Monday, April 7, 2025

Industrial Engineering Explanation by Prof. Narayana Rao K.V.S.S. - Summary

 Industrial engineering explained by Narayana rao

Grok Summary on 7.4.2025



Narayana Rao K.V.S.S., a prominent industrial engineering scholar and professor, provides a comprehensive and modern perspective on industrial engineering through his extensive writings, including his widely recognized e-book Introduction to Modern Industrial Engineering and various blog posts on his Industrial Engineering Knowledge Center. Here's an explanation of industrial engineering based on his insights:



Industrial engineering, as explained by Narayana Rao, is fundamentally about system efficiency engineering and human effort engineering. It is an engineering discipline focused on designing, improving, and optimizing systems—be they products, processes, or facilities—to enhance productivity while ensuring quality, safety, and human well-being. Rao emphasizes that industrial engineers "make things better" by making them more economical, efficient, and productive, building on the foundational work of pioneers like Frederick W. Taylor.


Core Definition


Rao defines industrial engineering as:


"Industrial Engineering is Human Effort Engineering and System Efficiency Engineering. It is an engineering discipline that deals with the design of human effort and system efficiency in all occupations: agricultural, manufacturing, and service. The objectives of Industrial Engineering are optimization of productivity of work-systems and occupational comfort, health, safety, and income of persons involved."




This dual focus on human effort and system efficiency distinguishes industrial engineering from other engineering fields, as it integrates technical redesign with human-centric considerations.




Key Principles



Narayana Rao has developed a set of principles that encapsulate industrial engineering, presented at the 2017 IISE Annual Conference in Pittsburgh. These principles, inspired by Taylor’s scientific management, include:



  1. Productivity Science: Developing a scientific understanding of each element of work (machine and human) to improve efficiency and productivity.
  2. Productivity Engineering: Redesigning engineering systems—products, facilities, and processes—to enhance productivity without compromising quality.
  3. Resource Utilization: Ensuring efficient use of machines, materials, and human resources through principles like machine utilization economy and motion economy.
  4. Human Focus: Prioritizing operator comfort, health, and safety while incorporating their suggestions for continuous improvement. 
  5. System-Level Management: Planning and managing productivity at the system level to achieve enterprise-wide benefits.



Focus Areas

Rao organizes industrial engineering into key focus areas:



  • Product Industrial Engineering: Redesigning products to reduce costs and increase value (e.g., through value engineering and design for manufacture).

  • Facilities Industrial Engineering: Optimizing the layout and use of facilities for lean operations.

  • Process Industrial Engineering: Improving processes to minimize effort and waste (e.g., through techniques like SMED and Poka-Yoke).

  • Productivity Management: Overseeing system-level productivity improvements and incorporating employee involvement.




Historical Context and Evolution



Rao traces industrial engineering back to Taylor’s work on productivity improvement, such as his studies on machine speeds and human effort (e.g., time study). He credits Taylor, Frank Gilbreth (motion study), and Harrington Emerson for laying the groundwork. Rao’s modern framework builds on these foundations, adapting them to contemporary technologies like Industry 4.0, automation, and data analytics, which he terms "Industrial Engineering 4.0."

Practical Application



In Rao’s view, industrial engineers analyze the productivity of every resource—machines, materials, and people—within a system. They use tools like time studies, process charts, and statistical methods to identify inefficiencies and propose redesigns. For example, Rao highlights Toyota’s Production System as a pinnacle of industrial engineering, where principles like Just-In-Time (JIT) and Jidoka (autonomation) reflect process and machine effort optimization.


Modern Relevance



Rao emphasizes that industrial engineering is not static; it evolves with technology and management practices. He advocates for its application across all engineering branches and industries, from manufacturing to IT and services, ensuring cost reduction, quality maintenance, and customer satisfaction through affordable pricing and efficient delivery.




In summary, Narayana Rao explains industrial engineering as a dynamic, human-centered, and system-focused discipline that drives productivity and efficiency. His work provides both a theoretical framework and practical tools, making it accessible and actionable for students, engineers, and managers alike. For a deeper dive, his free e-book (Introduction to Modern Industrial Engineering, Version 3.0) is highly recommended, available on platforms like Academia.edu, where it ranks in the top 0.5% of publications.


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Focus Areas of Industrial Engineering

 2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html





Focus Areas of Industrial Engineering

Industrial Engineering Strategy 

Productivity Science


Facilities Industrial Engineering 

Product Industrial Engineering

Process Industrial Engineering

Industrial Engineering Optimization

Industrial Engineering Statistics

Industrial Engineering Economics

Human Effort Industrial Engineering

Productivity Measurement

Productivity Management

Data Processing and Information Systems for Industrial Engineering - Added on 16 July 2019

Applied Industrial Engineering

I am a happy. Prof. Beth Cudney, Ph.D, Professor of Data Analytics, Maryville University liked my comment. 
"Industrial engineering inputs to the product development process are important. Product industrial engineering makes significant contribution to product development."
on the post: 

Course Modules for Each Focus Area



Objectives of Basic Engineering and Industrial Engineering


Engineering has two aims: 
To develop effective products and processes that satisfy customers. 
To develop efficient products and processes that give profits and satisfaction to the producers (both managers-capitalists and employees). 
Industrial engineering is focused on efficiency while the functional engineers are focused on effectiveness. 
Both engineering streams have big data bases of knowledge, information and data that are to be used to do the design and execution work successfully to the satisfaction of customers.



