooth and steady flow of production material, equipment and manpower at minimum cost. Facility layout looks at physical allocation of space for economic activity in the plant. Therefore, main objective of the facility layout planning is to design effective workflow as to make equipment and workers more productive.
Like the subject area of process planning which plans the process to be used to produce a part or an assembly, there is the subject area facilities planning that deals with infrastructure facilities as well as production and related equipment. Layout of facilities is discussed as a topic in facilities planning. But full length books on plant layout are available.
Industrial engineers may evaluate system level resources and activities like facilities selection and facilities layout independently. They also evaluate the facilities for replacement during process improvement studies. Facilities related to processing operations, inspection operations, material handling and transport operations, and warehousing operations are examined for appropriateness and replacement. Plant layouts of an assembly line for a single product can be examined during process improvement study of that product.
Design and Simulation Plant Layout Using Systematic Layout Planning
D Suhardini, W Septiani and S Fauziah
IOP Conference Series: Materials Science and Engineering, Volume 277, conference 1, 2017 https://iopscience.iop.org/article/10.1088/1757-899X/277/1/012051
The foremost and the most important step of establishing a business is setting up a factory. While designing of a factory layout has been nowadays handed over to professional architects, the apparel manufacturers must have a basic knowledge of what a ‘good’ factory layout actually means. A good factory layout offers minimum transportation time and flexibility with no back and forth motion. This series is a one-stop solution for all the factors to be considered, apart from the checklist, and the ways to maximum optimise the factory along with case studies of apparel manufacturing plant layouts in India.
An Applied Guide to Process and Plant Design, 2nd edition, is a guide to process plant design for both students and professional engineers. The book covers plant layout and the use of spreadsheet programs and key drawings produced by professional engineers as aids to design; subjects that are usually learned on the job rather than in education. You will learn how to produce smarter plant design through the use of computer tools, including Excel and AutoCAD, “What If Analysis, statistical tools, and Visual Basic for more complex problems. The book also includes a wealth of selection tables, covering the key aspects of professional plant design which engineering students and early-career engineers tend to find most challenging.
Professor Moran draws on over 20 years’ experience in process design to create an essential foundational book ideal for those who are new to process design, compliant with both professional practice and the IChemE degree accreditation guidelines.
Includes new and expanded content, including illustrative case studies and practical examples
Explains how to deliver a process design that meets both business and safety criteria
Covers plant layout and the use of spreadsheet programs and key drawings as aids to design
Includes a comprehensive set of selection tables, covering aspects of professional plant design which early-career designers find most challenging
The Engineer's Guide to Plant Layout and Piping Design for the Oil and Gas Industries
Geoff B. Barker
Gulf Professional Publishing, 25-Nov-2017 - Business & Economics - 532 pages
The Engineer’s Guide to Plant Layout and Piping Design for the Oil and Gas Industries gives pipeline engineers and plant managers a critical real-world reference to design, manage, and implement safe and effective plants and piping systems for today’s operations. This book fills a training void with complete and practical understanding of the requirements and procedures for producing a safe, economical, operable and maintainable process facility. Easy to understand for the novice, this guide includes critical standards, newer designs, practical checklists and rules of thumb.
Due to a lack of structured training in academic and technical institutions, engineers and pipe designers today may understand various computer software programs but lack the fundamental understanding and implementation of how to lay out process plants and run piping correctly in the oil and gas industry. Starting with basic terms, codes and basis for selection, the book focuses on each piece of equipment, such as pumps, towers, underground piping, pipe sizes and supports, then goes on to cover piping stress analysis and the daily needed calculations to use on the job.
Delivers a practical guide to pipe supports, structures and hangers available in one go-to source
Includes information on stress analysis basics, quick checks, pipe sizing and pressure drop
Ensures compliance with the latest piping and plant layout codes and complies with worldwide risk management legislation and HSE
Focuses on each piece of equipment, such as pumps, towers, underground piping, pipe sizes and supports
Covers piping stress analysis and the daily needed calculations to use on the job
Process Plant Layout, Second Edition, explains the methodologies used by professional designers to layout process equipment and pipework, plots, plants, sites, and their corresponding environmental features in a safe, economical way. It is supported with tables of separation distances, rules of thumb, and codes of practice and standards.
The book includes more than seventy-five case studies on what can go wrong when layout is not properly considered. Sean Moran has thoroughly rewritten and re-illustrated this book to reflect advances in technology and best practices, for example, changes in how designers balance layout density with cost, operability, and safety considerations.
The content covers the ‘why’ underlying process design company guidelines, providing a firm foundation for career growth for process design engineers. It is ideal for process plant designers in contracting, consultancy, and for operating companies at all stages of their careers, and is also of importance for operations and maintenance staff involved with a new build, guiding them through plot plan reviews.
Based on interviews with over 200 professional process plant designers
Explains multiple plant layout methodologies used by professional process engineers, piping engineers, and process architects
Includes advice on how to choose and use the latest CAD tools for plant layout
Ensures that all methodologies integrate to comply with worldwide risk management legislation
Industrial engineering is human effort engineering and system efficiency engineering.
____________
Now the video has 2500+ views 27 May 2021
____________
____________
Note: Industrial engineers make production systems or business systems more profitable by making them more efficient. Plans utilization of facilities, equipment, materials, and personnel to improve efficiency of operations: Studies functional statements, organization charts, and project information to determine functions and responsibilities of workers and work units and to identify areas of duplication. Establishes work measurement programs and analyzes work samples to develop standards for labor utilization. Analyzes work force utilization, facility layout, and operational data, such as production costs, process flow charts, and production schedules, to determine efficient utilization of workers and equipment. Recommends methods for improving worker efficiency and reducing waste of materials and utilities, such as restructuring job duties, reorganizing work flow, relocating work stations and equipment, and purchase of equipment. Confers with management and engineering staff to implement plans and recommendations. May develop management systems for cost analysis, financial planning, wage and salary administration, and job evaluation. Source: Youtueb page: http://www.youtube.com/watch?v=TYoyxEtEgRg
_____________
Top 100 Industrial Engineering Videos on YouTube Top 100 Industrial Engineering Online Articles Industrial Engineering Online Articles Books
Industrial Engineering of Systems - Narayana Rao K.V.S.S.
Keio University, Tokyo, Japan
Principles of Industrial Engineering - Taylor - Narayana Rao
All videos on industrial engineering reflect the principles of scientific management and ideas on productivity improvement and cost reduction that F.W. Taylor gave over the period 1886 to 1911. Basic list of principles of industrial engineering and detailed list of principles of industrial engineering were developed by Narayana Rao K.V.S.S. during 2016-17.
Presented in IISE 2017, Pittsburgh Annual Conference
________________
27. What is Industrial Engineering and Operations Research?
14,356 views
Department of Industrial Engineering and Operations Research at Columbia University, https://www.youtube.com/watch?v=3KS01WDSsE8