Focus Areas of Industrial Engineering - Brief Explanation


Productivity Science: Science developed for each element of machine operation and each element of human tasks in industry.
Productivity Science - Determinants of Productivity

Industrial Engineering Strategy: 
Industrial engineering is profit engineering. If a company is not employing industrial engineering, it is unnecessarily foregoing profits inherent in the products that it developed and designed to the performance satisfaction of good number of users. Profit conscious managers and owners have to understand and employ industrial engineering to achieve the full profit potential of their products. Certain strategic decisions related to industrial engineering function are to be taken by top management of the organization as part of strategic plan of the organization. Certain strategic decisions are to be taken by the Chief Industrial Engineer. These decisions are part of the focus area of industrial engineering strategy.

Facilities Industrial Engineering:
The processes of different products and its components are performed using the facilities of the organization. In designing various facilities of industrial buildings and different facilities within the building, industrial engineering has a role to play. In selection of the equipment used by multiple processes industrial engineering has a role to play. Improvement of machines to increase productivity was done by F.W. Taylor, founder of industrial engineering. Maintenance of various equipment and its overhaul can also be examined by industrial engineers as part of facilities industrial engineering. Layout of the equipment and various production departments decide the amount of material handling and transport within the facility. Layout improvement is an important task of industrial engineering.  Hence facilities level industrial engineering  or facilities industrial engineering is to be identified as an important area in industrial engineering.

Product Industrial Engineering: Redesign of products to reduce cost and increase value keeping the quality intact.
Product Industrial Engineering


Process Industrial Engineering: Redesign of processes to reduce cost and increase value keeping the quality intact.
Process Industrial Engineering

Industrial Engineering Optimization: Optimizing industrial engineering solutions created in Product Industrial Engineering and Process Industrial Engineering.
Operations Research - An Efficiency Improvement Tool for Industrial Engineers

Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity.
Statistics and Industrial Engineering

Industrial Engineering Economics: Economic analysis of industrial engineering projects.
Engineering Economics is an Efficiency Improvement Tool for Industrial Engineers

Machine Effort Industrial Engineering

Machine Effort Industrial Engineering Component of IE curriculum must have the following areas.

1. Productivity Science of Machine Effort

2. Industrial Engineering of Machine Designs.

3. Industrial Engineering of Facilities Layout and Work Station Design

4. Industrial Engineering of Machine Operation.

5. Industrial Engineering of Material Handling, Storage and Transport.

6. Industrial Engineering of Machine Maintenance.

https://nraoiekc.blogspot.com/2023/04/machine-effort-effort-industrial.html



Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators.

Human Effort Industrial Engineering - Module to be in IE curriculum 

Subjects

Introduction to Human Effort Industrial Engineering

Productivity  Science of Human Effort and Motion Study

Design of Handtools and Machine-Man Interfaces

Work Measurement of Operators  and Predetermined Motion Time Systems

Ergonomics (Human Comfort and Health)  and Safety Engineering

Selections from Behavioral Sciences and Organizational Behavior Relevant to IE Work.

Job Evaluation and Wage Incentives

Motion Study - Human Effort Industrial Engineering


Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering.
Industrial Engineering Data and Measurements

Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management.
Productivity Management

Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.


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Sunday, April 6, 2025

Machine Effort Effort Industrial Engineering - Design of Machine Effort for Overall Process and Equipment Effectiveness and Efficiency

Industrial Engineering is System Efficiency Engineering.  Its main areas are   Machine Effort Industrial Engineering  and Human Effort Industrial Engineering. Narayana Rao K.V.S.S.,  Industrial Engineering Knowledge Center. 


Machine Effort Effort Industrial Engineering  - Design of Machine Effort for Overall Process and Equipment Effectiveness and Efficiency

In each of the operations shown in the flow process chart, namely, processing, inspection, transport, temporary storage (due to delay in next operation) and permanent storage, there is involvement of machines and men. There are machine effort and human effort. Industrial engineering is primarily focused on machine effort as engineers' activity and additionally developed science and engineering of human effort. That way, industrial engineering also studies integration issues between machines and men apart from the study of machines and related engineering. So there are process machine effort industrial engineering and process human effort industrial engineering as main components of process industrial engineering.

To do machine effort industrial engineering, industrial engineers need to have full knowledge of the machine elements, various operations that can be done on the machine and the process plan of the job. Then only they can look for more productive alternatives from new engineering development, new machine accessories that are being offered by vendors and from their internal learning and creative breakthroughs.


Machine Effort Industrial Engineering Component of IE curriculum must have the following areas.

1. Productivity Science of Machine Effort

2. Industrial Engineering of Machine Designs.

3. Industrial Engineering of Facilities Layout and Work Station Design

4. Industrial Engineering of Machine Operation.

5. Industrial Engineering of Material Handling, Storage and Transport.

6. Industrial Engineering of Machine Maintenance.


Frameworks for Productivity Science of Machine Effort and Human Effort

Rao, Kambhampati Venkata Satya Surya Narayana.IIE Annual Conference. Proceedings; Norcross (2020): 429-434.

https://www.proquest.com/openview/5786c4e6edff56abf808b4db26f083b3/1.pdf




The productivity analysis of each operation in flow process chart related to machine effort  is presented below. 


82


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91


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93



94. 



95


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97



Productivity Engineering


101


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105

106


107






What is machine effort industrial engineering? according to narayana rao


Grok's Answer on 6.4.2025



2 / 2

25 web pages


According to K.V.S.S. Narayana Rao, a prominent industrial engineering scholar, Machine Effort Industrial Engineering is a key component of industrial engineering that focuses on improving the efficiency and productivity of machines within engineering systems. Narayana Rao defines industrial engineering as "System Efficiency Engineering," encompassing both Machine Effort Industrial Engineering and Human Effort Industrial Engineering. These two aspects work together to optimize the performance of man-machine systems, ensuring maximum productivity while minimizing costs and resource use.



Core Concept of Machine Effort Industrial Engineering


Machine Effort Industrial Engineering involves the systematic study, analysis, and redesign of machines, their operations, and associated processes to enhance their productivity. It emphasizes engineering interventions that reduce the time, cost, and resources required for machine-based tasks while maintaining or improving output quality. This includes optimizing machine design, tools, accessories, and operational methods based on data such as cost, time, and performance metrics.



Narayana Rao highlights that this concept traces back to the work of F.W. Taylor, whom he credits as the father of industrial engineering. Taylor’s early efforts, such as his studies on belt drives and machine shop productivity, demonstrated how machine-related improvements could significantly boost efficiency. Rao builds on this foundation, arguing that industrial engineering must address the machine component of production systems as a distinct focus area, separate yet complementary to human effort engineering.



Key Features


1. Machine Work Study: Rao advocates for "Machine Work Study" as a specific technique within industrial engineering. This involves analyzing the machine's role in a process—its speed, downtime, setup time, and operational cost—and redesigning it to minimize the machine cost component of production. For example, reducing machining time through better tools or methods directly lowers costs and increases output.


2. Productivity Improvement: The goal is to maximize the productivity of machines by ensuring they operate at optimal speeds, with minimal waste and downtime. Rao points to historical examples like Taylor’s slide rules for determining optimal cutting speeds and feeds, which improved machine performance in early industrial settings.


3. Cost Reduction: A central tenet of Rao’s framework is that machine effort engineering should leverage cost data to drive redesign decisions. This aligns with industrial engineering’s origins in cost-efficient engineering, where machines are reconfigured to deliver the same or better results at a lower expense.


4. Integration with System Efficiency: Machines are part of broader engineering systems, and their efficiency impacts the overall system. Rao emphasizes that machine effort engineering must consider interactions with human operators, materials, and other resources to achieve holistic improvements.


Historical Context and Evolution


Rao notes that while Taylor’s initial work included machine-focused improvements, the field of industrial engineering later shifted heavily toward human effort studies (e.g., motion and time study). He argues that this created a gap in attention to machines, which he seeks to address by reintroducing "Machine Effort Industrial Engineering" as a vital discipline. He cites examples like Toyota’s Jidoka pillar—focused on better automation and machine design—as evidence of ongoing relevance, suggesting that companies like Toyota continue to practice machine effort engineering under modern frameworks.

Practical Application
In practice, Machine Effort Industrial Engineering involves:

  • Analyzing machine performance data (e.g., cycle time, energy use, maintenance costs).
  • Redesigning machine elements, such as cutting tools or fixtures, to improve efficiency.
  • Implementing automation or mechanization where it enhances productivity without compromising quality.
  • Ensuring machines support operator comfort and system goals, avoiding over-optimization that harms the human component.


Rao’s Contribution


Narayana Rao formalized this concept in his writings and presentations, notably in his "Taylor - Narayana Rao Principles of Industrial Engineering" presented at the 2017 IISE Annual Conference. He positions Machine Effort Industrial Engineering as a rediscovery and expansion of Taylor’s original machine-focused productivity efforts, adapted to modern contexts with advanced technologies like Industry 4.0, AI, and digital twins.

In summary, according to Narayana Rao, Machine Effort Industrial Engineering is the branch of industrial engineering dedicated to optimizing machine performance through engineering redesign, with a focus on productivity, cost reduction, and system efficiency. It complements human effort engineering to create balanced, high-performing industrial systems.


Supporting Documents.

Machine Work Study
In industrial engineering, productivity improvement is the primary objective. Industrial engineering emerged out of the exhortation by the first president of ASME to engineers to focus on cost reduction of machines and engineering devices so that more people can use them.

linkedin.com
Introduction to Modern Industrial Engineering - Blog Based Book by Narayana Rao K.V.S.S.
Introduction to Modern Industrial Engineering - Version 2.0 by Prof.

linkedin.com
Industrial Engineering Knowledge Center: Online Handbook of Industrial Engineering - Narayana Rao
The principles were developed by Narayana Rao based on principles of scientific management by F.W. Taylor) ... 4. Principles of (machine) utilization economy to be developed for all resources used in engineering systems. ... 9. Principles of motion economy to be used in all IE studies in the area of human effort engineering · 10. Operator comfort and health are to be taken care of. ... 15. Employee involvement in continuous improvement of processes and products for productivity improvement. ... The principles were presented at the Annual Conference of IISE 2017 at Pittsburgh, USA. The paper is in the proceedings of the conference. The presentation made at the conference is given below. ... Levels of Industrial Engineering in an Enterprise. · Enterprise Level to Engineering Element Level Industrial Engineering. Industrial Engineering Strategy - Enterprise Level Industrial Engineering.

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Industrial Engineering Knowledge Center: System Efficiency Engineering - Industrial Engineering
Industrial engineering as system efficiency engineering and human effort engineering - Narayana Rao The system uses resources and syste...

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Industrial Engineering Knowledge Center: Machine Work Study - Productivity Improvement Based on Machine and Machine Work Redesign
Jamie Goettler leads MSC’s metalworking sales and innovation efforts. With over 20 years of experience in metalworking and industrial distribution. Over $1 Million in Profit Improvements and we are just getting started. ... MSC Industrial Supply Co. ... Updated on 9.8.2024, 5.7.2024, 28.1.2022, 19.8.2022, 30.5.2022, 16 Oct 2021, 18 August 2021, 16 May 2021, 1 March 2021, 5 August 2020, 23 May 2020, 11 May 2020, 16 November 2019, 4 July 2019, 27 June 2019, ... Narayana Rao K.V.S.S. at ... Machine work study is an important activity in industrial engineering. The time taken for machining is to be minimized with the objective of reducing machine cost component of total cost of a part or full product.ReplyDelete ... So true of you while pointing out the warmth and depth of the issue. The subject matter was the sensitive one which bounds one to have a thought on it for a while.

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Introduction to Modern Industrial Engineering - Blog Based Book by Narayana Rao K.V.S.S.
E-Book - Introduction to Modern Industrial Engineering by Prof. Narayana Rao K.

linkedin.com
Industrial Engineering Knowledge Center
Narayana Rao K.V.S.S. at ... Engineering, Industrial Engineering, Productivity Improvement, Science, Engineering and Management have an interesting 150 years history starting with Taylor taking up engineering education instead of law. 1875 - Taylor started his engineering education with an apprenticeship. 1880 - Founding of American Society of Mechanical Engineers. ... TAYLOR, F. W., "A Piece-Rate System, Being a Step Toward Partial Solution of the Labor Problem," Transactions of the American Society of Mechanical Engineers 16, 856-903, 1895 · The advantages of this system of management (Taylor's Piece Rate System) are : The manufactures are produced cheaper under it. The system is rapid in attaining the maximum productivity of each machine and man · TAYLOR, F. W., "A Piece-Rate System, Being a Step Toward Partial Solution of the Labor Problem," Transactions of the American Society ...

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(PDF) Industrial Engineering ONLINE Course - Modules 1 & 2 - Narayana Rao | Narayana Kvss - Academia.edu
K.V.S.S. Narayana Rao. This article is a review of the lessons included in the module two of the course. It has 29 lessons containing the concepts and practices advocated by leading authors in industrial engineering including Taylor, Gilbreth, Maynard, Barnes and Shigeo Shingo. ... Call for Papers-Special Issue: Recent Trends and Innovations in Industrial Engineering and Engineering Management, Industrial Engineering Journal, ISSN: 0970-2555, indexed in UGC Group I ... The future of industrial engineering is designing and manufacturing more flexible, connected, and adaptable machines. This can only be accomplished once machine builders embrace simulation-driven, digital product design. With the right tools in place, machine builders and equipment manufacturers can deliver a packaged system of integrated products and services tailored to meet their customers' needs.

academia.edu
Narayana Rao KVSS on LinkedIn: Online Handbook of Industrial Engineering - Narayana Rao
Now a Popular Handbook of Industrial Engineering. 10000 Hits. Online Handbook of Industrial Engineering - Narayana…

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Industrial Engineering Knowledge Center: Human Effort Engineering for Increasing Productivity - Principle of Industrial Engineering
So we can think of areas like Machine industrial engineering Energy industrial engineering Human effort industrial engineering Supply chain industrial engineering Power plant industrial engineering Material handling industrial engineering Information systems industrial engineering ... Human resources employed in engineering systems have their own needs. Industrial engineers are unique in engineering disciplines in taking up the engineering of human effort. They have to synthesize the theories of human sciences, some of which are developed by industrial engineering also, to design human work for an optimal combination of productivity, income, comfort, health, safety and satisfaction of the employed. Human Effort Industrial Engineering - Knowledge Book ... by Dr. K.V.S.S. Narayana Rao in the 2017Annual Conference of IISE (Institute of Industrial and Systems Engineering) at Pittsburgh, ...

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Narayana Rao KVSS on LinkedIn: Online Handbook of Industrial Engineering - Narayana Rao
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING EBook FREE DOWNLOAD. 2023 #BEST Book on IE. by Narayana Rao Kvss. Contents 1. Industrial Engineering - Introduction and History 2. Definition and Explanation 3. Contribution of Taylor, Gilbreth and Harrington Emerson 4. Principles of Industrial Engineering 5. Functions of Industrial Engineering 6. Focus Areas of Industrial Engineering https://lnkd.in/dKFb-jQi #IndustrialEngineering #Productivity #CostReduction #MBA #EngineeringManagement ... Is there a subject in IE curriculum - Management of Industrial Engineering Studies and Department? Will such a subject increase managerial knowledge and skills of industrial engineers? ... INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING with New Framework for #IndustrialEngineering (IE). PRODUCT INDUSTRIAL ENGINEERING - FACILITIES IE - PROCESS IE. FREE DOWNLOAD. https://lnkd.in/dDPPHzSp ...

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Industrial Engineering Knowledge Center: New Framework of Taylor's Industrial Engineering - Prof. Diemer - Prof. Narayana Rao
Lesson 42 of Industrial Engineering ONLINE Course Lesson 41 - Industrial Engineering - Productivity Improvement - Cost Reduction - Jidoka -...

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Management Theory Review: Industrial Engineering - Introduction
Articles on Management Subjects for Knowledge Revision and Updating by Management Executives ---by Dr. Narayana Rao, Professor (Retd.), NITIE---3.80 MILLION Page Views--- Global Top Blog for Management Theory---Management for Effectiveness, Efficiency and Excellence. ... Lesson 3 of Industrial Engineering FREE ONLINE Course - Introduction to Industrial Engineering Module Accompanying case study: BMW - Industrial Engineering Activities and Jobs · Lesson 2. Industrial Engineering - Definition and Explanation · Lesson 4. Pioneering Efforts of Taylor, Gilbreth and Emerson ... There is a difference between industrial engineering and engineering management. Now both these programs are run by IE departments only in USA. IE is better described as engineering in response to industry data, economic theories, social science theories, and management requirements etc.

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Narayana Rao KVSS on LinkedIn: Industrial Engineering - Bulletin Board
Industrial Engineering - Improving Operation Process Chart Industrial engineers have to first improve operation process chart. In it they have to improve…

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KVSSNRao's Industrial Engineering Handbook
Compiled by Dr. K.V.S.S. Narayana Rao, Professor, National Institute of Industrial Engineering (NITIE), Mumbai- 400087, India. Email: kvssnrao50@gmail.com ______________________________________ “Industrial Engineering is Human Effort Engineering. It is an engineering discipline that deals with the design of human effort in all occupations: agricultural, manufacturing and service.”

nrao-ie-handbook.blogspot.com
The Evolution of Taylor's Productivity System
From these best ways of doing elements he developed methods requiring less time and helped operators to do work in less time, producing more in a day. He gave higher wages for extra production. Thus there is machine effort industrial engineering or machine effort redesign. Operators were trained in new machine methods and hence there is human effort industrial engineering. ... Don’t have the app? Get it in the Microsoft Store. Open the app ... By clicking Continue, you agree to LinkedIn’s User Agreement, Privacy Policy, and Cookie Policy. ... Hebei Cucheng Trading Co., Ltd. 7mo ... Syneffex Inc.

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Industrial Engineering Knowledge Center: Total Cost Industrial Engineering - Industrial Engineering of Enterprise Cost
Principles of Machine Utilization Economy and Prac... Trends in Manufacturing Organizations, Systems and... ... Supply Chain Industrial Engineering - Human Effor... Manufacturing Processes for Operation Analysis - V... ... Drishti - Company Facilitating Computer Vision Bas... ... Work Measurement Training Programs, Software & Pra... ... Total Productive Maintenance - Nakajima - JIPM - ... Optimization - Minimization of Resources Used in B... ... Industrial Engineering and Management Professors -... ... Industrial Engineering Projects - Formulation and ... Industrial Engineering and Scientific Management i... Narayana Rao Kambhampati - 1994 - Joining NITIE as... Human Effort Engineering for Increasing Productivi... DevOps - Evolution in Information Technology and I...

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Industrial Engineering Knowledge Center: Productivity Engineering - Principle of Industrial Engineering
TAYLOR - NARAYANA RAO PRINCIPLES OF INDUSTRIAL ENGINEERING Download full paper - Principles of Industrial Engineering IISE Annual Conf...

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Industrial Engineering Knowledge Center: Taylor - Narayana Rao Principles of Industrial Engineering
Industrial Engineering is System Efficiency Engineering. It is Machine Effort and Human Effort Engineering. 2.60 Million Page View Blog. 200,000+ visitors. (17,000+ visitors in the current calendar year) Blog Provides Industrial Engineering Knowledge: Articles, Books, Case Studies, Course Pages and Materials, Lecture Notes, Project Reviews, Research Papers Study Materials, and Video Lectures. Blog provides full IE Online Course Notes ... Industrial Engineers, Display Industrial Engineering Principles in Your Department. · Practice them and Provide Value to the organization. Taylor - Narayana Rao Principles of Industrial Engineering were developed Prof. Narayana Rao K.V.S.S. in two stages. In the first Stage, Taylor's principles of scientific management were converted into basic principles of industrial engineering. The managers following scientific management thought do the following ...

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Industrial Engineering Knowledge Center: A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications
Taylor - Narayana Rao Principles of Industrial Eng... 2024 Thanks Giving Day Greetings - INDUSTRIAL ENGI... 2024 Machine Shop Engineering, Technology & Indust... IIIE 2024 Conference - Jamshedpur - Innovation & A... Processes - Process Charts - Collection - Bulletin... ... Work-Related Limb Disorders - Musculoskeletal Diso... Process Human Effort Industrial Engineering Course... Operator Comfort and Health - Principle of Industr... Human Effort Engineering for Increasing Productivi... Process IE Methods - Part 5. Toyota IE - Process M... Kaizen - The Japanese Style Productivity Improveme... ... Behavioral, Cognitive and Managerial Ergonomics fo... Kaikaku: The Power and Magic of Lean : a Study in ... Kaizen - Engaging Front-Line Staff in Continuous I... Industrial Engineering in Japan - Achievements - N... ... A to Z of Industrial Engineering - Principles, Met...

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Industrial Engineering Knowledge Center: February 2021
Industrial Engineering is System Efficiency Engineering. It is Machine Effort and Human Effort Engineering. 2 Million Page View Blog. 167,000 visitors. Blog Provides Industrial Engineering Knowledge: Articles, Books, Case Studies, Course Pages and Materials, Lecture Notes, Project Reviews, Research Papers Study Materials, and Video Lectures. Blog provides full IE Online Course Notes ... Narayana Rao K.V.S.S. at ... Location: Juarez, Chih. Mexico · Accountability of industrial engineering department in charge of three engineers, eight process technician and six welding technician. Responsible of labor productivity, efficiency and utilization, budget, cost reduction projects and over time (KPI’s). Head count calculation according to the customers demand to guarantee the safety, quality, cost and deliveries metrics. Supporting the production lines where there are 600 direct labors ...

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Industrial Engineering Knowledge Center: Productivity - Definition
Narayana Rao K.V.S.S. at ... IE in different branches of engg. (30) ... Lessons 16 to 30 - Industrial Engineering Online C... Faucet Design and Manufacturing Process - Industri... Industrial Engineering Knowledge Center - Industri... Is There a Cost Reduction Benefit in Using Hybrid ... ... Harrington Emerson - A Pioneer Industrial Engineer... API Based Services for Performance Improvement and... Zero Flow Processes - Eliminate Operations and Red... Machine vision Based Inspection Productivity Impro... Tata Technologies for Productivity Improvement thr... ... 

THE CENTRALITY OF PRODUCTIVITY FOR GROWTH OF FIRMS... Undergraduate Industrial Engineering Programs - India · Authorities of Industrial Body and Accounting for ... System Engineering - Systems Engineering - Bibliog... Human Effort Industrial Engineering - Design of Hu... ... Productivity Science of Human Effort - MOTION STUD...

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Product Industrial Engineering for Cost Reduction - Value Engineering
Industrial engineering (IE) originated from the first paper by F.W.

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(PDF) INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING - Version 3.0
A Collection of Blog Posts on Industrial Engineering. Introduction to Modern Industrial Engineering: History, Principles, Functions and Focus Areas.

academia.edu
Industrial Engineering Knowledge Center: Human Effort Engineering - Bulletin Board
Sensors in Machine Tools - Data Generation and Ana... ... Jidoka - Automation and Mechanization - Process En... Component Store - Warehouse - Industrial Engineeri... Raw Material Store or Warehouse - Design, Operatio... ... Bayer Pharmaceuticals, Garbagnate, Italy - Smart F... Hearty Cooperation - Principle of Industrial Engin... Big Data Analytics Applications in Product Design,... Productivity Methods Training - Principle of Indus... Industrial engineering Principles, Methods Tools a... 

THE PURPOSE AND EVOLUTION OF INDUSTRIAL ENGINEERIN... Industrial Engineering - Knols of Narayana Rao K V... Bottle Filling Process - Technology, Machines, Met... ... Modern Industrial Engineering and Lean in Low Volu... ... Material Handling Analysis in Methods Efficiency E... Material Handling and Transport Industrial Enginee...

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What is machine effort industrial engineering?
ChatGPT Answer (On 11 April 2023)

Machine effort industrial engineering is a field of study that focuses on designing and optimizing manufacturing and production processes by utilizing principles of engineering, mathematics, and computer science. The goal of machine effort industrial engineering is to increase efficiency, productivity, and quality while reducing waste, cost, and time.

This field involves the use of advanced technologies such as robotics, automation, and artificial intelligence to improve manufacturing processes. Machine effort industrial engineers analyze and evaluate production processes, identify areas that need improvement, and develop and implement solutions to optimize those processes.

Machine effort industrial engineering also involves the design and development of machines, tools, and equipment used in manufacturing processes. Industrial engineers use their knowledge of engineering principles and manufacturing processes to create and test prototypes, as well as design production lines and production systems.

Overall, machine effort industrial engineering is a multidisciplinary field that combines engineering, mathematics, and computer science to optimize manufacturing and production processes, making them more efficient and cost-effective.


Ud. 6.4.2025
Pub. 11.4.2023

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Saturday, April 5, 2025

A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts





Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Posts Proposed for April 2025.

Each day one post - No post on Sundays.


1. Advances in Engineering and Industrial Engineering.

https://nraoiekc.blogspot.com/2025/04/advances-in-engineering-and-industrial.html


2. Behavioral Sciences and Industrial Engineering

https://nraoiekc.blogspot.com/2025/04/behavioral-sciences-and-industrial.html


3. Cooperation - Importance in  Industrial Engineering

https://nraoiekc.blogspot.com/2025/04/cooperation-importance-in-industrial.html


4. Department of  Industrial Engineering

https://nraoiekc.blogspot.com/2025/04/department-of-industrial-engineering.html


5. Efficiency and Effectiveness - Excellence - Terms Relevant to  Industrial Engineering

https://nraoiekc.blogspot.com/2025/04/efficiency-and-effectiveness-excellence.html



6. Focus Areas of  Industrial Engineering

7. Goals - Result Areas of  Industrial Engineering

8. Human Effort  Industrial Engineering

9. Innovation and Intellectual Property Creation by  Industrial Engineering

10. Job Design and  Industrial Engineering

11. Knowledge Management and  Industrial Engineering

12. Labor Productivity Improvement  Industrial Engineering

13. Management Module for  Industrial Engineering

14. New Technologies and  Industrial Engineering

15. Operations Management and  Industrial Engineering

16. Productivity Management by  Industrial Engineers - A Review

17. Quality and  Industrial Engineering

18. Reengineering by  Industrial Engineering

19. System  Industrial Engineering - A Relook

20. Total Innovation Management and Total  Industrial Engineering

21. Understanding and Developing Human Effort Productivity Science

22. Value Engineering and  Industrial Engineering

23. Winning the Productivity Game - Ladders and Snakes

24. X - The Words Related to  Industrial Engineering Beginning with X

25. Yes - Industrial Engineering Benefits the Society and Organizations

26. Zig Zag Machine Improvement  - Industrial Engineering



Modern Industrial Engineering - LinkedIn Newsletter - Please Subscribe.

Coverage: Industrial Engineering - Innovations, News, Research and Success Stories.

2150+ Subscribers so far.

https://www.linkedin.com/pulse/industrial-engineering-innovations-news-research-success-kvss-9ewlc/


O-Book - Modern Industrial Engineering - A Book of Online Readings.

365+ Lessons and articles and 100+ Case Studies on Industrial Engineering. 

Based on Principles of Industrial Engineering (2017) - Functions and Focus Areas of Industrial Engineering (2016).

https://www.academia.edu/126612353/Modern_Industrial_Engineering_A_Book_of_Online_Readings




Ud. 4.4.2024


Pub. 19.2.2025





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Efficiency and Effectiveness - Excellence - Terms Relevant to Industrial Engineering

 2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Efficiency and Effectiveness - Excellence - Terms Relevant to  Industrial Engineering


Peter Drucker on Efficiency and Effectiveness

Peter Drucker brought the importance of efficiency in his book Management: Tasks, Responsibilities. Practices in the chapter titled "The Dimensions of Management." He said, "Effectiveness is the foundation of success - efficiency is a minimum condition for survival after success has been achieved. Efficiency is concerned with doing things right. Effectiveness is doing the right things." Industrial engineers need not argue with Peter Drucker. They can accept the view of Drucker, that effectiveness is the foundation of success of managers select the right things. Industrial engineering is focused on providing a service to managers in  helping his deparment or his organization in doing things right. Industrial engineering is a service to managers in managing their organization.

Drucker also emphasized in another paragraph, "Of course efficiency is important. Even the healthiest business, the business with the greatest effectiveness, can die of poor efficiency. But the the most efficient business cannot survive, let alone succeed, if it is efficient in doing the wrong things, that is, if it lacks effectiveness. No amount of efficiency would have enabled the manufacturer of buggy whips to survive." So, Drucker emphasized the importance of efficiency in the survival and growth of business organizations and also brought out the obvious fact that an organization must have the skills to deliver what market wants. Organizations have to produce what market wants and not what they are efficient at. When market conditions change, organizations have to take up new products and services, produce and market them even thought they are not very skilled at the new activities. But over a period of time, they need to make them efficient.

Efficiency, the dimension which is core concern of industrial engineering discipline is an important dimension of management and industrial engineers must provide efficiency services to organizations effectively.

What is Productivity?

Peter Drucker has written in 'The Practice of Management', "Management has to give direction to the institution it manages. It has to think through the institution's mission, has to set its objectives, and has to organise resources the results the institution has to contribute." Further he adds that to fulfil its mission and achieve its objectives "It has to organize work for productivity, it has to lead the worker toward productivity and achievement."

The productivity that Drucker mentions is efficiency in effective activities. Effective activities contribute to the fulfilment of mission of the enterprise and achievements of its objectives. Managers have to select the right objectives and goals,  assemble right resources and then lead the members of the organization toward efficiently working toward the goals. It is in the area of efficiency that industrial engineers contribute and when they are able to make effective activities more efficient within a plan peiod, they are helping  the organisations in becoming more productive.

Excellence


Continuous improvement can be defined as an ongoing effort to improve an organization’s processes, products, or services over time. While continuous improvement is essential, it is generally not enough. On the other hand, operational excellence is about applying the right tools and processes to create an ideal work culture that empowers employees to take ownership of the operational flow, thus ensuring that continuous improvement remains constant.


What is operational excellence?

Operational excellence refers to the process of executing a business strategy more reliably and consistently than the competition, resulting in increased revenue, lower operational risk, and lower operating costs.

https://kaizen.com/insights/operational-excellence-organizational-improvement/

Productivity and excellence depend on people
The payoff that matters is sustained, higher productivity to fuel innovation and growth.

Achieving operational excellence

McKinsey’s assessment of operational excellence, the Operational Excellence Index (OEI) evaluates organizations on their level of adherence to more than three dozen management practices. An analysis of organizations that have repeated the OEI assessment over the course of a transformation finds a crucial inflection point: once an organization sustains a score of at least 40 (on a 100-point scale) for 18 months,  it is much more likely to retain a score of at least 40 even after an assessment gap of several years. In short, by adhering to OEI practices for 18 months to reach a threshold score, an organization is substantially more likely than its peers to sustain improved performance.

What it takes is leaders who continually monitor all five operational-excellence elements.


What’s missing from these change efforts, according to survey findings from 2010, 2015, 2017, and 2021, is a focus on the people side of productivity, performance, and technology.

Read the article for five elements.

https://www.mckinsey.com/capabilities/operations/our-insights/todays-good-to-great-next-generation-operational-excellence


More on Operational Excellence

https://nraomtr.blogspot.com/2015/03/what-is-operational-excellence-in.html     - Detailed content.

https://nraoiekc.blogspot.com/2023/01/operational-excellence-concept-practice.html

https://nraomtr.blogspot.com/2015/03/the-ibm-cognos-8-business-intelligence.html    IBM tool for monitoring OE.

https://nraoiekc.blogspot.com/2024/10/asq-certified-manager-of.html

https://nraoiekc.blogspot.com/2023/09/design-thinking-for-operational.html

https://nraoiekc.blogspot.com/2023/08/operational-excellence-ametek.html


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Friday, April 4, 2025

Department of Industrial Engineering - Value to be Created for the Organization and Society

 2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Department of  Industrial Engineering - Value to be Created for the Organization and Society


Department of Industrial Engineering is an important department to be set in engineering organizations of all branches of engineering. It is of utility in all engineering tasks like design, manufacturing, construction, operation of power plants, telephone exchanges or mobile communication systems, rail transportation systems, air travel systems, information systems etc.

What is the purpose of industrial engineering department. It is primarily profit improvement through revenue growth and cost reductions achieved through productivity improvement of resources. From where does the productivity improvement come? From engineering and technology developments that keep appearing. Industrial engineering is concerned with incremental improvements in processes, products and facilities. It also does productivity evaluation and improvement as the design stage of products and processes and selection of facilities.

What is the possible value addition?


Value Creation Model for Industrial Engineering

For $100 million cost, there can be one MS IE and 6 BSIEs. Value created: $3,600,000 per year on $100,000,000 cost of production per year.  Value to be created by IE department is 3.6% of the cost of production per year. Its cost of operating the department has to be 20% or one-fifth of the savings. Investment in improvement projects is addition to it.

Explanation
We start with a MS Industrial Engineer earning $12,000 per month. He is expected to have 6 BS industrial engineers under him. Each BS industrial engineer is earning a salary of $6000 per month.

Let us take a team of one  BS industrial engineer + Supervision by MSIE + staff support totaling $10,000 per month. which is equal to $120,000 per year.

This team is expected to generate a saving of $600,000 per year in 50 IE projects. That means each project has to save 12,000 dollars on average.

Let us assume each project is on an operator earning $3000 per month. The total cost of the work center can be taken as $30,000 per month. Which means $360,000 per year. Industrial engineers have to find $12,000 savings out of that expenditure every year assuming that a BSIE is responsible for work of 50 operators . Operation Analysis is used on One Machine + Operator combination. It is possible that multiple machines are operated by one operator in which case we may think of one machine + part operator.  Maynard and Stegemerten authored a full book on operation analysis and Niebel explained it well in a chapter in his book on Motion and Time Study.

The IE department's expenditure per month is $60,000 ((1 MSIE + 5 BSIEs + Staff)). They have to find savings of $300,000 per month. $3,600,000 per year on $100,000,000 cost of production per year.


Are they able to find such cost savings year after year and justify their compensation?



Breakup of Productivity Benefit  - Sharing Scheme


Savings of $300,000 per month

Benefit break up:

IE department staff: $60,000
Investment in projects: $60,000
Increase in benefits to other employees:$60,000
Benefit to customers: $60,000
Increase in profits of the company: $60,000

In the second year, the share of IE department staff and Investment in projects may get reduced to $30,000 and $90,000 may be given customers thus increasing the demand for the product to absorb the increased productivity.

An alternative benefit breakup model. Is it more sustainable?

Savings of $300,000 per month

Benefit break up:

IE department staff: $60,000

Increase in benefits to other employees:$30,000

Increase in profits of the company: $30,000
Investment in projects: $30,000  - This point needs to be discussed and understood better. Investment in IE or productivity projects can be in multiples $60,000 if you think it is contributing to the cost of capital of the company.

Benefit to customers: $150,000



Look forward to comments from Industrial Engineers on the feasibility of achieving productivity savings year after year and sharing them with other employees, shareholders and consumers apart from taking their compensation.



You can use the numbers in the model to calculate payback period and NPV


Let us say one BSIE IE team will have per annum $120,000 department expenses (personal sal + department office expenses)

Per annum investment in productivity projects is $120,000. So total investment in productivity improvement can be taken as $240,000.

While it gives savings of $600,000, from 2nd year onwards, $360,000 is shared with consumers. $120,000 is shared with employess. $120,000 is the return to capital invested.

Hence we can as investment: $240,000

From 2 year end every year there is cash inflow of $120,000. This will give payback period of 3 years because in the first year we are assuming that there is no cash inflow.

The NPV at the end of four years at a discount rate of 10% is $52,680.

As an Industrial Engineer, and IE manager are you following value addition and value allocation?

Taylor rubric: "an increase in productivity was allocated (1) one-third to the worker in the form of increased wages, (2) one-third to the owners in the form of stock dividends and capital investment, and (3) one-third to consumers in the form of lower prices for the products the company produced."

Source: https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html











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Thursday, April 3, 2025

Cooperation - Importance in Industrial Engineering

2025 - A to Z Industrial Engineering - Blogging Theme - Industrial Engineering Benefits the Society and Organizations




Industrial Engineering - Systems/Processes/Methods Improvement Using Engineering solutions creatively.

Industrial Engineering - Prime focus - Productivity Improvement.

Productivity improvement gives National Prosperity and Organization Prosperity.



Source: https://www.linkedin.com/posts/national-productivity-council-gandhinagar_cartoonseriesabr10-productivity-economicgrowth-activity-7301162658278379520-eyyl




A to Z of Industrial Engineering - Blogging Challenge April 2025 - Proposed Posts

https://nraoiekc.blogspot.com/2025/02/a-to-z-of-industrial-engineering.html


Existing Collection of Articles

A to Z of Industrial Engineering - Principles, Methods, Techniques, Tools and Applications

https://nraoiekc.blogspot.com/2018/06/a-to-z-of-industrial-engineering.html


Cooperation - Importance in  Industrial Engineering


Principles of Scientific Management - Taylor

The managers following scientific management thought do the following things.


Third. They heartily cooperate with the men so as to insure all of the work being done in accordance with the principles of the science which has been developed.

Fourth. There is an almost equal division of the work and the responsibility between the management and the workmen. The management take over all work for which they are better fitted than the workmen, while in the past almost all of the work and the greater part of the responsibility were thrown upon the men.

Cooperation and mutual increase in incomes are the principles on which the factory system is established. Why should an artisan working on his own and earning a good income join a factory under a different owner as wage employee? The artisan joins a factory as there is promise of higher wages compared to the income he is earning as an independent artisan. From where does this extra income come from? It comes from the productivity increase of the factory system. The increase in productivity comes from process changes brought about by the owner of the factory. As the factories become big managers enter the picture.  Industrial engineering is a management discipline with foundation in engineering with focus on efficiency or productivity improvement. 

Industrial engineers also have to work on the basis of cooperation principles. They have to cooperate with operators, foremen, engineers and managers to do the job of increasing productivity and other performance dimensions through engineering and management improvements.

Industrial Engineering Principle 17. Hearty cooperation Principle of Industrial Engineering.

Industrial engineers and managers must have cooperative attitudes. They are in the production system to facilitate work. 

An industrial engineer does not exploit anybody in the organization.



How to develop hearty cooperation?

F.W. Taylor included hearty cooperation as a principles in Scientific management. But how to achieve hearty cooperation was not described by him. As an engineer by education and profession, he is not the right person to discuss how to achieve it. In his writing he might have mention some acts he has done to increase cooperation.  Henri Fayol in his essay on "General and Industrial Administration" also included cooperation as a principle. Chester Barnard discussed cooperation in much more detail. At the present moment, Organizational Behavior is the subject that is discussing cooperation in more detail as the subject is concerned with managers and employees in organizations.

Industrial engineers have to master the subject of Organizational Behavior, implement it in the practice and must engage continuous discussion regarding the utility and limitation of the concepts, relations, and implications developed so far in the discipline.

Introduction to Organizational Behavior - Online Book

Principles of Industrial Engineering - Presentation 


by Dr. K.V.S.S. Narayana Rao in the 2017Annual Conference of IISE (Institute of Industrial and Systems Engineering) at Pittsburgh, USA on 23 May 2017


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Principles of Industrial Engineering - Narayana Rao - Detailed List

Clicking on the link will take you to more detailed content on the principle


The full paper on the principles by Prof. K.V.S.S. Narayana Rao is now available for downloading from IISE 2017 Annual Conference Proceedings in Proquest Journal Base.

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